Tunneling system including conduit construction system

Abstract

A tunneling system includes a tunneling device (102) configured to travel through an underground location and displace material to form a tunnel (103). The tunnel has a sidewall (106) defining an interior cavity (112). The tunneling system also includes a conduit construction system (104) including a placement device (142) coupled to the tunneling device and configured to deploy a conduit wall material (138) along the sidewall of the tunnel. The conduit wall material is configured to engage the sidewall and define a conduit passageway.

Description

TUNNELING SYSTEM INCLUDING CONDUITCONSTRUCTION SYSTEMBACKGROUND

[0001] The field of the disclosure relates to tunneling systems, and more particularly to tunneling systems including conduit construction systems.

[0002] Tunneling devices are used to travel through underground locations and displace material to form and shape tunnels through the underground locations. After the tunnels are formed, conduits can be constructed and then positioned within the tunnel. However, at least some known systems for constructing and positioning the conduits require the tunnels to be formed and the conduit to be constructed and positioned within the tunnel in a multi-phase process which increases the time and cost required to form the tunnel and the conduit. In addition, some underground locations may include non-cohesive materials such as sand and mud that make it difficult to form a tunnel and / or may cause the tunnel to collapse before a conduit is positioned.

[0003] Accordingly, it is desirable to provide conduit construction systems that reduce the time and cost required to form the conduit and increase the structural stability of the tunnel.BRIEF DESCRIPTION

[0004] In one aspect, a tunneling system includes a tunneling device configured to travel through an underground location and displace material to form a tunnel. The tunnel has a sidewall defining an interior cavity. The tunneling system also includes a conduit construction system including a placement device coupled to the tunneling device and configured to deploy a conduit wall material along the sidewall of the tunnel. The conduit wall material is configured to engage the sidewall and define a conduit passageway.

[0005] In another aspect, a conduit construction system includes a conduit wall material and a placement device coupled to a tunneling device. The tunneling device is configured to travel through an underground location and displace material to form a tunnel. The tunnel has a sidewall defining an interior cavity. The placement device is configured to deploy the conduit wall material along the sidewall of the tunnel. The conduit wall material is configured to engage the sidewall and define a conduit passageway.

[0006] In yet another aspect, a method for constructing a conduit in a tunnel having a sidewall defining an interior cavity includes moving a tunneling device through an underground location and displacing material using a tunneling tool on the tunneling device to form a tunnel having a sidewall defining an interior cavity. The method also includes deploying a conduit wall material along the sidewall of the tunnel using a placement device coupled to the tunneling device, wherein the conduit wall material is configured to engage the sidewall and define a conduit passageway.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0008] FIG. 1 is a schematic diagram of a system including a conduit construction system and a tunneling device traveling underground;

[0009] FIG. 2 is a schematic diagram of a portion of an embodiment of a conduit construction system for use with the system shown in FIG. 1, the conduit construction system including a sprayer configured to discharge a conduit wall material;

[0010] FIG. 3 is a schematic diagram of a portion of another embodiment of a conduit construction system for use with the system shown in FIG. 1. the conduit construction system including an inverted membrane;

[0011] FIG. 4 is a schematic diagram of a portion of another embodiment of a conduit construction system for use with the system shown in FIG. 1, the conduit construction system including a conduit wall material that is pulled behind a placement device; and

[0012] FIG. 5 is a flow chart of an example method of constructing a conduit using the system shown in FIG. 1.

[0013] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems including one or more embodiments of this disclosure.As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.DETAILED DESCRIPTION

[0014] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0015] The singular forms ‘"a”, "an”, and ‘"the” include plural references unless the context clearly dictates otherwise.

[0016] '‘Optional or ‘"optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not.

