Lead sheathed power cable

A reinforced power cable comprising:

• a continuous armor sheath having a contoured inner surface defining a cavity therein, said armor sheath having a longitudinal axis and being substantially rigid transversely of said longitudinal axis;
• power conveying means, located in said cavity and extending along said longitudinal axis, for transmitting power;
• filler means enclosing and engaging said power conveying means;
• a continuous malleable tube having an inner surface and an outer surface,
• said tube inner surface enclosing and engaging said filler means,
• said tube outer surface being inwardly spaced from said armor sheath inner surface and being contoured, said tube contoured outer surface having substantially the same configuration as said armor sheath contoured inner surface and being interfitted therewith;
• and
• spacer means, interposed between and engaging said tube outer surface and said armor sheath inner surface, for maintaining said tube outer surface inwardly spaced from said armor sheath inner surface,
• said power conveying means comprising an electrical conductor and an insulation layer enclosing said electrical conductor,
• said power conveying means further comprising a chemical layer enclosing said electrical conductor.

A reinforced power cable comprising:

• a continuous armor sheath having a contoured inner surface defining a cavity therein, said armor sheath having a longitudinal axis and being substantially rigid transversely of said longitudinal axis;
• power conveying means, located in said cavity, and extending along said longitudinal axis, for transmitting power;
• filler means enclosing and engaging said power conveying means;
• a continuous malleable tube having an inner surface and an outer surface,
• said tube inner surface enclosing and engaging said filler means,
• said tube outer surface being outwardly spaced from said armor sheath inner surface and being contoured, said tube contoured outer surface having substantially the same configuration as said armor sheath contoured inner surface and being interfitted therewith;
• and
• spacer means, interposed between and engaging said tube outer surface and said armor sheath inner surface, for maintaining said tube outer surface inwardly spaced from said armor sheath inner surface,
• said filler means comprising a vulcanized filler material.

A reinforced power cable comprising:

• a continuous armor sheath having a contoured inner surface defining a cavity therein, said armor sheath having a longitudinal axis and being substantially rigid transversely of said longitudinal axis;
• power conveying means, located in said cavity and extending along said longitudinal axis, for transmitting power;
• filler means enclosing and engaging said power conveying means;
• a continuous malleable tube having an inner surface and an outer surface,
• said tube inner surface enclosing and engaging said filler means,
• said tube outer surface being inwardly spaced from said armor sheath inner surface and being contoured, said tube contoured outer surface having substantially the same configuration as said armor sheath contoured inner surface and being interfitted therewith;
• and
• spacer means, interposed between and engaging said tube outer surface and said armor sheath inner surface, for maintaining said tube outer surface inwardly spaced from said armor sheath inner surface,
• said spacer means comprising a bedding tape comprising a fabric backing tape and a vulcanized material engaged therewith.

A reinforced power cable comprising:

• a continuous armor sheath having a contoured inner surface defining a cavity therein, said armor sheath having a longitudinal axis and being substantially rigid transversely of said longitudinal axis;
• power conveying means, located in said cavity and extending along said longitudinal axis, for transmitting power;
• filler means enclosing and engaging said power conveying means;
• a continuous malleable tube having an inner surface and an outer surface,
• said tube inner surface enclosing and engaging said filler means,
• said tube outer surface being inwardly spaced from said armor sheath inner surface and being contoured, said tube contoured outer surface having substantially the same configuration as said armor sheath contoured inner surface and being interfitted therewith;
• and
• spacer means, interposed between and engaging said tube outer surface and said armor sheath inner surface, for maintaining said tube outer surface inwardly spaced from said armor sheath inner surface,
• said spacer means comprising first and second bedding tapes.

A method of making a reinforced power cable comprising the steps of

• enclosing a power conveying line with vulcanizable filler material,
• enclosing the filler material with a continuous malleable tube,
• enclosing the malleable tube with a continuous, substantially transversely rigid armor sheath having a contoured inner surface,
• heating the power conveying line, filler material, malleable tube and armor sheath, thereby thermally outwardly expanding and vulcanizing the filler material, and outwardly expanding the malleable tube under the influence of the expanding filler material so that the contour on the inner surface of the armor sheath is impressed into the outer surface of the malleable tube, and
• cooling the power conveying line, filler material, malleable tube and armor sheath.

A method of making a reinforced power cable comprising the steps of

• enclosing and engaging a power conveying line with a vulcanizable filler assembly,
• enclosing and engaging the filler assembly with a continuous malleable tube,
• enclosing and engaging the malleable tube with a bedding tape,
• enclosing and engaging the bedding tape with a continuous, substantially transversely rigid armor sheath having a contoured inner surface,
• heating the power conveying line, filler assembly, malleable tube, bedding tape and armor sheath, thereby thermally outwardly expanding and vulcanizing the filler assembly, and outwardly expanding the malleable tube under the influence of the expanding filler assembly so that the contour on the inner surface of the armor sheath is impressed into the outer surface of the malleable tube, and
• cooling the power conveying line, filler assembly, malleable tube, bedding tape and armor sheath.