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Method of making electrical power cable

Image Number 9 for United States Patent #7469470.

A cable comprises at least two cores stranded together, an expanded inner jacket layer, a substantially circular metallic armor partially contacting the inner jacket to form unfilled interstices outside the inner jacket, and a polymeric outer jacket. The expanded inner jacket substantially takes the shape of the periphery of the stranded cores, providing a non-circular cross section for the expanded inner jacket. A method of producing a cable comprises providing at least two cores, expanding a polymeric material, extruding the expanded polymeric material around the cores, and allowing the expanded polymeric material to collapse onto the cores. A substantially circular metallic armor is applied, resulting in a plurality of unfilled voids between the inner jacket and the metallic armor. An outer jacket is extruded on the metallic armor.

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