[0017] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0018] As used herein, the terms “processor” and “computer,” and related terms, e.g.. “processing device,” “computing device,” and “controller” are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), and application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, “memory” may include, but is not limited to, a computer-readable medium, such as a random access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magnetooptical disk (MOD), and / or a digital versatile disc (DVD) may also be used. Also, in the embodiments descnbed herein, additional input channels may be, but are not limited to,computer peripherals associated with an operator interface such as a touchscreen, a mouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the example, additional output channels may include, but not be limited to. an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a PLC, a field programmable gate array (FPGA), a digital signal processing (DSP) device, and / or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and / or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are exemplary only, and thus are not intended to limit in any way the definition and / or meaning of the term processor and processing device.

[0019] Embodiments described herein relate to a tunneling system including a conduit construction system. The conduit construction system is coupled to a tunneling device and is configured to place a conduit in a tunnel as the tunneling device travels through an underground location. The conduit construction system includes a conduit wall material and a placement device coupled to the tunneling device. The placement device is configured to deploy the conduit wall material along a sidewall of a tunnel. The conduit wall material is configured to engage the sidewall and define a conduit passageway. For example, the conduit wall material extends along the sidewall of the tunnel from the tunneling device to an entrance of the tunnel. The placement device may include a sprayer, a printer, and / or a tool configured to position the conduit wall material relative to the sidewall of the tunnel. The conduit wall material may be dispensed in an uncured state or a cured state. In some embodiments, the placement device is configured to pull the conduit wall material behind the placement device and / or push the conduit wall material. In further embodiments, the conduit wall material includes a membrane or bladder that is inverted through the tunnel and the placement device facilitates placement of the membrane.The conduit construction system facilitates simultaneous construction of a conduit and a tunnel. As a result, the time required to construct the conduit is reduced. Further, the conduit construction system reduces costs of tunneling operations.

[0020] FIG. l is a schematic diagram of a system 100 including a tunneling device, broadly a maintenance apparatus 102, traveling underground and a conduit construction system 104. For example, tunneling device 102 is configured to travel through a tunnel 103 and / or displace material to form tunnel 103. Tunnel 103 includes a sidewall 106 having an interior surface 108 extending around a central axis 110 and defining an interior cavity 112. Tunneling device 102 is configured to fit within interior cavity7112 and travel along the length of tunnel 103. Accordingly, tunneling device 102 facilitates construction of tunnel 103 and / or inspection and repair of tunnel 103. Moreover, tunneling device 102 is self- propelled, meaning that tunneling device 102 moves within interior cavity' 112 without an external force acting on tunneling device 102.

[0021] During operation, for example, tunneling device 102 may be positioned at a surface 114 proximate an underground location, and tunneling device 102 travels through surface 114 to form an opening into tunnel 103. In the illustrated embodiment, tunneling device 102 travels in a travel direction 115. In some embodiments, tunneling device 102 traverses transitions in tunnel 103 such as bends or size transitions. As tunneling device 102 travels through underground locations, tunneling device 102 is configured to form tunnel 103 and / or inspect and / or repair any portions of tunnel 103.

[0022] Tunneling device 102 is any device capable of traveling underground. In the example, tunneling device 102 includes a body assembly 134 including at least one section 136 that extends along central axis 110. At least one section 136 of body assembly 134 is configured to move body assembly 134 through underground locations. For example, at least one section 136 of body assembly 134 is designed to provide an axial force and a radial force that propel body assembly 134 and tether 132 through underground locations. In the example embodiment, body assembly 134 and tether 132 do not require a separate linear actuator for propulsion. In some embodiments, body assembly 134 includes at least three sections 136 (e.g., a first section, a second section, and a third section) that are configured to cooperate and provide a crawling action to propel body assembly 134 through tunnel 103. In further embodiments, body assembly 134 includes one or more drive systemsconfigured to provide propulsion for tunneling device 102. In alternative embodiments, tunneling device 102 includes any body assembly 134 that enables tunneling device 102 to operate as described herein.

[0023] System 100 includes tunneling device 102, conduit construction system 104, a controller 116 communicatively coupled to tunneling device 102, and at least one supply system 118. In some embodiments, supply system 118 includes a pressurized fluid source 120, a power source, and / or a reservoir of material for tunneling device 102. Supply system 118 is coupled to tunneling device 102 via a tether 132.

