Toneable conduit and method of preparing same

• US 20040262023A1
• Filed: 04/23/2004
• Published: 12/30/2004
• Est. Priority Date: 11/20/2001
• Status: Active Grant

• Current Assignee: Dura Line Corporation
• Original Assignee: Commscope Solutions Properties LLC (CommScope Holding Company, Inc.)
• Inventors: Kale, Zeb Leonard, Ward, Robert Miller Jr., Morrow, Jason Norman, Bollinger, George, Gemme, Christopher, Lumley, Scott, Bailey, Michael Ray
• Granted Patent: US 7,820,090 B2
• Time in Patent Office: Days
• US Class Current: 174/481
• CPC Class Codes: B29C 48/022 characterised by the choice of material
• CPC Class Codes: B29C 48/06 Rod-shaped
• CPC Class Codes: B29C 48/09 Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
• CPC Class Codes: B29C 48/15 incorporating preformed parts or layers, e.g. extrusion moulding around inserts
• CPC Class Codes: B29C 48/154 Coating solid articles, i.e. non-hollow articles
• CPC Class Codes: B29C 48/34 Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
• CPC Class Codes: B29K 2023/06 PE, i.e. polyethylene
• CPC Class Codes: B29K 2023/065 HDPE, i.e. high density polyethylene
• CPC Class Codes: B29K 2023/12 PP, i.e. polypropylene
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2027/18 PTFE, i.e. polytetrafluorethene , e.g. ePTFE, i.e. expanded polytetrafluorethene
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2075/00 Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2077/00 Use of PA, i.e. polyamides, e.g. polyesteramides or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: F16L 1/11 for the detection or protection of pipes in the ground
• CPC Class Codes: F16L 11/127 electrically conducting
• CPC Class Codes: F16L 25/01 specially adapted for realising electrical conduction between the two pipe ends of the joint or between parts thereof
• CPC Class Codes: F16L 9/125 : electrically conducting
• CPC Class Codes: G02B 6/4431 : with provision in the protective covering, e.g. weak line, for gaining access to one or more fibres, e.g. for branching or tapping break-out terminations G02B6/4471
• CPC Class Codes: G02B 6/4459 : Ducts; Conduits; Hollow tubes for air blown fibres
• CPC Class Codes: G02B 6/562 : locatable, e.g. using magnetic means
• CPC Class Codes: H02G 1/08 : through tubing or conduit, e.g. rod or draw wire for pushing or pulling inserting electrical cables into tubes using wallbores E21B17/206; for optical cables G02B6/4401
• CPC Class Codes: H02G 2200/20 : Identification of installed cables
• CPC Class Codes: H02G 3/0481 : with a circular cross-section H02G3/0468, H02G3/0475 take precedence
• CPC Class Codes: H02G 3/06 : Joints for connecting lengths of protective tubing or channels, to each other or to casings, e.g. to distribution boxes; Ensuring electrical continuity in the joint
• CPC Class Codes: H02G 9/06 : in underground tubes or conduits; Tubes or conduits therefor
• CPC Class Codes: H02G 9/065 : Longitudinally split tubes or conduits therefor
• CPC Class Codes: Y10T 428/139 : Open-ended, self-supporting conduit, cylinder, or tube-type article

Abstract

The present invention is a toneable conduit that can transmit a signal and that can therefore be readily detected by toning equipment. In addition, the conduit of the invention can be readily coupled with other conduit to provide extended lengths of conduit. The toneable conduit includes an elongate polymeric tube having a wall with an interior surface, an exterior surface, and a predetermined wall thickness. A channel preferably extends longitudinally within the wall of the elongate polymeric tube and a stabilizing rib extends longitudinally along the interior surface of the wall of the elongate polymeric tube and is located radially inward from the channel. A continuous wire is coincident with the channel in the elongate polymeric tube and is preferably coated with a coating composition that prevents the wire from adhering to the polymer melt used to form the elongate polymeric tube. The present invention further includes methods of making the toneable conduit and methods of coupling a first toneable conduit with a second toneable conduit.

Claims

1. A method of making toneable conduit, comprising the steps of:

advancing a continuous wire; and

extruding a polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface, and a stabilizing rib extending longitudinally along the interior surface of the wall of the elongate polymeric tube such that the wire is embedded in the wall of the elongate polymeric tube and the stabilizing rib is located radially inward from the wire.

2. The method according to claim 1, wherein said extruding step comprises forming the polymer melt into the form of an elongate polymeric tube through the use of a die and a tip, wherein a groove in said tip forms the stabilizing rib in the conduit.

3. The method according to claim 1, wherein said advancing step comprises advancing the wire through a wire guide tube into the polymer melt.

4. The method according to claim 1, wherein said extruding step further comprises forming additional ribs extending longitudinally along the interior surface of the elongate polymeric tube to facilitate the installation of cable into the conduit.

5. The method according to claim 1, wherein said advancing step comprises advancing a high elongation wire.

6. The method according to claim 5, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 1%.

7. The method according to claim 5, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 3%.

8. The method according to claim 5, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

9. The method according to claim 8, wherein said advancing step comprises advancing a copper-clad steel wire.

10. The method according to claim 1, wherein said advancing step comprises advancing a continuous wire having a tensile strength of at least about 150 lbs.

11. The method according to claim 1, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

12. The method according to claim 11, wherein said advancing step comprises advancing a copper-clad steel wire.

13. The method according to claim 1, wherein said advancing step comprises advancing a continuous wire having a diameter of from about 0.32 mm to about 2.59 mm.

14. The method according to claim 1, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a wall of a predetermined thickness.

