An insulated conduit, and methods of using and producing the same

Abstract

Embodiments described herein generally pertain to multi-layered conduits for housing conductors. An assembly includes a hollow tubular body having an outer surface and an inner surface defining a lumen. The hollow tubular body includes an annular portion between the outer surface and the inner surface, the annular portion including a reinforcing layer defining the inner surface of the hollow tubular body. An electrically insulating layer is disposed in the annular portion, extending along the length of the hollow tubular body. The assembly may include an external layer defining the outer surface of the hollow tubular body, and a sheath layer with high electrical conductivity (e.g., an electrical conductivity of greater than 104 S / m). At least one screen layer may be disposed between the reinforcing layer and the external layer.

Description

Agent’s File Ref. VEIR-006 / 01WO 338760-2067AN INSULATED CONDUIT, AND METHODS OF USING AND PRODUCING THE SAMECROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 790,487, titled “Insulated Conduit, and Methods of Using and Producing the Same,” and filed April 17, 2025, the disclosure of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] Embodiments described herein generally pertain to multi-layered conduits for housing conductors. The multi-layered conduits provided herein can allow for a bare electrically conducting wire to be made and installed separately from the electrical insulation.BACKGROUND

[0003] Electrical conductors (also referred to as wires) are available in insulated and uninsulated forms. Insulated wires are more typical for residential and commercial installations and are often required by relevant electrical codes. Insulation on insulated wires prevents the unintended flow of electricity between wires, to surrounding objects, or to people. Insulation acts as a barrier, keeping the electric current flowing within the conductor for safety and efficiency. Without insulation, electrical systems are prone to short circuits, which can damage equipment or cause fires. Insulation also protects the wires from external environmental factors, such as moisture or corrosive substances, which can cause degradation of the conductor over time.

[0004] Conductors are often housed in conduits made of materials like metal or plastic, particularly in commercial and industrial applications. In some instances, it may be desirable to run a bare conductor through conduit, for example, for particularly large conductors, where additional insulation may unacceptably increase the diameter or in implementations where thermal concerns make insulated conductors undesirable. Known conduits, while providing some protection to wires against mechanical damage, extreme conditions, and hazards like fire or corrosion are generally unsuitable for uninsulated conductors. Metal conduit, in particular, is conductive, typically grounded, and typically relies on shielded conductors to provide electrical isolation. Known plastic or plastic-containing conduits provide insufficient electrical1334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067isolation for bare conductors and any damage to such conduits presents an unacceptably high risk of exposing energized unshielded conductors, presenting a fire and safety hazard.

[0005] In addition, known electrical insulation systems and conduits are typically designed as integrated constructions in which the conductor and its insulation are permanently combined during manufacture. Such configurations generally prevent or complicate post-installation modification, repair, or upgrade of the insulation without removal and replacement of the conductor itself. This limitation can result in increased installation time, higher lifecycle cost, and prolonged service interruptions, particularly in applications involving long-distance power transmission, underground infrastructure, or environments with restricted physical access. Moreover, existing approaches provide limited flexibility for adapting installed electrical infrastructure to evolving operational requirements, such as changes in voltage class, thermal load, or environmental exposure.SUMMARY

[0006] Embodiments of the systems and methods described herein allow a bare electrically conducting wire to be manufactured and installed separately from its electrical insulation.

[0007] Some embodiments described herein relate to an assembly including a hollow tubular body having an outer surface and an inner surface defining a lumen. The lumen extends along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface and the inner surface. The annular portion includes a reinforcing layer defining the inner surface of the hollow tubular body, an electrically insulating layer, and a first screen layer. The reinforcing layer is configured to provide structural support to the assembly. The electrically insulating layer extends along a length of the hollow tubular body. The first screen layer is disposed between the reinforcing layer and the electrically insulating layer.

[0008] In some embodiments, the electrically insulating layer includes a polymer. In some embodiments, the first screen layer is disposed around the reinforcing layer. In some embodiments, the annular portion can further include a second screen layer disposed around the electrically insulating layer. In some embodiments, the assembly may further include a sheath layer disposed within the annular portion or wrapped by an external layer.

[0009] In some embodiments, the lumen is configured for housing a conductor (e.g., one or more conductors). The conductor extends along the length of the tubular body. The lumen2334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067can house an electrical conductor configured to transmit electrical power at any suitable voltage based on the specific requirements of the intended application. For example, in some embodiments, the lumen can house an electrical conductor configured to transmit electrical power at 1 kV or below. In some embodiments, the lumen can house an electrical conductor configured to transmit electrical power at 1 kV or above. In some embodiments, the lumen can house an electrical conductor configured to transmit electrical power at 46 kV or above. In some embodiments, the lumen can house an electrical conductor configured to transmit electrical power at 69 kV or above. In some embodiments, the conductor itself can be uninsulated prior to being disposed in the lumen. In some embodiments, the conductor can include one or more uninsulated electrical conductors.

[0010] In some embodiments, the assembly may include an external layer defining the outer surface of the hollow tubular body. The external layer is configured to provide mechanical and / or environmental protection to the assembly.[0011 | In some embodiments, the assembly may include a sheath layer including a highly electrically conducting material (e.g., an electrically conducting material having an electrical conductivity of greater than 104S / m). In some embodiments, the sheath layer is configured to provide electromagnetic shielding of the lumen.

[0012] Some embodiments described herein relate to an assembly including a hollow tubular body with an outer surface and an inner surface defining a lumen, which extends along the longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface and the inner surface. The annular portion includes a reinforcing layer defining the inner surface of the hollow tubular body, and extending along the length of the hollow tubular body. In some embodiments, the inner surface can be made of a metal. The annular portion further includes an electrically insulating layer disposed around the reinforcing layer. In some embodiments, the assembly can further include an external layer defining the outer surface of the hollow tubular body. In some embodiments, the lumen can house an electrical conductor configured to transmit power under 1 kV. The electrical conductor extends along the length of the tubular body. In some embodiments, the electrically insulating layer is a first electrically insulating layer, and the assembly further can include a second electrically insulating layer disposed between the first electrically insulating layer and the outer surface. In some embodiments, the assembly further includes a screen layer disposed within the annular portion. In some embodiments, the assembly can further include a sheath layer wrapped by the external layer.3334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067

[0013] Some embodiments described herein relate to an assembly including a hollow tubular body having an outer surface and an inner surface defining a lumen. The lumen extends along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface and the inner surface. The annular portion includes a reinforcing layer defining the inner surface of the hollow tubular body, an electrically insulating layer extending along a length of the hollow tubular body, an external layer defining the outer surface of the hollow tubular body, and a screen layer disposed between the reinforcing layer and the external layer. In some embodiments, the screen layer includes a polymer configured to conduct electricity. In some embodiments, the screen layer can include at least one screen layer disposed between the reinforcing layer and the electrically insulating layer. In some embodiments, the screen layer can include at least one screen layer disposed between the electrically insulating layer and the external layer. In some embodiments, the assembly may include a sheath layer including a highly electrically conducting material (e.g., an electrically conducting material having an electrical conductivity of greater than 104S / m) disposed between the reinforcing layer and the external layer. In some embodiments, the sheath layer may include at least one sheath layer disposed between the reinforcing layer and the electrically insulating layer (e.g., a sheath layer wrapping around the reinforcing layer). In some embodiments, the sheath layer may include at least one sheath layer disposed between the electrically insulating layer and the external layer (e.g., a sheath layer wrapped by the external layer).

[0014] Some embodiments described herein relate to methods of manufacturing assemblies as described above, allowing for a bare electrically conducting wire to be fabricated separately from the electrical insulation. The method can enable the independent production and installation of the conducting wire and the insulating layers.

[0015] In some embodiments, a method can include forming a hollow tubular body having an inner surface, an outer surface, and an annular portion between the inner surface and the outer surface, wherein the annular portion includes one or more functional layers. The method may include providing a reinforcing layer that defines the inner surface of the hollow tubular body. In some embodiments, the reinforcing layer defines a lumen extending along a longitudinal axis of the tubular body. In some embodiments, the method can include wrapping the reinforcing layer by a first screen layer. In some embodiments, the method can further include adding an electrically insulating layer into the annular portion. In some embodiments, the electrically insulating layer may be disposed (e.g., wrapped) around the first screen layer4334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067or the reinforcing layer. In some embodiments, the method may further include adding an insulation screen layer into the annular portion by disposing (e.g., wrapping) it over the electrically insulating layer to enhance the insulation properties of the assembly. In some embodiments, the method can include adding an external layer into the annular portion to define the outer surface of the tubular body, such as through extrusion, coating, or wrapping, to provide mechanical and / or environmental protection. In some embodiments, the method may include depositing or wrapping a sheath layer including an electrically conducting material into the annular portion. In some embodiments, the method may include wrapping the insulation screen layer or the electrically insulating layer by the sheath layer. The method may also include introducing one or more conductors into the lumen of the hollow tubular body, wherein the conductors may optionally be uninsulated.