[0024] Conduit construction system 104 includes a placement device 142 coupled to tunneling device 102 and configured to deploy a conduit wall material 138 along sidewall 106 of tunnel 103. For example, in some embodiments, placement device 142 is configured to pull and / or push conduit wall material 138 along sidewall 106 of tunnel 103 as tunneling device 102 travels underground. In further embodiments, placement device 142 includes a dispenser configured to discharge conduit wall material 138 toward sidewall 106. For example, the dispenser may include a sprayer (e.g., sprayer 204 shown in FIG. 2), a tool or trowel, and / or a printer that is configured to place conduit wall material 138 in one or more layers along sidewall 106 to fabricate a conduit as tunneling device 102 travels underground. In alternative embodiments, conduit construction system 104 includes any placement device 142 that enables conduit construction system 104 to operate as described herein. For example, in some embodiments, conduit wall material is dispensed from placement device 142 and delivered to sidewall 106 in an unshaped state and a portion of placement device 142 or body assembly 134 engages and shapes conduit wall material 138 as tunneling device 102 travels through tunnel 103.

[0025] In addition, in the example embodiment, placement device 142 is configured to move with tunneling device 102 and position conduit wall material 138 along sidewall 106 of tunnel 103 when tunneling device 102 travels through tunnel 103. For example, placement device 142 is coupled to body assembly 134 of tunneling device 102. Placement device 142 is configured to dispense conduit wall material 138 such that conduit w all material 138 extends away from tunneling device 102 and along sidew all 106 of tunnel 103.

[0026] In the example embodiment, conduit wall material 138 extends from tunneling device 102 to an entrance of tunnel 103. In addition, when deployed, conduit wall material 138 is cylindrical and extends continuously around a circumference of tunnel 103. In addition, conduit wall material 138 may be liquid impermeable and define a passageway for fluid to flow through tunnel 103. In some embodiments, conduit wall material 138 is flexible and conforms to a shape of sidewall 106. For example, conduit wall material 206 may include a polymer, a thermoplastic, and / or a binder. In other embodiments, conduit wall material 206 is rigid. For example, in some embodiments, conduit wall material 138 may include a metal and / or a plastic.

[0027] During operation, in the example embodiment, placement device 142 positions conduit wall material 138 along sidewall 106 of tunnel 103 to form a continuous support along sidewall 106 as tunneling device 102 (shown in FIG. 1) moves through the underground location. In some embodiments, conduit wall material 138 is dispensed in an uncured state and conduit wall material 138 is configured to cure in place along sidewall 106 into a solid, rigid shape that supports sidewall 106.

[0028] Conduit wall material 138 is configured to engage sidewall 106 of tunnel 103 and provide structural support for tunnel 103. For example, conduit wall material 138 is configured to provide a force to sidewall 106 that supports sidewall 106 and facilitates maintaining structural stability of tunnel 103. In the example embodiment, conduit wall material 138 is configured to deliver the force along an entirety of sidewall 106. In alternative embodiments, conduit construction system 104 includes any conduit wall material 138 that enables conduit construction system 104 to operate as described herein.

[0029] In the example embodiment, tether 132 extends through tunnel 103 and along central axis 110. In some embodiments, placement device 142 includes an interface 133 for tether 132, and conduit wall material 138 defines a passageway 131 for tether 132. In alternative embodiments, conduit wall material (s) 138 and tether 132 are arranged in any manner that enables conduit construction system 104 to operate as described herein.

