Methods of manufacturing an expansion compensator

1. A method of producing an expansion compensator, the method comprising:

(a) providing an inner plastic liner having first and second spaced apart ends, an inner surface, an outer surface, and an interior volume extending from the first end to the second end;

(b) positioning the inner plastic liner interior of an elongate metal conduit, the elongate metal conduit having first and second spaced apart ends, an inner surface, an outer surface, and an expansion/contraction section;

(c) applying pressure to a fluid positioned in the interior volume of the inner plastic liner while the inner plastic liner is at or above a forming temperature to expand the inner plastic liner whereby the expanded inner plastic liner has an expansion/contraction section; and,

(d) cooling the inner plastic liner to below the forming temperature

wherein the expansion/contraction section of the elongate metal conduit comprises a bellows having radial inner valleys and radial outer peaks, and the inner plastic liner has a wall of generally uniform thickness whereby the expanded inner plastic liner has an expansion/contraction section having a non-uniform thickness.

2. The method of claim 1 wherein radial inner valleys of the expansion/contraction section of the inner plastic liner have a greater wall thickness than radial outer peaks of the expansion/contraction section of the inner plastic liner.

3. The method of claim 1 further comprising providing a plurality of openings at the first and second ends of the elongate metal conduit and overmolding a first connector on the first ends of the inner plastic liner and the elongate metal conduit and overmolding a second connector on the second ends of the inner plastic liner and the elongate metal conduit.

4. The method of claim 1 further comprising providing a sleeve having a generally longitudinally extending outer surface, wherein the elongate metal conduit is provided interior of the sleeve.

5. The method of claim 1 , further comprising heating the inner plastic liner so that the inner plastic liner is at or above the forming temperature during expansion of the inner plastic liner.

6. The method of claim 5 wherein heating the inner plastic liner comprises providing a heated fluid in the interior volume of the inner plastic liner.

7. The method of claim 6 wherein step (c) comprises applying pressure to the heated fluid after the inner plastic liner has been heated by the heated fluid.

8. The method of claim 1 further comprising providing a first connector on the first ends of the inner plastic liner and the elongate metal conduit and providing a second connector on the second ends of the inner plastic liner and the elongate metal conduit.

9. The method of claim 8 further comprising providing a gasket on the outer surface of the elongate metal conduit adjacent the first end of the elongate metal conduit prior to providing the first connector over the first ends of the inner plastic liner and the elongate metal conduit whereby the gasket is positioned between the elongate metal conduit and the first connector.

10. The method of claim 8 , wherein the first and second connectors are provided by overmolding.

11. The method of claim 10 further comprising providing a gasket on the outer surface of the elongate metal conduit adjacent the first end of the elongate metal conduit prior to overmolding the first connector over the first ends of the inner plastic liner and the elongate metal conduit whereby the gasket is positioned between the elongate metal conduit and the overmolded first connector.

12. The method of claim 1 wherein, prior to expanding the inner plastic liner, an air gap is located between the outer surface of the inner plastic liner and the inner surface of the elongate metal conduit and wherein step (d) includes withdrawing air from the air gap while expanding the inner plastic liner.

13. The method of claim 12 wherein the air is withdrawn by applying a vacuum to the air gap.

14. The method of claim 12 wherein at least one of the inner surface of the elongate metal conduit and the outer surface of the inner plastic liner has a longitudinally extending recess, and wherein withdrawing air from the air gap comprises drawing air through the longitudinally extending recess while expanding the inner plastic liner.

15. The method of claim 12 further comprising inserting a thin elongate member in the air gap prior to expanding the inner plastic liner.

16. A method of producing an expansion compensator, the method comprising:

(a) providing an inner plastic liner having first and second spaced apart ends, an inner surface, an outer surface, and an interior volume extending from the first end to the second end;

(b) positioning the inner plastic liner interior of an elongate metal conduit, the elongate metal conduit having first and second spaced apart ends, an inner surface, an outer surface, and an expansion/contraction section;

(c) applying pressure to a fluid positioned in the interior volume of the inner plastic liner while the inner plastic liner is at or above a forming temperature to expand the inner plastic liner whereby the expanded inner plastic liner has an expansion/contraction section; and,

(d) cooling the inner plastic liner to below the forming temperature

(e) providing a first connector on the first ends of the inner plastic liner and the elongate metal conduit and providing a second connector on the second ends of the inner plastic liner and the elongate metal conduit

wherein the first and second connectors are provided by overmolding, and

wherein the first end of the elongate metal conduit is provided with a plurality of openings and the method further comprises overmolding the first connector on the first ends of the inner plastic liner and the elongate metal conduit whereby the first connector comprises a first portion on the outer surface of the elongate metal conduit, a second position on the inner surface of the inner plastic liner and connecting portions that extend through the plurality of openings.