[0016] In some embodiments, provided herein is a method of manufacturing a conductor assembly. The method includes forming a multi-layered conduit and disposing a conductor inside a central cavity (i.e., lumen) of the multi-layer conductor.BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The foregoing and other features of the present disclosure will become more fully apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Understanding that these drawings depict only several implementations in accordance with the disclosure and are therefore, not to be considered limiting of its scope, the disclosure will be described with additional specificity and detail through use of the accompanying drawings.

[0018] FIG. 1 is a schematic block diagram of a conduit assembly, configured for housing a conductor, according to an embodiment.

[0019] FIG. 2 is a cross-sectional view of a conduit assembly, configured for housing a conductor, according to an embodiment.

[0020] FIG.3 is a cross-sectional view of a conduit assembly, configured for housing a conductor, according to an embodiment.

[0021] FIG. 4 is a cross-sectional view of a conduit assembly, configured for housing a conductor, according to an embodiment.

[0022] FIG. 5 is an illustration of a conduit assembly including a conductor, according to an embodiment.5334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067

[0023] Reference is made to the accompanying drawings throughout the following detailed description. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative implementations described in the detailed description, drawings, and claims are not meant to be limiting. Other implementations may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure.DETAILED DESCRIPTION

[0024] Electric wire insulation generally surrounds a conductive core of the electric wires, blocking electrical flow to unintended areas and, in some implementations, safeguarding against environmental hazards such as moisture, heat, and chemicals. Insulation materials are selected for their dielectric strength, thermal stability, and resistance to environmental degradation. Electric wire insulation can serve multiple roles, including preventing electrical leakage, reducing energy losses, and protecting electric wires from environmental and mechanical damage. Common materials include thermoplastics like polyvinyl chloride (PVC) and polyethylene, as well as thermosets such as cross-linked polyethylene (XLPE) and rubber. These materials are generally applied using extrusion, where the insulation is uniformly coated over the conductor to create a durable barrier that meets specific performance requirements.

[0025] Insulation layers have been engineered depending on the operating voltage of the system and the intended application, such as overhead, underground, or sub-ocean installations. For low-voltage applications, a single layer of common insulation materials (e.g., thermoplastics such as polyvinyl chloride (PVC) and polyethylene, as well as thermoset polymers such as cross-linked polyethylene (XLPE) and rubber), is often sufficient, as these materials offer adequate dielectric strength for low voltage applications.

[0026] Medium- and high-voltage applications (e.g., applications using electric wires operating at IkV or above) often require additional layers with enhanced thermal and dielectric properties to manage higher electrical stresses. For instance, while a primary insulation layer made of XLPE or rubber can provide the necessary dielectric strength to isolate the conductor electrically, this is often followed by a shielding layer, which helps distribute the electric field evenly around the conductor and minimizes the risk of electrical discharges. An outer6334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067protective layer, typically made of a durable polymer, protects against environmental factors like moisture, UV radiation, and mechanical impacts.

[0027] The insulation is typically applied directly over the conductor during the wire manufacturing process, often by extrusion where the insulating material is melted, and uniformly applied around the wire. Since insulation is integrated directly during production, it is not designed to be separately manufactured and installed later. As a result, creating modular or interchangeable insulation layers becomes impractical.

[0028] Electrical systems sometimes incorporate separate conduits for housing insulated wires. These conduits, typically made of a single layer of plastic or metal, provide additional physical protection, and may help organize multiple wires within an installation. They also serve as a pathway for routing and installing cables. Because cables are continuous and cannot always be installed on their own, conduits allow for a structured raceway through which cables can be pulled and positioned during installation. Plastic conduits, such as those made from PVC, are lightweight, cost-effective, and resistant to corrosion, while metal conduits, commonly constructed from steel or aluminum, offer added strength and shielding against electromagnetic interference. However, they are not designed to provide the electrical isolation needed for energized conductors and serve only as a supplementary layer of protection rather than a replacement for primary insulation. For example, in high-voltage applications, these conduits can be made of a single layer of plastic or metal and may not be suitable to replace the direct insulation applied to the conductor because they lack the necessary dielectric properties. Their primary purpose is to complement insulated wires by organizing and / or shielding them, but they may not adequately address the need for electrical isolation.

[0029] Accordingly, some embodiments described herein pertain to an electrically insulated multi-layered conduit configured for housing conductors, such as transmission lines, which addresses and mitigates the insulation issues prevalent in the art. In some embodiments, the electrically insulated multi-layer conduit provided herein is configured to provide electrical insulation and shielding capabilities. In some embodiments, the conduit not only prevents electrical currents from escaping but also protects an internal conductor from external electrical interference, thereby enhancing overall safety and performance.

[0030] Embodiments of apparatuses and methods described herein may provide one or more benefits, including, for example: (1) enabling modular insulation and physical protection solutions; (2) allowing a bare electrically conducting wire to be manufactured and installed7334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067separately from its electrical insulation, thereby facilitating easier maintenance, upgrades, and system reconfigurations; (3) enhancing structural and environmental protection of the electrically conducting wires, ensuring that wires are shielded from physical damage, external electrical interference, and environmental factors such as moisture or chemical exposure, which improves reliability and safety over time; (4) increasing adaptability and flexibility in design, where the multi-layered conduit can accommodate diverse wire configurations, sizes, and operational requirements, providing scalability for various applications; (5) tailoring insulation and shielding layers according to the operating voltage of the system and the intended application environment.[00311 In some embodiments, separation of the conductor from the electrically insulating and / or protective layers can enable modular installation and replacement of individual components of the assembly without disturbing other components. For example, an electrically insulating layer or one or more screen layers may be replaced, augmented, or reconfigured while retaining a conductor positioned within the lumen. Such modularity can facilitate voltage upgrades, environmental re-rating of installed infrastructure, or replacement of aged or damaged insulation independently of the conductor, thereby enabling extended service intervals and reduced service interruptions.

[0032] In some embodiments, the apparatuses and methods described herein mitigate operational risks during maintenance by allowing electrical insulation and mechanical protection to be installed, repaired, or replaced without direct handling of an energized or insulated conductor. This separation can improve worker safety and limit the likelihood of insulation damage during conductor installation or removal. Additionally, decoupling conductor lifespan from insulation lifespan allows system designers to select conductors optimized for electrical performance and longevity, while independently selecting insulating and shielding layers optimized for environmental resistance, regulatory requirements, or evolving performance standards.

[0033] In some embodiments, the multi-layered conduit described herein can be suitable for housing transmission lines (e.g., conventional aluminum core steel reinforced (ACSR) conductors, superconducting conductors).[0034[ The apparatuses and methods described herein generally offer multiple benefits by all combinations of the foregoing concepts and additional concepts discussed herein (provided such concepts are not mutually inconsistent) are contemplated as being part of the subject8334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067matter disclosed herein. The terminology explicitly employed herein that also may appear in any disclosure incorporated by reference should be accorded a meaning most consistent with the particular concepts disclosed herein.

[0035] The terminology used herein is for the purpose of describing particular embodiments, implementations, and / or concepts (including any feature(s) or aspect(s) thereof) and is not intended to be limiting. Unless defined otherwise, all technical and / or scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Any explanation or discussion of or using particular terms is intended to provide context and to facilitate understanding and is not necessarily intended to replace or supersede commonly used or known definitions understood by one skilled in the art unless explicitly stated otherwise. Moreover, various terms may be used to describe similar or substantially the same embodiments, implementations, and / or concepts (including any feature(s) or aspect(s) thereof) and thus, the use of particular terms is not intended to be limiting and / or to the exclusion of other terms unless the terms are mutually exclusive, or the context clearly states otherwise.

[0036] As used herein, the term “a” or “an” refers to one or more of that entity; for example, “an element” refers to one or more element or at least one element. As such, the terms “a” (or “an”), “one or more” and “at least one” are used interchangeably herein. In addition, reference to “an element” by the indefinite article “a” or “an” does not exclude the possibility that more than one of the elements is present, unless the context clearly requires that there is one and only one of the elements.