[0030] In addition, in the example embodiment, controller 116 is configured to provide instructions to move tunneling device 102 through tunnel 103 and / or to perform inspection or repair operations. Controller 116 includes a transceiver 124, aprocessor 126, and a memory 128. In some embodiments, controller 1 16 is positioned remotely from tunneling device 102, e.g., controller 116 is located at a base station that enables an operator on an exterior of tunnel 103 to interact with tunneling device 102, and / or controller 116 can be at least partly incorporated into and located on board tunneling device 102. Transceiver 124 is communicatively coupled with tunneling device 102, and is configured to send information to and receive information from a transceiver of tunneling device 102. In some embodiments, transceiver 124 and a transceiver on tunneling device 102 communicate wirelessly. In alternative embodiments, tunneling device 102 and controller 116 communicate in any manner that enables system 100 to operate as described herein. For example, in some embodiments, controller 116 and tunneling device 102 exchange information through a wired link extending between tunneling device 102 and controller 116 through tether 132.

[0031] In addition, in some embodiments, controller 116 is at least partly located on board tunneling device 102 and is configured to execute instructions for controlling components of tunneling device 102. such as a maintenance device and drive systems. For example, controller 116 executes instructions that cause tunneling device 102 to move in a selected direction. In alternative embodiments, tunneling device 102 includes any controller that enables system 100 to operate as described herein. In some embodiments, controller 116 is not located on board tunneling device 102.

[0032] In some embodiments, tunneling device 102 includes one or more sensors and / or repair tools or pipe maintenance tools. For example, in some embodiments, tunneling device 102 includes a repair tool configured to repair interior surface 108, or an inspection tool configured to inspect a portion of the interior cavity 112.

[0033] Also, in the example embodiment, an operator interface 130 is configured to display information relating to the characteristics detected by tunneling device 102 for interpretation by the operator. Operator interface 130 may be included on a remote computing device (not shown) and / or may be incorporated with controller 116. Operator interface 130 may include, among other possibilities, a web browser and / or a client application. For example, in some embodiments, operator interface 130 displays images of interior surface 108 and / or conduit wall material 138 based on received signals. In some embodiments, operator interface 130 allows an operator to input and / or view informationrelating to control of tunneling device 102. In the example, operator interface 130 is configured to display information relating to the state of one or more of a maintenance device and a power source for interpretation by the operator. For example, state information may include a position of tunneling device 102 along a length of tunnel 103. State information may also include a charge status of a power source and / or a current draw for the various drive and positioning motors. In various embodiments, processor 126 translates operator inputs into steering, tool motion, camera control, sensor control, sensor motion, and / or any other commands and sends information via transceiver 124 to tunneling device 102 via a transceiver of tunneling device 102. In some embodiments, operator control of tunneling device 102 and / or conduit construction system 104 is in real time, such as through ajoystick, a keyboard, a touchscreen, a remote motion capture system, and / or a wearable motion capture system or other interface having similar function. In other embodiments, tunneling device 102 and / or conduit construction system 104 is controlled partially or wholly according to a pre-programmed routine. In further embodiments, tunneling device 102 and / or conduit construction system 104 is at least partially automated. In some embodiments, an operator inputs information such as operation goals or conditional directions. In further embodiments, information, such as information received by controller 116 from tunneling device 102, control data sent to tunneling device 102, and additional operator inputs or state information (e.g., location, time, orientation, datalink quality, battery levels, repair material levels, failure mode indicators), is logged into memory' 128.

[0034] Moreover, in the example embodiment, controller 116 is positioned on the exterior of tunnel 103 and communicates with tunneling device 102 positioned within interior cavity 112 of tunnel 103. For example, controller 116 is configured to send information to tunneling device 102 relating to the propulsion and / or steering of tunneling device 102 and / or positioning of conduit wall material 138 while tunneling device 102 is moving within interior cavity' 112 of tunnel 103 through a wireless connection and / or tether 132. In alternative embodiments, controller 116 and tunneling device 102 are configured in any manner that enables system 100 to operate as described herein.

