Void-free electrical conductor for power cables and process for making same

摘要

A void-free electrical conductor for power cables including a stranded electrical conductor formed of a central member and a plurality of abutting peripheral conducting members, the stranded conductor having a primary layer of electrical insulation heat shrunk about the exterior thereof and having an insulation material completely filling the internal space of the conductor within the primary external electrical insulation layer, the filler insulation adapted to fill all interstices between individual conducting strands outward from the abutment points between peripheral conducting members and the area inside of the abutment points being insulated by the insulation around the central conducting member to thereby form a completely void-free filling of the space within the primary electrical insulation in order to prevent the axial flow of any liquid or gaseous substance therethrough, said primary electrical insulation layer being void-free to increase the dielectric strength of the final electrical conductor construction, the primary insulation and the filler insulation being applied simultaneously to the stranded electrical conductor from a laminated tape having an exterior layer formed of the primary electrical insulation material and an interior layer formed of the filler insulation material such that when this assembly is heat shrunk the primary electrical insulation material forms the external dielectric insulation and the filler insulation material flows inwardly to fill all the interstices between strands of electrical conductors and completely filling the interior of the primary electrical insulation with a void-free insulation.