[0037] As used herein, the terms “about” and “approximately” when preceding a numerical value mean a range (e.g., plus or minus 10% of that value). For example, “about 50” can mean 45 to 55, “about 25,000” can mean 22,500 to 27,500, etc., unless such an interpretation would result in a value above or below range of possible values, such as below 0% or above 100% of a possible value. Furthermore, the phrases “less than about / approximately” a value or “greater than about / approximately” a value should be understood in view of the definition of the term “about / approximately” provided herein, as applied to any recited endpoint. Similarly, the term “about / approximately” when preceding a series of numerical values or a range of values (e.g., “about 10, 20, 30” or “about 10-30”) refers to and / or modifies, respectively, all values in the series, and / or the endpoints of the range.10038] Where a range of values is provided, it is to be understood that each intervening9334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067value (e.g., to the tenth of the unit of the lower limit unless the context clearly dictates otherwise) between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. That the upper and lower limits of these smaller ranges can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the disclosure. All ranges described herein include each individual member or value of the listed range, including the end members or values. Any listed ranges are intended to encompass any and all possible subranges and / or combinations of subranges thereof unless expressly stated otherwise. Any listed range should be recognized as sufficiently describing and enabling the same range being broken down into at least equal subparts unless expressly stated otherwise.|0039| As used herein, the phrase “and / or,” as used herein, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases. Multiple elements listed with “and / or” should be construed in the same fashion, i.e., “one or more” of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and / or” clause, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, a reference to “A and / or B”, when used in conjunction with open-ended language such as “comprising” can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.(0040) As used herein, the term “or” should be understood to have the same meaning as “and / or” as defined above. For example, when separating items in a list, “or” or “and / or” shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one of a number or list of elements, and, optionally, additional unlisted items. Only terms clearly indicated to the contrary, such as “only one of’ or “exactly one of,” “not more than one of,” and / or the like will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e., “one or the other but not both”) when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” “Consisting essentially of,” when used in the embodiments, shall have its ordinary meaning as used in the10334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067field of patent law.

[0041] As used herein, the phrase “at least one,” in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements. This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one” refers, whether related or unrelated to those elements specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and / or B”) can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0042] It should be noted that the term “for example” or “exemplary” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and / or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0043] As used herein, the terms “set” and “plurality” can refer to multiple features or a singular feature with multiple parts. For example, when referring to a set of electrodes, the set of electrodes can be considered as one electrode with multiple portions, or the set of electrodes can be considered as multiple, distinct electrodes. Additionally, for example, when referring to a plurality of electrochemical cells, the plurality of electrochemical cells can be considered as multiple, distinct electrochemical cells or as one electrochemical cell with multiple portions. Thus, a set of portions or a plurality of portions may include multiple portions that are either continuous or discontinuous from each other. A plurality of particles or a plurality of materials can also be fabricated from multiple items that are produced separately and are later joined together (e.g., via mixing, an adhesive, or any suitable method).

[0044] The phrase “based on” does not mean “based only on,” unless expressly specified otherwise. In other words, the phrase “based on” describes both “based only on” and “based at11334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067least on.

[0045] In the embodiments, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “carrying,” “having,” “containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of’ and “consisting essentially of’ shall be closed or semi-closed transitional phrases, respectively, as set forth in the United States Patent Office Manual of Patent Examining Procedures, Section 2111.03.

[0046] As used herein, the term “conduit” refers to any structure or component that defines or forms a passageway through which materials, such as fluids, gases, or other substances, can be conveyed, transported, or transferred. The conduit can be a tubular member forming a passageway through which something (e.g., a wire or a plurality of wires) can be conveyed. The conduit may include, but is not limited to, tubular members such as pipes, headers, hoses, vessels, manifolds, tubes, ducts, channels, or similar structures. The conduit may be rigid, flexible, or semi-flexible.

[0047] FIG. 1 is a block diagram of a conduit assembly 100 (hereafter, referred to as “assembly 100”) configured for housing a conductor, according to an embodiment. The assembly 100 includes a hollow tubular body having an outer surface and an inner surface. The inner surface defines a lumen 110 (e.g., an inner most cavity) extending along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface and the inner surface. The annular portion of the assembly 100 includes a reinforcing layer 120 defining the inner surface of the hollow tubular body, and an electrically insulating layer 140 extending along a length of the hollow tubular body. In some embodiments, the annular portion may further include a first screen layer 130 (e.g., a conductor screen layer) disposed between the reinforcing layer 120 and the electrically insulating layer 140 (e.g., wrapped by the electrically insulating layer 140). In some embodiments, the annular portion may further include a second screen layer 150 (e.g., an insulation screen layer) disposed around the electrically insulating layer 140. The assembly 100 further includes an external layer 170 defining the outer surface of the hollow tubular body. In some embodiments, the assembly 100 can include a sheath layer 160, within the annular portion, wrapped by the external layer 170.

[0048] In some embodiments, the assembly 100 can be flexible and capable of withstanding pre-determined bending stresses without failure. In some embodiments, the12334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067assembly 100 can be suitable for applications requiring flexibility in environments particularly under constrained bending conditions. In some embodiments, the hollow tubular body can be formed to minimize the amount of heat reaching the inner surface of the hollow tubular body from the surrounding environment.

[0049] In some embodiments, an additional tube can be placed inside the lumen 110 to provide mechanical support. Alternatively, or in addition, a cable, a metal rope, a solid rod, or any combination thereof can be placed inside the lumen 110 to provide mechanical support. In some embodiments, the lumen 110 is configured to allow a fluid to flow therethrough.

[0050] In some embodiments, the lumen 110 is configured to house a conductor extending along the length of the tubular body. In some embodiments, the lumen 110 is further configured to allow a fluid to flow therethrough at a pressure (e.g., between about 5 bar and about 15 bar, or between about 25 bar and about 30 bar) greater than atmospheric pressure. In some embodiments, the fluid can flow through the lumen 110 at a specified temperature.

[0051] The reinforcing layer 120 is configured to provide structural support to the assembly 100. In some embodiments, the reinforcing layer 120 may define both the inner surface and at least a portion of the structural thickness of the tubular body. In some embodiments, the reinforcing layer 120 may be configured to serve as the foundation (e.g., frame) of the assembly 100, providing the structural integrity of the assembly 100.10052] The reinforcing layer 120 may be configured in various ways along the longitudinal axis of the tubular body, depending on the desired application and structural requirements. In some embodiments, the reinforcing layer 120 may fully extend along the entire length of the tubular body. Alternatively, in some embodiments, the reinforcing layer 120 may be positioned at discrete intervals along the longitudinal axis, offering targeted reinforcement in specific regions. In some embodiments, the reinforcing layer 120 may partially extend along the longitudinal axis.

[0053] In some embodiments, the reinforcing layer 120 may include a metallic conduit defining the inner surface of the tubular body. That is, in some embodiments, the reinforcing layer 120 is a metallic conduit forming around the lumen 110. In some embodiments, the reinforcing layer 120 may include a plastic conduit. That is, in some embodiments, the reinforcing layer 120 is a plastic conduit forming around the lumen 110. In some embodiments, the reinforcing layer 120 can be made of any material suitably configured to bear loads resulting from the use of the assembly in the field where necessary for electric transmission,13334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067thereby protecting the conductor when housed within the lumen 110. In some embodiments, the reinforcing layer 120 can be made of or can include a highly electrically conductive material having an electrical conductivity of greater than 104S / m, greater than 105S / m, greater than 106S / m, greater than 107S / m, or greater than 108S / m. In some embodiments, the reinforcing layer 120 can be made of a metal, an alloy, or a combination thereof. In some embodiments, the reinforcing layer 120 can be a composite material designed to meet the desired mechanical strength and electrical conductivity.

[0054] In some embodiments, the reinforcing layer 120 can be made of any material suitable for use at cryogenic temperatures (e.g., at temperatures around and / or below -196°C (77K)), and operating pressures. For example, the reinforcing layer 120 can be made of at least one of a metal, an alloy, a polymer, or a composite (e.g., fiber reinforced polymers). In some embodiments, the reinforcing layer 120 may include at least one of metallic material or a non-metallic material. In some embodiments, the reinforcing layer 120 can include stainless steel, aluminum, copper, or Hastelloy alloy.

[0055] The plastic material may be selected based on desired properties such as chemical resistance, flexibility, and / or thermal insulation. In some embodiments, the reinforcing layer 120 may include a spiral-welded pipe extending along the length of the hollow tubular body. The spiral-welded pipe may provide both longitudinal and circumferential strength, making it suitable for high-pressure or high-stress applications. In some embodiments, the reinforcing layer 120 may include a plurality of wires. In some embodiments, the plurality of wires may be helically wound or arranged in a braided pattern to provide additional structural support and improve resistance to torsional and bending stresses. Additionally, the reinforcing layer 120 may function as a friction-bearing surface, facilitating the installation of a conductor by allowing it to be pulled smoothly through the lumen 110. This design helps reduce resistance during installation, enhancing ease of use and efficiency.