[0035] FIG. 2 is a schematic diagram of a portion of a conduit construction system 200 for use with system 100 shown in FIG. 1. Conduit construction system 200 includes a placement device 202 including a sprayer 204 configured to discharge a conduitwall material 206 toward sidewall 106 of tunnel 103. For example, in some embodiments, sprayer 204 includes one or more nozzles 210 arranged to dispense conduit wall material 206 outward from sprayer 204 and toward sidewall 106. In the example embodiment, sprayer 204 includes an array of nozzles 210 positioned at intervals along a length of sprayer 204 and around a circumference of sprayer 204. Nozzles 210 are positioned to provide overlapping spray patterns in longitudinal and circumferential directions and such that conduit wall material 206 completely covers sidewall 106. In some embodiments, sprayer 204 is coupled to body assembly 134 between opposing ends of body assembly 134, e.g., a middle of body assembly 134. In further embodiments, sprayer 204 is coupled to a rear of body assembly 134, as illustrated in FIG. 2.

[0036] In addition, in the example embodiment, conduit construction system 200 includes a reservoir 212 containing conduit wall material 206. Reservoir 212 is coupled to sprayer 204 and configured to provide a supply of conduit wall material 206 to be dispensed from sprayer 204 of placement device 202. In some embodiments, conduit wall material 206 may be dispensed in a single layer or two or more layers on sidewall 106. In alternative embodiments, conduit wall material 206 is stored and / or dispensed in any manner that enables conduit construction system 200 to operate as described herein. In some embodiments, conduit wall material 206 is extruded or printed onto sidewall 106. For example, conduit wall material 206 may be heated within reservoir 212 and dispensed from reservoir 212 using atool. After being heated and dispensed, conduit wall material 206 may cool in place along sidewall 106. In further embodiments, conduit wall material 206 includes a binder and the binder is dispensed onto sidewall 106 to bind, solidify, or otherwise consolidate the material around tunnel 103 to form a conduit.

[0037] In the example embodiment, conduit wall material 206 has an uncured state and a cured state. For example, conduit wall material 206 is stored in a liquid, uncured state within reservoir 212. Conduit wall material 206 transitions into a solid, uncured state after conduit wall material 206 is dispensed from placement device 202. In the example embodiment, conduit wall material 206 is configured to cure in place along sidewall 106. For example, during operation, sprayer 204 is configured to dispense conduit wall material 206 in the uncured state toward sidewall 106. Conduit wall material 206 engages sidewall 106, attaches to sidewall 106, and cures in place along sidewall 106. In some embodiments.placement device 202 or body assembly 134 (shown in FIG. 1) contacts and shapes conduit wall material 206 in the uncured state. For example, a portion of body assembly 134 may have a width that is equal to a desired width of the conduit and may contact conduit wall material 206 to shape conduit wall material to the desired width.

[0038] Conduit wall material 206 is configured to define a passageway 214 for tether 132. For example, conduit wall material 206 defines passageway 214 extending around and along axis 110. In addition, conduit construction system 200 includes a tether support 216 extending from tunneling device 102 and configured to prevent tether 132 contacting conduit wall material 206 in the uncured state and / or facilitate tether 132 moving through passageway 214. In alternative embodiments, conduit wall material 206 defines any passageway 214 and / or interface that enables conduit construction system 200 to operate as described herein.

[0039] During operation, sprayer 204 discharges conduit wall material 206 as conduit wall material 206 moves through the underground location. A controller (e.g., controller 116 shown in FIG. 1) is configured to control an operating parameter of sprayer 204 (e.g.. a flowrate of conduit wall material 206 being dispensed from sprayer 204) based on a speed of tunneling device 102. For example, the controller may increase or decrease the flowrate of conduit wall material 206 being dispensed from sprayer 204 to prevent underapplication or overapplication of conduit wall material 206 on sidewall 106 when the speed of tunneling device 102 increases or decreases.

[0040] FIG. 3 is a schematic diagram of a portion of a conduit construction system 300 for use with system 100 shown in FIG. 1. Conduit construction system 300 includes a placement device 302 and conduit wall material 304. In the example embodiment, conduit wall material 304 includes an inverted membrane that forms a bladder 306. For example, bladder 306 is constructed of an elastic, flexible material such as a plastic sheet that may be dispensed in one or more layers. Bladder 306 is able to change shape and conform to the shape of sidewall 106 and traverse bends and obstacles in tunnel 103. In other example embodiments, bladder 306 is constructed of any material that enables conduit construction system 104 to operate as described herein. For example, in some embodiments, conduit wall material 304 is constructed of a porous material. In further embodiments, conduit wall material 304 is constructed of an impermeable fabric.

