Patent ID: 7586042

Claim:
A method for manufacturing a cable comprising: (a) providing at least one insulated conductor; (b) extruding a first polymeric material layer over the insulated conductor; (a) serving a first layer of armor wires around the polymeric material and embedding the armor wires in the first polymeric material layer to eliminate interstitial gaps; (b) extruding a second polymeric material layer over the first layer of armor wires embedded in the first polymeric material layer, and bonding the second polymeric material layer with the first polymeric material layer; and (c) serving a second layer of armor wires around the second polymeric material layer and embedding the armors in the second polymeric material layer to eliminate interstitial gaps; wherein the first polymeric material layer and second polymeric material layer form a continuously bonded layer which separates and encapsulates the armor wires forming the inner armor wire layer and the outer armor wire layer.