[0056] In some embodiments, the reinforcing layer 120 may further include electrically conductive elements. In some embodiments, the electrically conductive elements can include metals and / or alloys. In some embodiments, the electrically conductive elements may be incorporated into the reinforcing layer 120 to provide at least one of electrical functionality or electromagnetic shielding properties to the reinforcing layer 120. In some embodiments, the electrically conductive elements may have an electrical conductivity of greater than 104S / m, greater than 105S / m, greater than 106S / m, greater than 107S / m, or greater than 108S / m.14334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067

[0057] In some embodiments, the reinforcing layer 120 may have a multi-layered structure. For instance, in some embodiments, the reinforcing layer 120 can be made of a metal or an alloy (e.g., stainless steel) coated with a coating material (e.g., polymer) for additional protection against environmental factors.

[0058] In some embodiments, the reinforcing layer 120 may additionally be configured to participate in electrical reference potential control or current management under non-steadystate operating conditions. For example, where the reinforcing layer 120 includes electrically conductive material, it may provide a grounding path, a defined electrical reference, and / or a controlled current return during transient events, leakage conditions, and / or other unintended electrical states. In such configurations, the reinforcing layer 120 may cooperate with one or more screen layers 130, 150, or the sheath layer 160 to manage electrical stress, limit voltage rise, and / or dissipate electrical energy in a controlled manner.10059] In some embodiments, the electrically insulating layer 140 is configured to provide a dielectric strength, providing electrical insulation between a conductor that the assembly 100 is configured to house and the outer environment. In some embodiments, the electrically insulating layer 140 is configured to isolate a conductor that the assembly 100 is configured to house from surrounding elements, preventing, or mitigating electrical short circuits. In some embodiments, the electrically insulating layer 140 extends continuously along the length of the hollow tubular body, thereby maintaining insulation throughout the assembly 100. In some embodiments, the electrically insulating layer 140 may be configured to withstand high voltage stresses, with a dielectric strength of 8kV / mm or higher, lOkV / mm or higher, 12kV / mm or higher, 14kV / mm or higher, 16kV / mm or higher, 18kV / mm or higher, 20 kV / mm or higher. In some embodiments, the electrically insulating layer 140 may have a dielectric strength ranging from 8 kV / mm to 80 kV / mm, inclusive, or higher.

[0060] In some embodiments, the electrically insulating layer 140 may be configured to include additional features such as thermal resistance. In some embodiments, the electrically insulating layer 140 may also incorporate additives or fillers to improve its resistance to environmental factors such as moisture, chemicals, and UV radiation.

[0061] In some embodiments, the electrically insulating layer 140 can be in the form of a tape. Specifically, the electrically insulating layer 140 can include a plurality of electrically insulating tapes that are disposed around the reinforcing layer 120 or the first screen layer 130. These wrapped tapes can be stacked on top of each other, forming multiple layers. In some15334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067embodiments, the electrically insulating layer 130 can be in a form of coating or film, configured to withstand the operational temperatures and environmental conditions of the assembly 100.

[0062] In some embodiments, the electrically insulating layer 140 can have an electrical conductivity of less than 10'8S / m and can provide resistance to the flow of electrical current from conductors disposed within the lumen to the exterior of the assembly 100. For example, the electrically insulating layer 140 be at least partially constructed of a high-grade electrically insulating polymer having a volume resistivity greater than 10'13S / m. Such high-grade electrically insulating polymers can enable electrical isolation and prevent or mitigate current leakage. In some embodiments, the high-grade electrically insulating polymers may include at least one of polytetrafluoroethylene (PTFE), polyimide (PI), polyphenylene sulfide (PPS), or fluorinated ethylene propylene (FEP), depending on the application requirements. In some embodiments, the high-grade electrically insulating polymer is configured to withstand high voltages without electrical breakdown and can exhibit a dielectric strength ranging from 20 kV / mm to 80 kV / mm, inclusive, or higher, depending on the polymer’s thickness and formulation.

[0063] In some embodiments, the electrically insulating layer 140 can include thermoplastic polymers, which can include, but are not limited to, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polyethylene terephthalate (PET), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), and nylon (polyamide, PA). In some embodiments, the polymer matrix comprises at least one of polyphenylene sulfide (PPS), poly ether ether ketone (PEEK), poly etherketoneketone (PEKK), poly etherketone (PEK), or another polymer that is part of the polyaryletherketone (PAEK) family. Thermoplastic polymers are typically used in demanding environments (e.g., cryogenic environments) requiring a certain level of thermal and chemical resistance. Thermoplastic polymers can be melted and reshaped multiple times without undergoing a chemical change, which allows for easier processing and recycling.

[0064] In some embodiments, the electrically insulating layer 140 can include thermosetting polymers, which can include, but are not limited to, epoxy resins, phenolic resins, polyimides, bismaleimides (BMI), cyanate esters, vinyl esters, polyurethanes, and combination thereof. In some embodiments, the electrically insulating layer 140 can include a combination of thermoplastic and thermosetting polymers, leveraging the unique properties of both types to achieve desired properties (e.g., thermal coefficient, elastic bend radius, yield16334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067strength) for specific applications. In some embodiments, the electrically insulating layer 140 can include at least one of a thermoplastic polymer or a thermosetting polymer. In some embodiments, the electrically insulating materials can include an elastomer. In some embodiments, the electrically insulating layer 140 includes ethylene propylene rubber. In some embodiments, the electrically insulating layer 140 can include at least one of cross-linked polyethylene (XLPE), ethylene propylene rubber (EPR), or fluoropolymers such as polytetrafluoroethylene (PTFE).

[0065] In some embodiments, the electrically insulating layer 140 may be made from various insulating materials, such as plastic polymers, glass fiber, or other (typically) non-conductive composites, depending on the thermal and mechanical requirements of the desired application of the assembly 100. In some embodiments, the electrically insulating layer 140 can include one or more insulating materials (e.g., polymers), each having a dielectric strength of at least 8 kV / mm, up to or exceeding 80 kV / mm.

[0066] In some embodiments, the electrically insulating layer 140 can include polymer fibers. The electrically insulating layer can be made of a polymer derived synthetically, naturally, or a combination thereof. These polymers may be selected based on their dielectric properties, compatibility with other materials in the assembly, or specific processing requirements.

[0067] In some embodiments, the electrically insulating layer 140 may have a dielectric constant of less than 4.0, and in some cases, less than 3.5, which helps reduce energy loss. In some embodiments, the electrically insulating layer 140 may exhibit low moisture absorption (e.g., less than 0.01% by weight), which can reduce the risk of electrical performance degradation caused by environmental humidity or moisture ingress. For example, the electrically insulating layer 140 may demonstrate moisture absorption values as low as 0.01%, providing long-term reliability in humid, high-moisture, or submerged environments.

[0068] In some embodiments, the electrically insulating layer 140 may be configured to exhibit thermal stability at operating temperature up to about 100°C, about 200°C, or higher, while maintaining electrical insulation properties without significant degradation. This level of thermal stability can ensure that the electrically insulating layer 140 remains at least partially effective in high-temperature environments, such as those encountered in dessert applications, where materials are routinely subjected to extreme heat and thermal cycling. In some embodiments, the electrically insulating layer 140 can be thermally stable between about -17334438184Agent’s File Ref. VEIR-006 / 01WO 338760-206755°C (e.g., temperatures at Nordic areas) to about 150°C, to about 200°C, or higher. In some embodiments, the electrically insulating layer 140 can be thermally stable between about -40°C (e.g., temperatures at Nordic areas) to about 150°C. In some embodiments, the electrically insulating layer 140 can be suitable for use at cryogenic temperatures (e.g., at temperatures around and / or below -196°C (77K)), and operating pressures.

[0069] In some embodiments, forming the electrically insulating layer 140 as part of the assembly 100 in a manner that is structurally separate from a conductor configured to be disposed within the lumen 110 can allow the electrically insulating layer 140 to be designed, selected, and configured independently of the conductor. This separation can enable the electrical and physical properties of the electrically insulating layer 140, and any associated screen or protective layers of the assembly 100, to be tailored to application specific electrical, thermal, or environmental requirements without being constrained by conductor geometry or conductor installation sequence. As a result, the assembly 100 may be optimized for dielectric performance, electric field control, or environmental resistance while maintaining compatibility with conductors of varying type, size, or construction.

[0070] In some embodiments, the assembly 100 can include at least one of the first screen layer 130 (e.g., a conductor screen) wrapped by the electrically insulating layer 140, or the second screen layer 150 (e.g., an insulation screen layer) disposed around the electrically insulating layer 140.