[0041] Conduit wall material 304 extends from tunneling device 102, along sidewall 106 of tunnel 103, and along and around tether 132. Conduit wall material 304 may support tunnel 103 and form a conduit through tunnel 103. For example, conduit wall material 304 is configured to form a passageway through tunnel 103 and remain in place after tunneling device 102 is removed. In addition, conduit wall material 304 forms bladder 306 between tether 132 and sidewall 106 and reduces friction on tether 132. Seals may be located at the interface of tether 132 and bladder 306.

[0042] Bladder 306 may be selectively pressurized to regulate the formation of bladder 306 and facilitate movement of tether 132. In some examples, pressurized fluid drives conduit wall material 304 along the sidewalls when tether 132 is pulled along behind a maintenance apparatus. In other examples, a drive system such as a pulley is arranged to direct conduit wall material 304 along with tether 132. The drive system may be positioned on the exterior of conduit construction system 300. In other examples, conduit wall material 304 is propelled along sidewalls in any manner that enables conduit construction system 300 to operate as described herein.

[0043] In some embodiments, a supply station 310 is configured to continuously supply and weld material to form bladder 306. For example, supply station 310 includes at least one spool of material and a welder. Conduit wall material 304 is dispensed from the spool and welded at seams by the welder to form a continuous bladder 306. Conduit wall material 304 can be continuously supplied in a virtually endless chain because the spools can be swapped out and welder will weld the new material. For example, supply station 310 is configured to continuously supply conduit wall material 304 for bladder 306 to expand as the tunneling device travels underground. In some embodiments, bladder 306 is preformed and does not require welding. For example, supply station 310 may include atube containing and configured to dispense conduit wall material 304 in the preformed state.

[0044] In the example embodiment, conduit wall material 304 defines a passageway 308 sized to receive tether 132. For example, conduit wall material 304 extends along central axis 110 and around tether 132 within passageway 308. Passageway 308 extends along central axis 110 and along the entire length of conduit wall material 304. During operation, tether 132 extends through passageway 308 and may move relative toconduit wall material 304 as tunneling device 102 travels through underground locations. Conduit wall material 304 supports tether 132 and reduces friction forces on tether 132. Accordingly, passageway 308 facilitates tether 132 extending from tunneling device 102 to an exterior of tunnel 103.

[0045] FIG. 4 is a schematic diagram of a portion of a conduit construction system 400 for use with system 100 shown in FIG. 1. Conduit construction system 400 includes a placement device 402 and a conduit wall material 404 that is pulled behind placement device 402. For example, placement device 402 is configured to pull conduit wall material 404 along sidewall 106 of tunnel 103 as tunneling device 102 travels underground.

[0046] In the example embodiment, conduit wall material 404 is a cylinder and extends around a circumference of tunnel 103. In addition, conduit wall material 404 is rigid. In alternative embodiments, conduit construction system 400 includes any conduit wall material 404 that enables conduit construction system 400 to operate as described herein. For example, in some embodiments, conduit wall material 404 is flexible and changes shape as conduit wall material 404 is positioned along sidewall 106. In some embodiments, conduit wall material 404 is stored in a collapsed configuration and is transitioned to an extended position when conduit wall material 404 is positioned along sidewall 106. In further embodiments, conduit wall material 404 includes a plurality of sections that are deployed and coupled together to form the conduit.

[0047] In the example embodiment, conduit wall material 404 is configured to facilitate an interface with tether 132 for placement and / or removal of tether 132. For example, in some embodiments, conduit wall material 304 is C-shaped or includes a joint or seam that facilitates tether 132 being positioned in a passageway 406 defined by conduit wall material 404. The joint or seam in conduit wall material 404 may be sealed after tether 132 is positioned relative to conduit wall material 404. In further embodiments, tether 132 and conduit wall material 404 are arranged on one or more spools to be deployed in a coordinated manner with tether 132 positioned within passageway 406 of conduit wall material 404.

