Electrical cables

A corrosion resistant wellbore cable comprising:

• (a) a plurality of insulated electrical conductors, each of said conductors comprising:
• (i) a central coated metallic conductor and a plurality of coated metallic conductors helically positioned around said central coated metallic conductor;
• (ii) a coating flake trapping polymeric layer disposed adjacent the electrical conductor;
• (iii) a first insulating jacket disposed adjacent the polymeric layer wherein the first insulating jacket has a first relative permittivity;
• and,
• (iv) a second insulating jacket disposed adjacent the first insulating jacket and having a second relative permittivity that is less than the first relative permittivity, and wherein the first insulating jacket is mechanically bonded to the second insulating jacket;
• wherein the polymeric layer has a relative permittivity less than the first relative permittivity;
• (b) an outer jacket surrounding said plurality of said insulated electrical conductors, and an interstitial filler disposed between the outer jacket and said insulated electrical conductors, wherein the interstitial filler is made from a material selected from the group consisting of perfluoropolyether polymers, perfluoropolyether-silicone polymers, Krytox® grease, fluoropolymers, and any mixtures thereof;
• (c) a plurality of current return conductors disposed between the outer jacket and said insulated electrical conductors;
• and,
• (d) at least one armor wire layer surrounding the outer jacket.

A corrosion resistant wellbore cable comprising:

• (a) a plurality of insulated electrical conductors, each of said conductors comprising:
• (i) a central coated metallic conductor and a plurality of coated metallic conductors helically positioned around said central coated metallic conductor;
• (ii) a coating flake trapping polymeric layer disposed adjacent the electrical conductor;
• (iii) a first insulating jacket disposed adjacent the polymeric layer wherein the first insulating jacket has a first relative permittivity;
• and,
• (iv) a second insulating jacket disposed adjacent the first insulating jacket and having a second relative permittivity that is less than the first relative permittivity, and wherein the first insulating jacket is mechanically bonded to the second insulating jacket;
• wherein the polymeric layer has a relative permittivity less than the first relative permittivity;
• (b) an outer jacket surrounding said plurality of said insulated electrical conductors, and an interstitial filler disposed between the outer jacket and said insulated electrical conductors;
• (c) at least one armor wire layer surrounding the jacket which further comprises at least one current return conductor disposed about the armor wire layer.

A method of providing a corrosion resistant wellbore electrical cable with improved durability, the method comprising:

• (a) providing at least one coated electrical conductor;
• (b) extruding a coating flake trapping polymeric layer over the electrical conductor, the polymeric layer comprising coating flakes produced during manufacture of the cable;
• (c) extruding a first insulating jacket having a first relative permittivity over the polymeric layer;
• and
• (d) extruding a second insulating jacket having a second relative permittivity over the first insulating jacket, wherein the second relative permittivity is less than the first relative permittivity;
• wherein the polymeric layer has a relative permittivity less than the first relative permittivity.