[0071] In some embodiments, the first screen layer 130 can be disposed between the reinforcing layer 120 and the electrically insulating layer 140, serving as an interface between these two layers. The first screen layer 130 helps reduce voids, gaps, or discontinuities around the lumen 110, thereby mitigating the risk of electric discharge from a conductor configured to be housed in the assembly 100. In some embodiments, the first screen layer 130 can be in the form of a uniform layer that conforms to a shape of the reinforcing layer 120. In some embodiments, the first screen layer 130 can help smooth the electric field resulting from the conductor when the assembly houses the conductor, as it enters the electrical insulation. This helps ensure that the electric field is evenly distributed, reducing any irregularities that could compromise the effectiveness of the insulation.

[0072] In some embodiments, the first screen layer 130 is configured to provide a uniform electric field distribution around the lumen 110 and reduce electrical stress at the interface between a conductor configured to be housed in the assembly 100 and the adjacent electrically18334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067insulating layer 140. That is, in some embodiments, the first screen layer 130 can serve as a transitional layer that improves the mechanical and electrical coupling between a conductor configured to be housed in the assembly 100 and the insulating layer 140.

[0073] In some embodiments, the second screen layer 150 can be disposed around the electrically insulating layer 140. In some embodiments, the second screen layer 150 is configured to serve as a shielding interface around the electrically insulating layer 140. The second screen layer 150 can reduce electrical field gradients at the interface of the insulating layer 140.

[0074] In some embodiments, the second screen layer 150 is particularly suitable for high-voltage and medium-voltage applications, where electrical stress control is critical. Accordingly, in some embodiments, the assembly 100 including the second screen layer 150 is configured to house an electrical conductor (e.g., an electrical conductor for transmitting power at and / or above 1 kV).

[0075] In some embodiments, the first screen layer 130 and / or the second screen layer 150 can include one or more polymers configured to conduct electricity. In some embodiments, the first screen layer 130 can include a first weakly conducting material having an electrical conductivity from 10'8S / m to 104S / m. In some embodiments, the second screen layer 150 can include a second weakly conducting material having an electrical conductivity from 10'8S / m to 104S / m. In some embodiments, the first weakly conducting material and the second weakly conducting material can differ from each other in at least one property, such as physical, electrical, or physicochemical properties. For example, the first weakly conducting material may exhibit a higher thermal conductivity, while the second weakly conducting material may provide improved chemical resistance. Such differences allow the screen layers to be specifically tailored for their respective functions within the assembly 100. In some embodiments, the first weakly conducting material and the second weakly conducting material can be same. In some embodiments, the first weakly conducting material and / or the second weakly conducting material can have an electrical resistivity of up to 1000 ohm-meter. In some embodiments, the first weakly conducting material and / or the second weakly conducting material can include a polymer matrix. In some embodiments, the first weakly conducting material and / or the second weakly conducting material can be the same or different in terms of polymeric composition. Examples of suitable polymers that can be present in the polymer matrix include polyethylene, crosslinked polyethylene (XLPE), ethyl ene-propylene rubber (EPR), thermoplastic elastomers, or other polymer-based materials. In some embodiments, the19334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067first screen layer 130 and / or the second screen layer 150 can further include conductive and / or semiconductive fillers such as carbon black, metal particles, carbon nanotubes, or conductive polymers to achieve the desired electrical conductivity. In some embodiments, the conductive and / or semiconductive fillers can be incorporated into the polymer matrix.

[0076] In some embodiments, the first screen layer 130 and the second screen layer 150 can be provided with varying thicknesses to meet specific design and application requirements. For example, the first screen layer 130 can include a greater thickness to provide robust mechanical reinforcement and shielding for a conductor configured to be housed in the assembly 100, while the insulation screen layer 150 can be optimized for stress grading and controlled electrical properties.(0077] In some embodiments, the first screen layer 130 and the second screen layer 150 may be configured to regulate electric field distribution. By mitigating electric field stress and reducing localized charge accumulation, the first screen layer 130 and the second screen layer 150 can enhance the overall dielectric properties of the conduit assembly 100. In some embodiments, the first screen layer 130 and the second screen layer 150 may be configured to provide an intermediate conductive interface.

[0078] In some embodiments, the first screen layer 130 and / or the second screen layer 150 can enhance electrical reliability by stabilizing electrical interfaces between conductive and insulating regions within the annular portion of the assembly 100. The screen layers 130, 150 may reduce localized electrical stress and suppress partial discharge initiation at interfaces between layers, including during voltage transients or thermal cycling. Such configurations can promote long-term dielectric stability of the assembly 100 when subjected to varying electrical loads and / or environmental conditions.

[0079] In some embodiments, the sheath layer 160 can be applied to at least a portion of (e.g., an entire exterior surface of) the electrically insulating layer 140. In some embodiments, the sheath layer 160 can be applied to at least a portion of (e.g., an entire exterior surface of) the second screen layer 150. In some embodiments, the sheath layer 160 can be wrapped or covered by the external layer 170. In some embodiments, the sheath layer 160 can include at least one of a plurality of wires or a plurality of straps concentrically formed directly atop the electrically insulating layer 140 or the second screen layer 150. These wires or straps can be helically disposed around the electrically insulating layer 140 or the second screen layer 150, providing a continuous conductive path.20334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067

[0080] In some embodiments, the sheath layer 160 can be configured to provide electromagnetic shielding, such as in the case of a Faraday cage, by blocking external electromagnetic fields from entering a conductor configured to be housed in the assembly 100 and preventing / mitigating the leakage of electrical signals or radiation. In some embodiments, the sheath layer 160 may be made of electrically conductive materials, such as copper, aluminum, or specialized metallic alloys, configured to absorb or reflect electromagnetic waves. In some embodiments, the sheath layer 160 can also serve to protect a conductor configured to be housed in the assembly 100, from mechanical damage, environmental factors such as moisture, abrasion, and corrosion.

[0081] The sheath layer 160 can include a metal or another electrically conductive material that provides a high degree of electrical conductivity (e.g., greater than 104S / m, greater than 105S / m, greater than 106S / m, greater than 107S / m, or greater than 108S / m). In some embodiments, the sheath layer 160 can be composed of various materials known for their high electrical conductivity. Examples of such materials include, but are not limited to, copper, aluminum, silver, and gold. For instance, copper, with an electrical conductivity of approximately 5.8 x 107S / m, can be included in the sheath layer 160. In some embodiments, copper can form the sheath layer 160. In some embodiments, the sheath layer can include a highly electrically conductive material having an electrical conductivity of greater than 104S / m, greater than 105S / m, greater than 106S / m, greater than 107S / m, or greater than 108S / m.

[0082] In some embodiments, the current flowing through sheath layer 160 can be controlled to adjust the self-inductance of a conductor housed within assembly 100. In some embodiments, by controlling the magnitude and / or polarity of the current in the sheath layer 160, it may be possible to control the magnetic field interactions between the sheath layer 160 and the conductor. For instance, if the sheath layer 160 carries a current equal in magnitude but opposite in polarity to that of the conductor, the external magnetic field can be canceled or reduced, resulting in reduced self-inductance.|0083] The sheath layer 160 can be configured to include additional elements. For instance, the sheath layer 160 can incorporate a combination of wires and straps to have desired flexibility and durability. The wires can be made of a high-conductivity metal, while the straps can provide additional mechanical support and stability. In some embodiments, the sheath layer 160 can be configured in various forms to meet specific application requirements. For example, the sheath layer 160 can be in the form of a braided mesh, a solid foil, or a combination of both.21334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067

[0084] In some embodiments, the sheath layer 160 can be at ground potential. In some embodiments, the sheath layer 160 can be electrically connected to a grounding system to discharge any induced electromagnetic energy or excess electrical charges to ground, thus preventing electrical buildup and mitigating the risk of electrical shock. In configurations where the assembly houses a conductor, the sheath layer 160 can be grounded or electrically floating, depending on the desired electrical characteristics. Grounding the sheath layer 160 can establish a defined electric field distribution around the conductor, thereby reducing electromagnetic interference and enhancing performance. This grounding may be achieved through direct metal connections, such as a conductive wire or metal bonding elements, which link the sheath layer 160 to an appropriate earth ground or ground plane. For configurations where the sheath layer 160 functions as an external metal component, grounding prevents unintended voltage accumulation and ensures safe operation. In some embodiments, the grounding system may also include a shielded connection to dissipate high-voltage surges and provide continuous protection against electrical interference in high-voltage or high-sensitivity applications.