[0048] FIG. 5 is a flow chart of an example method 500 of maintaining tunnel 103 (shown in FIG. 1) using tunneling device 102 (shown in FIG. 1) and conduit construction system 104 (shown in FIG. 1). In reference to FIGS. 1 and 5. method 500 includes moving 502 tunneling device 102 through an underground location and displacing504 material using a tunneling tool on tunneling device 102 to form tunnel 103 having sidewall 106 defining an interior cavity 112.

[0049] In addition, method 500 includes deploying 506 conduit wall material 138 along sidewall 106 of tunnel 103 using placement device 142 coupled to tunneling device 102. For example, in some embodiments, placement device 142 pulls conduit wall material 138 behind placement device 142 and positions conduit wall material 138 along sidewall 106 as tunneling device 102 travels underground. In further embodiments, placement device 142 sprays conduit wall material 138 toward sidewall 106. In further embodiments, placement device 142 includes a printer configured to deposit conduit wall material 138 along sidewall 106 to fabricate a conduit as tunneling device 102 travels underground. In further embodiments, conduit wall material 138 includes a membrane that forms a bladder and is positioned along sidewall 106 by placement device 142.

[0050] When positioned by placement device 142. conduit wall material 138 is configured to extend away from tunneling device 102 and along sidewall 106 of tunnel 103. Conduit wall material 138 is configured to engage sidewall 106 and define a conduit passageway. In some embodiments, placement device 142 continuously dispenses material for conduit wall material 138 to expand as tunneling device 102 travels underground. Also, in some embodiments, placement device 142 dispenses conduit wall material 138 in an uncured state and conduit wall material 138 is configured to cure in place along sidewall 106. In some embodiments, conduit wall material 138 is transitioned from a collapsed configuration inside reservoir 212 to an extended configuration when conduit wall material 138 is dispensed. In the example embodiment, conduit construction system 104 is configured to position conduit wall material 138 and construct conduit in place as tunneling device 102 travels. As a result, conduit construction system 104 reduces the time and cost to form conduits.

[0051] In the example embodiment, any steps of method 500 are repeated any number of times required for tunneling device 102 to travel a desired distance through tunnel 103 and / or to displace material and form a desired length of tunnel 103.

[0052] An example technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) reducing the time to construct tunnels through underground locations; (b) enabling tunneling operations and / or inspection and repair of aninterior cavity of a tunnel at greater distances from an access opening; (c) facilitating construction of tunnels in a wider range of materials; (d) facilitating new tunnel designs including curves, bends, and turns; and (e) reducing the cost of tunneling operations.

[0053] Examples of systems and methods for use in tunneling operations are described above in detail. The methods and systems are not limited to the specific embodiments described herein, but rather, components of systems and / or steps of the methods may be utilized independently and separately from other components and / or steps described herein. For example, the method may also be used in combination with other components, and are not limited to practice only with tunnels as described herein. Rather, the example can be implemented and utilized in connection with many other applications.

[0054] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and / or claimed in combination w ith any feature of any other drawing.

[0055] This w ritten description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A tunneling system comprising: a tunneling device configured to travel through an underground location and displace material to form a tunnel the tunnel having a sidewall defining an interior cavity; and a conduit construction system including a placement device coupled to said tunneling device and configured to deploy a conduit wall material along the sidewall of the tunnel, wherein the conduit wall material is configured to engage the sidewall and define a conduit passageway.

2. The tunneling system in accordance with Claim 1, wherein the deployed conduit wall material is cylindrical and extends around a circumference of the tunnel, and wherein said placement device is configured to pull the deployed conduit wall material along the sidewall of the tunnel as said tunneling device travels underground.

3. The tunneling system in accordance with Claim 1, further comprising a tether coupled to said tunneling device and extending through the conduit passageway.

