Toneable Conduit with Internal Toning Wire and Air Gap
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Solution Overview
Problem
Conduits buried underground, especially those with non-metallic cables, are difficult to locate using conventional detection methods, and existing constructions that include metallic or magnetic strips face issues with moisture ingress, damage during installation, and limited detection depth and distance.
Innovation Solution
A toneable conduit design featuring an elongate polymeric tube with a sub-channel for a continuous toning signal wire, coated with a non-stick material to prevent adhesion and allow easy coupling, and an air gap within the sub-channel to accommodate wire movement and reduce damage during bending and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If an exterior rib with metallic wire is used for detection, then detection capability is improved, but coupling between conduits is compromised and moisture can enter
Solution Approach 1:
The metallic toning wire is extracted from the exterior rib structure and repositioned to run through the interior of the conduit. This allows the detection function to be maintained while eliminating the interference with exterior coupling surfaces, resolving the contradiction between detection capability and coupling integrity.
Solution Approach 2:
The toning wire is nested within the conduit interior rather than being embedded in the exterior rib. This nesting approach allows the wire to be protected and functional while not interfering with the exterior coupling surfaces, simultaneously achieving detection capability and coupling reliability.
2Difficulty of detecting and measuring
If an exterior rib with metallic wire is used for detection, then detection capability is improved, but the wire can be ripped off during directional boring or plowing installation
Solution Approach 1:
The toning wire is extracted from the vulnerable exterior rib position and relocated to the protected interior environment. This extraction protects the wire from mechanical damage during directional boring or plowing installation while maintaining its detection function.
Solution Approach 2:
The wire is positioned within the conduit interior where it is cushioned and protected from the mechanical stresses of installation. This prior protection prevents the wire from being ripped off during directional boring or plowing, while the wire remains functional for detection.
3Difficulty of detecting and measuring
If intermittent magnetic strip is used, then detection by metal detection devices is possible, but toning signal transmission over extended distances is not achieved
Solution Approach 1:
The toning wire is implemented as a continuous conductor running through the entire length of the conduit rather than intermittent magnetic strips. This continuity enables both metal detection capability and long-distance toning signal transmission, resolving the contradiction between detection capability and transmission distance.
4Difficulty of detecting and measuring
If continuous metallic ribbon is used for detection, then detection at three to five feet depth is achieved, but toning signal transmission for extended distances is not suitable
Solution Approach 1:
A continuous metallic wire is used instead of limited-capability ribbons, enabling both adequate detection depth and extended-distance toning signal transmission. The continuous wire provides the electrical continuity needed for long-distance signal transmission while maintaining detection capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables effective detection by toning equipment over extended distances and depths, reduces the risk of wire damage during coiling and installation, and maintains conduit integrity by allowing the wire to slide within the sub-channel, thus preventing moisture ingress and performance issues.
Implementation Method 1
coated with a non-stick material to prevent adhesion and allow easy coupling
Data Source
AI summary
A toneable conduit includes an elongate polymeric tube having a sidewall with an interior surface and an exterior surface. The interior surface defines a main channel. A sub-channel, smaller in cross sectional area than the main channel, extends longitudinally between the exterior and interior surfaces of the tube. A continuous toning signal wire is located within the sub-channel. The sub-channel has a larger cross sectional area than a cross sectional area of the toning signal wire, so that an air gap exists within said sub-channel around portions of the toning signal wire.