[0085] In some embodiments, the sheath layer 160 may be configured to carry a controlled electrical current, whether passively induced or actively imposed, to influence magnetic field distribution around a conductor disposed within the lumen 110. By selecting grounding configurations, current paths, or electrical continuity of the sheath layer 160, the assembly 100 may reduce external electromagnetic fields, manage inductive effects, or limit electromagnetic interference with adjacent structures or equipment.

[0086] In some embodiments, the sheath layer 160 can be configured to accommodate electrical energy associated with transient events, unintended current paths, leakage conditions, and / or externally induced electrical disturbances. In some embodiments, where the sheath layer 160 includes a highly electrically conductive material, the sheath layer 160 can be configured to provide a low-impedance current conduction path for distributing, conducting, and / or dissipating such electrical energy in a controlled manner. In some embodiments, the sheath layer 160 can be configured to cooperate with one or more of the screen layers 130, 150 and / or the reinforcing layer 120 to manage electrical stress, limit voltage excursions, and / or direct electrical energy away from the lumen 110 and surrounding structures.

[0087] The external layer 170 can be disposed around at least a portion of (e.g., an entire exterior surface of) the outer surface of the hollow tubular body, providing a protective barrier against external environmental factors. In some embodiments, the external layer 170 may be22334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067in direct physical contact with at least one of the sheath layer 160, the second screen layer 150, or the insulating layer 140. In some embodiments, the external layer 170 can be made of any material suitable for use at cryogenic temperatures (e.g., at temperatures around and / or below -196°C (77K)) as an outer surface of the external layer 170 can be at cryogenic temperatures during operation. For example, the external layer 170 may be configured to withstand cryogenic conditions by including materials such as cryogenic-grade elastomers, fluoropolymers, or specialized composites. In some embodiments, an outer surface of the external layer 170 can be at ambient temperature.

[0088] The external layer 170 may also provide mechanical protection, safeguarding the assembly 100 from external forces such as impacts or abrasion. In some embodiments, the external layer 170 can include a mechanical tensile support element, disposed within the external layer 170, to support the assembly 100, for example, to suspend the assembly 1000 off the ground, in the manner of an overhead power transmission line. Additionally, the external layer 170 can act as a barrier to environmental factors like dust, water, or chemicals, which could otherwise compromise the performance and reliability of the assembly 100.]0089] In some embodiments, the external layer 170 can be composed of various polymers, including but not limited to, polyvinyl chloride (PVC), polyethylene (PE), cross-linked polyethylene (XLPE), thermoplastic elastomers (TPE), and silicone rubber. The materials that can be included in the external layer 170 can be selected based on their ability to withstand a wide range of temperatures and environmental conditions. For instance, in some embodiments, the external layer 170 can operate within a temperature range spanning from -60°C to 200°C.

[0090] The external layer 170 can be in various forms, such as coatings, tapes, or extruded layers, with thicknesses ranging from 0.5 mm to 5 mm, depending on the specific application requirements.

[0091] In some embodiments, the assembly 100 may further include a thermally insulating material disposed within one of the layers and / or between the adjacent layers described in the aforementioned embodiments of the assembly 100. In some embodiments, the thermally insulating material can have a thermal conductivity of less than 5 Watt / m° C, less than 2.5 Watt / m° C, less than 1.0 Watt / m° C, less than 0.5 Watt / m° C, less than 0.1 Watt / m° C, less than 0.05 Watt / m° C, less than 0.04 Watt / m° C, less than 0.03 Watt / m° C, or less than 0.02 Watt / m° C.

[0092] In some embodiments, the thermally insulating material can include at least one of23334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067polyurethane foam, bitumen, cement, clay, concrete, ceramic filled Corian®, cork, cotton wool insulation, diatomaceous earth, epoxy, fiberglass, foam glass, glass pearls or beads, glass wool, gypsum, magnesite, magnesia insulation, mineral insulation, nylon, perlite, foamed plastic insulation, expanded polystyrene, porcelain, PTFE, PVC, Pyrex glass, sand, silica aerogel, Styrofoam, urethane foam, vermiculite or vinyl ester.

[0093] In some embodiments, the assembly 100 can be disposed within a thermally insulating jacket (not shown) disposed on and optionally spaced apart from the assembly 100. The thermally insulating jacket can be configured to reduce an amount of heat from the surroundings that reaches an outer surface of the assembly 100. The thermally insulating jacket, itself, can include, for example, two concentric pipes (e.g., metal pipes) spaced from one another, with vacuum or another material (e.g., carbon dioxide (CO2), an inert gas, etc.) disposed between the two pipes.100941 In some embodiments, one or more layers of the assembly 100 may be formed from composite materials that include multiple functional constituents, such as fiber-reinforced polymers, metal-polymer laminates, or hybrid composites incorporating structural, insulating, and / or electrically conductive phases. Such materials may be selected to provide a desired combination of mechanical strength, electrical behavior, thermal stability, and environmental resistance for a particular application. In some embodiments, materials used in the electrically insulating layer 140, the screen layers 130, 150, or the external layer 170 may include functional fillers or additives selected to modify electrical, thermal, or environmental properties. Such fillers or additives may include particulate, fibrous, or nanoscale materials configured to influence dielectric behavior, erosion resistance, flame retardance, ultraviolet stability, or thermal performance, while maintaining the intended electrical isolation characteristics of the respective layer.

[0095] In some embodiments, the lumen of the assembly is configured to receive a conductor extending along the longitudinal axis of the hollow tubular body. The conductor may be introduced into the lumen during manufacturing, installation, or subsequently during use of the assembly.

[0096] In some embodiments, the conductor configured to be disposed within the lumen is an uninsulated electrical conductor. As used herein, an uninsulated electrical conductor refers to a conductor that does not include a primary electrical insulation layer formed directly around the conductive core prior to introduction into the lumen. In such embodiments, electrical24334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067insulation, electrical stress control, and environmental protection of the conductor are provided primarily by the electrically insulating layer and other layers of the assembly, rather than by insulation applied directly to the conductor itself.

[0097] In some embodiments, the conductor disposed within the lumen may include one or more basic or partial insulating layers formed directly on the conductor, such as a thin coating, varnish, tape, or protective layer. Such insulating layers may provide limited electrical insulation, mechanical protection, or handling protection, while primary electrical insulation, electrical field control, and environmental protection are provided by the electrically insulating layer and other layers of the assembly. The presence of such basic insulating layers on the conductor does not alter the fundamental separation between the conductor and the primary insulation provided by the assembly.

[0098] FIG. 2 illustrates a cross-sectional view of a conduit assembly 200 (hereafter, referred to as “assembly 200”), according to an embodiment. The assembly 200 includes a hollow tubular body having an outer surface 202 and an inner surface 204. The inner surface 204 defines a lumen 210 extending along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface 204 and the inner surface 202. The annular portion of the assembly 200 includes a reinforcing layer 220 defining the inner surface 204 of the hollow tubular body, and an electrically insulating layer 240 extending along a length of the hollow tubular body. The annular portion of the assembly 200 further includes a first screen layer 230 wrapped by the electrically insulating layer 240, and a second screen layer 250 disposed around the electrically insulating layer 240. The assembly 200 further includes a sheath layer 260 disposed around the second screen layer 250, and an external layer 270 disposed around the sheath layer 260. The external layer 270 defines the outer surface 202 of the hollow tubular body. The hollow tubular body has an inner diameter r, and an outer diameter R, as shown in FIG. 2.

[0099] In some embodiments, the assembly 200 is configured to house a conductor inside the lumen 210. The conductor within lumen 210 may be uninsulated. In some embodiments, the assembly 200 is configured to house a single conductor within the lumen 210. Alternatively, the assembly 200 can include multiple (e.g., two, three, four, five, or between five and ten) conductors within the lumen 210. In some embodiments, the conductor can operate at IkV or above, up to 500kV. In some embodiments, the conductor can operate at between IkV and 46kV. In some embodiments, the conductor can operate at between IkV and 69kV. That is, the assembly 100 can be used for medium- and high-voltage applications (e.g., applications using25334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067electric wires operating at IkV or above).

