Multi-layer tubular conduit
Methods and devices related to multi-layer tubular conduit are disclosed. The method of making the multi-layer tubular conduit includes providing a hermetically sealed metal tube, inserting a thermoplastic conduit within the tube, and surrounding the exterior of the tube with an overjacket. The multi-layer tubular conduit device includes three layers: a layer of thermaplastic conduit, a layer of hermetically sealed metal tube, and a layer of overjacket. The three layers are arranged coaxially such that they share a common central axis. The method of use includes installing a multi-layer tubular conduit device in a public or non-public environment. The multi-layer tubular conduit offers mechanical protection from harsh and/or hostile environments while still offering the flexibility of traditional conduit.
1. A method of making a multi-layer tubular conduit, the method comprising:
accessing a metal tube having an inside diameter, an outermost diameter, a hermetically sealed length, an interior, and an exterior, wherein the exterior is longitudinally corrugated along the hermetically sealed length, wherein accessing comprises accessing a plurality of individual metal tubes, and orbitally welding together the individual metal tubes end-to-end such that the metal tube is formed;
positioning a thermoplastic conduit within the interior of the metal tube such that there are no intervening layers between the interior of the metal tube and the thermoplastic conduit, wherein the thermoplastic conduit having an inside diameter and an outside diameter less than the inside diameter of the metal tube, wherein the thermoplastic conduit is hollow;
routing a signal cable within the thermoplastic conduit longitudinally such that the thermoplastic conduit contains only one bundle including the signal cable; and
surrounding the exterior of the metal tube with an overjacket such that the thermoplastic conduit, the metal tube, and the overjacket are coaxial to each other and such that there are no intervening layers between the exterior of the metal tube and the overjacket, wherein the overjacket having an outside diameter and an innermost diameter greater than the outermost diameter of the metal tube.
2. The method of claim 1 , wherein the metal tube includes a stainless steel, wherein the exterior that is longitudinally corrugated includes the stainless steel.
3. The method of claim 1 , wherein the thermoplastic conduit includes at least one of one of a Polyvinylchloride (PVC), a Polyethylene (PE), a Polyurethane, or a Nylon engaging the metal tube.
4. The method of claim 1 , wherein the thermoplastic conduit includes a Polyethylene (PE) conduit including at least one of a high-density polyethylene (HDPE), a medium density polyethylene (MDPE), or a low density polyethylene (LDPE) engaging the metal tube.
5. The method of claim 1 , wherein the thermoplastic conduit includes a fire retardant material engaging the metal tube.
6. A method of making a multi-layer tubular conduit, the method comprising:
accessing a metal tube having an inside diameter, an outside diameter, a hermetically sealed length, an interior, and an exterior, wherein the exterior is longitudinally corrugated along the hermetically sealed length, wherein accessing comprises accessing a plurality of individual metal tubes, and orbitally welding together the individual metal tubes end-to-end such that the metal tube is formed;
positioning a thermoplastic conduit within the interior of the metal tube such that there are no intervening layers between the interior of the metal tube and the thermoplastic conduit, wherein the thermoplastic conduit having an inside diameter and an outside diameter less than the inside diameter of the metal tube, wherein the thermoplastic conduit is hollow, wherein the thermoplastic conduit includes a layer of friction-reducing material engaging the metal tube;
routing a signal cable within the thermoplastic conduit longitudinally such that contains only one bundle including the signal cable; and
surrounding the exterior of the metal tube with an overjacket such that the thermoplastic conduit, the metal tube, and the overjacket are coaxial to each other and such that there are no intervening layers between the exterior of the metal tube and the overjacket, wherein the overjacket having an outside diameter and an inside diameter greater than the outside diameter of the metal tube.
7. The method of claim 6 , wherein the friction-reducing material includes a silicone polymer engaging the metal tube.
8. The method of claim 1 , wherein the thermoplastic conduit has an outside diameter in a range of 2 millimeters to 15 inches.
9. The method of claim 1 , wherein the thermoplastic conduit is colored with a colored dye before the positioning.
10. The method of claim 9 , wherein the thermoplastic conduit includes at least one stripe of contrasting color before the positioning.
11. The method of claim 2 , wherein the stainless steel is type 304 stainless steel.
12. The method of claim 1 , further comprising:
extending the signal cable to a first length between 80 feet and 6,000 feet within the metal tube as the metal tube extends a second length between 80 feet to 6,000 feet based on the orbitally welding.
13. The method of claim 1 , further comprising:
orbitally welding together the individual metal tubes end-to-end such that the metal tube extends to a length between 160 feet and 12,000 feet.
14. The method of claim 1 , wherein the inside diameter of the metal tube is in a range of 2 millimeters to 15 inches.
15. The method of claim 1 , wherein the outermost diameter of the metal tube is in a range of 2 millimeters to 15 inches.
16. The method of claim 1 , wherein the overjacket has a thickness in a range of 0.05 inches to 0.10 inch.
17. The method of claim 1 , wherein the overjacket has a thickness in a range of 0.06 inches to 0.08 inches.
18. The method of claim 1 , wherein the overjacket has a thickness of 0.070 inches.
19. The method of claim 1 , wherein the overjacket includes at least one of a Polyvinylchloride (PVC), a Polyethylene (PE), a Polyurethane, or a Nylon.
20. The method of claim 1 , wherein the overjacket includes at least one of a high-density polyethylene (HDPE), a medium density polyethylene (MDPE), or a low density polyethylene (LDPE).
21. The method of claim 1 , wherein the overjacket includes a fire retardant material.
22. The method of claim 21 , wherein the fire retardant material includes at least one of a Low Smoke Zero Halogen (LSZH), a riser rated material, or a plenum rated material.
23. The method of claim 1 , wherein the overjacket includes at least one of a Polyvinylidene Fluoride (PVDF) or a Low Smoke Zero Halogen (LSZH).
24. The method of claim 1 , wherein the innermost diameter of the overjacket is in a range of 2 millimeters to 15 inches.
25. The method of claim 1 , wherein the outside diameter of the overjacket is in a range of 2 millimeters to 15 inches.
26. The method of claim 1 , wherein the orbitally welding comprises:
welding a pair of end portions of a pair of the metal tubes such that the pair of end portions forms a hermetic seal between the pair of metal tubes.
27. The method of claim 1 , wherein the signal cable includes a fiber optic cable.
28. The method of claim 1 , wherein the positioning the thermoplastic conduit within the interior of the metal tube comprises at least one of:
pushing the thermoplastic conduit into the metal tube as hermetically sealed,
pulling the thermoplastic conduit into the metal tube as hermetically sealed, or
propelling the thermoplastic conduit into the metal tube as hermetically sealed.
29. The method of claim 1 , wherein the positioning the thermoplastic conduit within the interior of the metal tube comprises:
wrapping the metal tube around the thermoplastic conduit, and
welding the metal tube with another tube to form a hermetic seal.
30. The method of claim 29 , wherein the wrapping comprises:
arranging the thermoplastic conduit within the metal tube, as hermetically sealed, coaxially such that the thermoplastic conduit and the metal tube share a common central axis.