15. The method according to claim 14, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a smooth exterior surface.

16. The method according to claim 1, wherein said advancing step comprises advancing a twisted pair of continuous wires.

17. A method of making toneable conduit, comprising the steps of:

advancing a continuous wire; and

extruding a polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface such that the wire is embedded in the wall of the elongate polymeric tube;

wherein the continuous wire is coated with a coating composition that prevents the wire from adhering to the polymer melt used in said extruding step.

18. The method according to claim 17, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of a polymeric material selected from the group consisting of fluoropolymers, polyamides, polyesters, polycarbonates, polypropylene, polyurethanes, polyacetals, polyacrylics, epoxies and silicone polymers.

19. The method according to claim 18, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of a polymeric material that has a melting temperature of at least about 500°

F.

20. The method according to claim 19, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of polytetrafluoroethylene.

21. The method according to claim 17, wherein said advancing step comprises advancing the wire through a wire guide tube into the polymer melt.

22. The method according to claim 17, wherein said advancing step comprises advancing a high elongation wire.

23. The method according to claim 22, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 1%.

24. The method according to claim 22, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 3%.

25. The method according to claim 22, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

26. The method according to claim 25, wherein said advancing step comprises advancing a copper-clad steel wire.

27. The method according to claim 17, wherein said advancing step comprises advancing a continuous wire having a tensile strength of at least about 150 lbs.

28. The method according to claim 17, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

29. The method according to claim 17, wherein said advancing step comprises advancing a copper-clad steel wire.

30. The method according to claim 17, wherein said advancing step comprises advancing a continuous wire having a diameter of from about 0.32 mm to about 2.59 mm.

31. The method according to claim 17, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a wall of a predetermined thickness.

32. The method according to claim 31, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a smooth exterior surface.

33. The method according to claim 17, wherein said advancing step comprises advancing a twisted pair of continuous wires.

34. The method according to claim 17, where said extruding step comprises extruding a polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface, and a stabilizing rib extending longitudinally along the interior surface of the wall of the elongate polymeric tube such that the wire is embedded in the wall of the elongate polymeric tube and the stabilizing rib is located radially inward from the wire.

35. A method of making toneable conduit, comprising the steps of:

advancing a continuous wire;

extruding a polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface such that the wire is embedded in the wall of the elongate polymeric tube; and

cooling the polymer melt to form the elongate polymeric tube;

wherein the continuous wire is capable of transmitting a toning signal to allow the conduit to be detected by toning equipment and, after said cooling step, is capable of being torn out of the resulting polymeric tube to allow the conduit and wire to be coupled.

36. The method according to claim 35, wherein said advancing step comprises advancing a continuous wire that is coated with a coating composition that prevents the wire from adhering to the polymer melt used in said extruding step.

37. The method according to claim 36, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of a polymeric material selected from the group consisting of fluoropolymers, polyamides, polyesters, polycarbonates, polypropylene, polyurethanes, polyacetals, polyacrylics, epoxies and silicone polymers.

38. The method according to claim 37, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of a polymeric material that has a melting temperature of at least about 500°

F.

39. The method according to claim 38, wherein said advancing step comprises advancing a continuous wire coated with a coating composition formed of polytetrafluoroethylene.

40. The method according to claim 36, wherein said extruding step further comprises extruding the polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface, and a stabilizing rib extending longitudinally along the interior surface of the wall of the elongate polymeric tube such that the wire is embedded in the wall of the elongate polymeric tube and the stabilizing rib is located radially inward from the wire.

41. The method according to claim 35, wherein said extruding step further comprises extruding the polymer melt around the advancing wire in the form of an elongate polymeric tube having a wall with an interior surface and an exterior surface, and a stabilizing rib extending longitudinally along the interior surface of the wall of the elongate polymeric tube such that the wire is embedded in the wall of the elongate polymeric tube and the stabilizing rib is located radially inward from the wire.

42. The method according to claim 41, wherein said extruding step comprises forming the polymer melt into the form of an elongate polymeric tube through the use of a die and a tip, wherein a groove in said tip forms the stabilizing rib in the conduit.

43. The method according to claim 41, wherein said extruding step further comprises forming additional ribs extending longitudinally along the interior surface of the elongate polymeric tube to facilitate the installation of cable into the conduit.

44. The method according to claim 35, wherein said advancing step comprises advancing the wire through a wire guide tube into the polymer melt.

45. The method according to claim 35, wherein said advancing step comprises advancing a high elongation wire.

46. The method according to claim 45, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 1%.

47. The method according to claim 46, wherein said advancing step comprises advancing a high elongation wire has an elongation of at least about 3%.

48. The method according to claim 45, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

49. The method according to claim 48, wherein said advancing step comprises advancing a copper-clad steel wire.

50. The method according to claim 35, wherein said advancing step comprises advancing a continuous wire having a tensile strength of at least about 150 lbs.

51. The method according to claim 35, wherein said advancing step comprises advancing a continuous wire selected from the group consisting of copper-clad steel wire, copper-clad aluminum wire, copper wire, and tin copper wire.

52. The method according to claim 35, wherein said advancing step comprises advancing a copper-clad steel wire.

53. The method according to claim 35, wherein said advancing step comprises advancing a continuous wire having a diameter of from about 0.32 mm to about 2.59 mm.

54. The method according to claim 35, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a wall of a predetermined thickness.

55. The method according to claim 54, wherein said extruding step comprises extruding the polymer melt in the form of an elongate polymeric tube having a smooth exterior surface.

56. The method according to claim 35, wherein said advancing step comprises advancing a twisted pair of continuous wires.