[0100] In some embodiments, the lumen 210, the reinforcing layer 220, the first screen layer 230, the insulating layer 240, the second screen layer 250, the sheath layer 260, and the external layer 270 can be similar to or substantially the same as the lumen 110, the reinforcing layer 120, the first screen layer 130, the insulating layer 140, the second screen layer 150, the sheath layer 160, and the external layer 170, as described above with reference to FIG. 1. Thus, certain aspects of the lumen 210, the reinforcing layer 220, the first screen layer 230, the insulating layer 240, the second screen layer 250, the sheath layer 260, and the external layer 270 are not described in greater detail herein.[01011 In some embodiments, a ratio of the inner diameter r of the hollow tubular body to the outer diameter R of the hollow tubular body can be configured such that, when the conductor is housed within the assembly 200, the conductor is accommodated in the lumen 210 with sufficient clearance to allow for thermal expansion, movement, or ease of installation (e.g., maintaining a loose fit within the lumen 210). In some embodiments, the outer diameter R is configured to provide environmental and / or electrical protection between the conductor and the external environment. Additionally, the inner and outer diameters r and R, respectively, can be adjusted to ensure that the conductor is mechanically protected against any external loads or forces acting on the assembly. FIG. 3 illustrates a cross-sectional view of a conduit assembly 300 (hereafter, referred to as “assembly 300”), according to an embodiment. The assembly 300 includes a hollow tubular body having an outer surface 302 and an inner surface 304. The inner surface 304 defines a lumen 310 extending along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface 304 and the inner surface 302. The annular portion of the assembly 300 includes a reinforcing layer 320 defining the inner surface 304 of the hollow tubular body, and an electrically insulating layer 340 extending along a length of the hollow tubular body. The annular portion of the assembly 300 further includes an external layer 270 defining the outer surface 302 of the hollow tubular body. The hollow tubular body has an inner diameter r, and an outer diameter R, as shown in FIG. 3.

[0102] In some embodiments, the assembly 300 is configured to house a conductor inside the lumen 310. The conductor within lumen 210 may be uninsulated. In some embodiments, the assembly 300 is configured to house a single conductor within the lumen 310, the assembly 300. Alternatively, the lumen 210 can include multiple (e.g., two, three, four, five, or between five and ten) conductors. In some embodiments, the conductor can operate at IkV or below. In26334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067some embodiments, the conductor can operate below IkV. That is, the assembly 300 can be used for low-voltage applications (e.g., applications using electric wires operating at IkV or below).

[0103] In some embodiments, the lumen 310, the reinforcing layer 320, the insulating layer 340, and the external layer 370 can be similar to or substantially the same as the lumen 110, the reinforcing layer 120, the insulating layer 140, and the external layer 170, as described above with reference to FIG. 1. In some embodiments, the external layer 370 can be similar to or substantially the same as the sheath layer 160, as described above with reference to FIG. 1. In some embodiments, the assembly 300 can further include a sheath layer disposed around the external layer 370. In some embodiments, the sheath layer can be similar to or substantially the same as the sheath layer 160, as described above with reference to FIG. 1. In some embodiments, the inner diameter r, and the outer diameter R of the assembly 300 can be similar to or substantially the same as the inner diameter r, and the outer diameter R of the assembly 200, described above with reference to FIG. 2. Thus, certain aspects of the lumen 310, the reinforcing layer 320, the insulating layer 340, and the external layer 370 are not described in greater detail herein.

[0104] FIG. 4 illustrates a cross-sectional view of a conduit assembly 400 (hereafter, referred to as “assembly 400”), according to an embodiment. The assembly 400 includes a hollow tubular body having an outer surface and an inner surface. The inner surface defines a lumen 410 extending along a longitudinal axis of the hollow tubular body. The hollow tubular body includes an annular portion between the outer surface and the inner surface. The annular portion of the assembly 400 includes a first reinforcing layer 420a. The first reinforcing layer 420a defines the inner surface of the hollow tubular body. The assembly 400 further includes a second reinforcing layer 420b disposed around the first reinforcing layer 420a. The assembly 400 further includes an electrically insulating layer 440 disposed around the second reinforcing layer 420b. The annular portion of the assembly 400 further includes a first screen layer 430 wrapped by the electrically insulating layer 440, and a second screen layer 450 disposed around the electrically insulating layer 440. The assembly 400 further includes a sheath layer 460 disposed around the second screen layer 450, and an external layer 470 disposed around the sheath layer 460. The external layer 470 defines the outer surface of the hollow tubular body.

[0105] In some embodiments, the lumen 410, the first screen layer 430, the insulating layer 440, the second screen layer 450, the sheath layer 460, and the external layer 470 can be similar to or substantially the same as the lumen 110, the first screen layer 130, the insulating layer27334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067140, the second screen layer 150, the sheath layer 160, and the external layer 170, as described above with reference to FIG. 1. Thus, certain aspects of the lumen 410, the first screen layer 430, the insulating layer 440, the second screen layer 450, the sheath layer 460, and the external layer 470 are not described in greater detail herein.

[0106] In some embodiments, the first reinforcing layer 420a can be similar to or substantially the same as the reinforcing layer 420, as described above with reference to FIG.1. In some embodiments, the first reinforcing layer 420a includes a plastic tube. The second reinforcing layer 420b is disposed around the first reinforcing layer 420a.10.1.071 In some embodiments, the second reinforcing layer 420b can be made of highly electrically conductive material having electrical conductivity of greater than 106S / m. In some embodiments, the second reinforcing layer 420b can be made of at least one of a metal, or an alloy (e.g., stainless steel). In some embodiments, the second reinforcing layer 420b can function as a sheath layer, serving both electrical and / or mechanical purposes. In some embodiments, the second reinforcing layer 420b may be in a form of a plurality of wires. In some embodiments, the plurality of wires may be helically wound or arranged in a braided pattern to provide additional structural support and improve resistance to torsional and bending stresses.|0108] In some embodiments, one or more layers of the assembly 400 may be absent depending on the specific application and operating requirements. For example, the presence or absence of layers may be influenced by the voltage level of the electrical conductor housed within the lumen 410.|0109] For low-voltage applications (e.g., 1 kV or below), some layers, such as the second reinforcing layer 420b or the second screen layer 450, may be omitted, as the structural and shielding requirements are reduced. Conversely, for medium-voltage (e.g., above 1 kV and up to 46 kV) or high-voltage (e.g., above 46 kV and up to 69 kV or higher) applications, these layers can provide enhanced mechanical support, electrical insulation, and shielding against electromagnetic interference. In some embodiments, the sheath layer 460 or the external layer 470 may be excluded in scenarios where the conduit assembly 400 is installed in environments that do not require additional mechanical, electrical protection, or resistance to external environmental factors. Such exclusions allow for cost and weight optimization while still meeting the functional requirements of the conduit assembly 400. In some embodiments, one or more layers of the conduit assembly 400 can be omitted based on factors such as voltage28334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067level, environmental conditions, mechanical stress, and electromagnetic shielding needs. For example, a conduit assembly used in a controlled indoor setting with low-voltage conductors may not use the same layers as one used in outdoor, high-voltage applications with exposure to mechanical and environmental stressors.[0110| FIG. 5 illustrates a conduit assembly 500 (hereinafter referred to as “assembly 500”) including a conductor 580 disposed within a lumen 510 of the conduit assembly 500, in accordance with an embodiment. In some embodiments, the assembly 500 and the lumen 510 are similar to or substantially same as the assemblies 100, 200, 300, and 400 described in the foregoing embodiments, except that the conduit assembly 500 further includes the conductor 580.[01111 The conductor 580 may include a single-core conductor or multiple conductors, such as multi-core configurations with several electric wires (e.g., copper wires) twisted or stranded together. The conductor 580 can be made from various materials, including copper, aluminum, or superconducting materials. The lumen 510 can be configured to accommodate conductors of varying sizes and configurations. In other embodiments, the lumen 510 may be configured with additional space to allow for insulation, cooling fluids, or shielding materials, which may be used for electromagnetic protection and / or temperature regulation. The conduit assembly 500 is therefore configurable to support a wide range of applications, including but not limited to, overhead power transmission lines, underground distribution systems, suboceanic power and communication networks, aerospace systems, high-frequency telecommunications, renewable energy infrastructure, industrial power networks, and data centers.

[0112] In some embodiments, provided herein is a method of manufacturing a conductor assembly described above in the foregoing embodiments. The method includes forming a multi-layered conduit similar to or substantially same as the assemblies 100, 200, 300, and 400 described in the foregoing embodiments. The method can further include disposing a conductor similar to or substantially same as the conductor described above with respect to FIG. 5, inside the lumen of the multi-layer conduit.

[0113] In some embodiments, each layer of the conductor assembly can be at least partially applied on and over the adjacent (previous) layer along the length of the tubular body using various techniques tailored to the material and functional requirements of the layer. In some embodiments, each new layer can be applied directly on top of or in contact with the previous29334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067layer. In some embodiments, extrusion may be used to form continuous layers, such as the reinforcing, insulating, or external layers, providing uniform thickness and strong adhesion. In some embodiments, wrapping techniques, such as spiral winding or taping, can be employed for layers like the first screen and / or the second screen layers. In some embodiments, coating methods, including dip-coating, spray-coating, or lamination, may be utilized to deposit thin and uniform layers, such as electrically insulating coatings or protective films. In some embodiments, advanced methods like sputtering, electroplating, or vapor deposition can be applied to create highly conductive sheath layers or specialized surface finishes. The multilayered conduit can be formed using any known technique in the art, including those described above, or any other suitable method that achieves the desired structural and functional properties.