4. The tunneling system in accordance with Claim 3, wherein the deployed conduit wall material is configured to engage said tether and reduce contact and friction force between said tether and the sidewall of the tunnel.

5. The tunneling system in accordance with Claim 1, wherein said placement device comprises a sprayer configured to discharge the conduit wall material toward the sidewall to deploy the conduit wall material.

6. The tunneling system in accordance with Claim 5, wherein the conduit wall material has an uncured state and a cured state, wherein said sprayer is configured to discharge the conduit wall material in the uncured state, and wherein the conduit wall material is configured to cure in place along the sidewall.

7. The tunneling system in accordance with Claim 6, further comprising a tether support extending from said tunneling device and configured to prevent a tether contacting the conduit wall material in the uncured state.

8. The tunneling system in accordance with Claim 1, wherein the deployed conduit wall material forms a bladder extending from said tunneling device to anend of the tunnel.

9. The tunneling system in accordance with Claim 8, further comprising a supply station configured to continuously supply material for the bladder to expand as said tunneling device travels underground.

10. The tunneling system in accordance with Claim 1, wherein said placement device comprises a printer that is configured to place the conduit wall material in one or more layers along the sidewall to fabricate a conduit as said tunneling device travels underground.

11. A conduit construction system comprising: a conduit wall material: and a placement device coupled to a tunneling device, wherein the tunneling device is configured to travel through an underground location and displace material to form a tunnel, the tunnel having a sidewall defining an interior cavity, wherein said placement device is configured to deploy said conduit wall material along the sidewall of the tunnel, and wherein said conduit wall material is configured to engage the sidewall and define a conduit passageway.

12. The conduit construction system in accordance with Claim 11, wherein the deployed conduit wall material is cylindrical and extends around a circumference of the tunnel, and wherein said placement device is configured to pull said deployed conduit wall material along the sidewall of the tunnel as the tunneling device travels underground.

13. The conduit construction system in accordance with Claim 11, wherein said conduit wall material has an uncured state and a cured state, wherein said placement device comprises a sprayer configured to discharge said conduit wall material in the uncured state toward the sidewall to deploy the conduit wall material, and wherein said conduit wall material is configured to cure in place along the sidewall.

14. The conduit construction system in accordance with Claim 1 , wherein said deployed conduit wall material forms a bladder extending from said tunneling device to an end of the tunnel, wherein a supply station is configured to continuously supply materialfor said bladder to expand as the tunneling device travels underground.

15. The conduit construction system in accordance with Claim 1 , wherein said placement device comprises a printer that is configured to place the conduit wall material in one or more layers along the sidewall to fabricate a conduit as said tunneling device travels underground.

16. A method for constructing a conduit in a tunnel having a sidewall defining an interior cavity, said method comprising: moving a tunneling device through an underground location; displacing material using a tunneling tool on the tunneling device to form a tunnel having a sidewall defining an interior cavity; and deploying a conduit wall material along the sidewall of the tunnel using a placement device coupled to the tunneling device, wherein the conduit wall material is configured to engage the sidewall and define a conduit passageway.

17. The method in accordance with Claim 16, wherein deploying a conduit wall material along the sidewall of the tunnel comprises pulling the conduit wall material along the sidewall of the tunnel as the tunneling device travels underground, wherein the deployed conduit wall material is cylindrical and extends around a circumference of the tunnel.

18. The method in accordance with Claim 16, wherein deploying a conduit wall material along the sidewall of the tunnel comprises spraying the conduit wall material in an uncured state toward the sidewall to deploy the conduit wall material, wherein the conduit wall material is configured to cure in place along the sidewall.

19. The method in accordance with Claim 16. wherein the placement device comprises a printer, and wherein deploying a conduit wall material along the sidewall of the tunnel comprises depositing, using the printer, the conduit wall material in one or more layers along the sidewall to fabricate a conduit as said tunneling device travels underground.

20. The method in accordance with Claim 16, further comprising continuously dispensing material for the conduit wall material to expand as the tunneling device travels underground.

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