[0114] In some embodiments, the conductor (e.g., one or more conductors) can be introduced into the lumen of the tubular body. This can be performed either on-site and / or at the manufacturing site. In some embodiments, the conductor can be introduced using automated machinery that pulls and / or pushes the conductor into the lumen. In some embodiments, the conductor can be introduced manually and / or with the aid of portable equipment designed for field installation. Methods such as pulling the conductors through the lumen using a pulling cable or pushing them with a rod can be employed. The conductor can be introduced into the lumen using any known technique in the art, including those described above, or any other suitable method that can securely positioned within the lumen, ready for subsequent connection and use.|0.115| In some embodiments, forming the multi-layered conduit and disposing the conductor within the lumen can be both performed at a manufacturing site. In other embodiments, forming the multi-layered conduit is performed at a manufacturing site, and disposing the conductor within the lumen is performed at a separate installation site after the multi-layered conduit has been transported and installed.|01l6| In some embodiments, disposing the conductor within the lumen includes introducing an uninsulated conductor into the lumen, such that electrical insulation, electrical stress control, and environmental protection are provided primarily by the layers of the multilayered conduit rather than by insulation applied directly to the conductor.

[0117] In some embodiments, the method may further include installing the multi-layered conduit at a desired location prior to disposing the conductor within the lumen. In some such30334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067embodiments, the multi-layered conduit may be installed as part of an existing electrical installation, and a conductor may be subsequently introduced into the lumen after installation of the multi-layered conduit.101181 In some embodiments, the method may further include removing a conductor from the lumen and introducing a replacement conductor into the lumen while maintaining the multilayered conduit in place. Such embodiments may enable staged installation, conductor replacement, repair, or system reconfiguration without removal or replacement of the multilayered conduit.101191 In some embodiments, the method may further include electrically grounding at least one of the reinforcing layer or a sheath layer before energizing the conductor. In some embodiments, the grounding configuration may be selected to manage electrical stress, electromagnetic interference, or current flow during transient or non-steady-state operating conditions of the conductor assembly.10.120 ] In some embodiments, the method may further include performing one or more tests before or after disposing the conductor within the lumen. Such tests may include electrical testing, dielectric testing, pressure testing, continuity testing, or combinations thereof to verify mechanical integrity, electrical insulation performance, or suitability for operation.

[0121] In some embodiments, the order of forming the layers of the multi-layered conduit and disposing the conductor within the lumen may be varied depending on manufacturing constraints, installation requirements, or application environment. For example, in some embodiments, the conductor may be disposed within the lumen prior to forming one or more outer layers of the multi-layered conduit.

[0122] Various concepts may be embodied as one or more methods, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments. As such, some of these features may be mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some features are applicable to one aspect of the innovations, and inapplicable to others.

[0123] In addition, the disclosure may include other innovations not presently described. Applicant reserves all rights in such innovations, including the right to embodiment such31334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067innovations, file additional applications, continuations, continuations-in-part, divisionals, and / or the like thereof. As such, it should be understood that advantages, embodiments, examples, functional, features, logical, operational, organizational, structural, topological, and / or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the embodiments or limitations on equivalents to the embodiments.334438184

Claims

Agent’s File Ref. VEIR-006 / 01WO 338760-2067CLAIMSWhat is claimed is:

1. An assembly, comprising:a hollow tubular body having an outer surface and an inner surface defining a lumen, the lumen extending along a longitudinal axis of the hollow tubular body, the hollow tubular body including an annular portion between the outer surface and the inner surface, the annular portion including:a reinforcing layer defining the inner surface of the hollow tubular body, the reinforcing layer configured to provide structural support to the assembly;an electrically insulating layer, the electrically insulating layer extending along a length of the hollow tubular body, the electrically insulating layer including a polymer; anda first screen layer disposed between the reinforcing layer and the electrically insulating layer.

2. The assembly of claim 1, further comprising:a second screen layer disposed around the electrically insulating layer.

3. The assembly of claim 2, further comprising:a sheath layer disposed around the second screen layer, the sheath layer including an electrically conducting material having an electrical conductivity of greater than 104S / m.

4. The assembly of any one of claims 1-3, further comprising:a sheath layer disposed around the electrically insulating layer, the sheath layer including an electrically conducting material having an electrical conductivity of greater than 104S / m.

5. The assembly of any one of claims 1-4, further comprising:an external layer defining the outer surface of the hollow tubular body, the external layer configured to provide mechanical and / or environmental protection to the assembly.

6. The assembly of any one of claims 1-5, wherein the electrically insulating layer includes at least one of a thermoplastic polymer or a thermosetting polymer.33334438184Agent’s File Ref. VEIR-006 / 01WO 338760-20677. The assembly of any one of claims 1-6, wherein the electrically insulating layer includes an elastomer.

8. The assembly of any one of claims 1-7, wherein the lumen is configured for housing a conductor, the conductor extending along the length of the tubular body.

9. The assembly of any one of claims 1-8, wherein the first screen layer comprises one or more polymers configured to conduct electricity.

10. The assembly of any one of claims 1-9, wherein the first screen layer has an electrical conductivity from about 10'8S / m to about 104S / m.

11. The assembly of any one of claims 1-10, wherein the first screen layer comprises a polymer matrix, the polymer matrix including at least one of a conductive filler or a semi conductive filler.

12. The assembly of any one of claims 1-11, wherein the lumen is configured for housing an uninsulated electrical conductor, the uninsulated electrical conductor extending along the length of the tubular body.

13. The assembly of any one of claim 12, wherein the uninsulated electrical conductor comprises a plurality of uninsulated electrical conductors.

14. The assembly of any one of claims 1-13, wherein the reinforcing layer comprises an electrically conductive material, and is configured to provide a grounding path.

15. The assembly of any one of claims 1-14, the first screen layer includes one or more polymers configured to conduct electricity.

16. An assembly, comprising:a hollow tubular body having an outer surface and an inner surface defining a lumen, the lumen extending along a longitudinal axis of the hollow tubular body, the hollow tubular body including an annular portion between the outer surface and the inner surface, the annular portion including:34334438184Agent’s File Ref. VEIR-006 / 01WO 338760-2067a reinforcing layer defining the inner surface of the hollow tubular body, the reinforcing layer configured to provide structural support to the assembly;an electrically insulating layer disposed around the reinforcing layer, the electrically insulating layer extending along a length of the hollow tubular body, the electrically insulating layer including a polymer; andan external layer defining the outer surface of the hollow tubular body, the external layer configured to provide mechanical and / or environmental protection to the assembly.

17. The assembly of claim 16, wherein the lumen is configured for housing an electrical conductor configured to transmit power under 1 kV, the electrical conductor extending along a length of the tubular body.

18. The assembly of claim 16 or 17, wherein the external layer includes one or more polymers.

19. The assembly of any one of claims 16-18, wherein the electrically insulating layer is thermally stable between about -55°C to about 150°C.

20. The assembly of any one of claims 16-19, further comprising:a screen layer disposed between the reinforcing layer and the electrically insulating layer.

21. The assembly of claim 20, wherein the screen layer comprises one or more polymers configured to conduct electricity.

22. The assembly of claim 20, wherein the screen layer comprises a polymer matrix, the polymer matrix including at least one of a conductive filler, or a semi conductive filler23. The assembly of claim 20, wherein the screen layer has an electrical conductivity from about 10'8S / m to about 104S / m.

24. The assembly of claim 20, wherein the screen layer is a first screen layer, and the assembly further comprising:a second screen layer disposed around the electrically insulating layer.35334438184Agent’s File Ref. VEIR-006 / 01WO 338760-206725. The assembly of any one of claims 16-24, further comprising:a sheath layer wrapped by the external layer.

26. The assembly of claim 25, wherein the sheath layer comprises an electrically conductive material having an electrical conductivity greater than about 104S / m.

27. The assembly of claim 25, wherein the sheath layer is configured to provide electromagnetic shielding of the lumen.

28. The assembly of any one of claims 16-27, wherein the lumen is configured for housing an electrical conductor configured to transmit power above 1 kV, the electrical conductor extending along a length of the tubular body.

29. The assembly of claim 28, wherein the electrical conductor is uninsulated.

30. The assembly of claim 29, wherein the uninsulated electrical conductor comprises a plurality of uninsulated electrical conductors.36334438184

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