Flexible conduit and method for forming the same

Abstract

A conduit defining a continuous conduit passage extending from a first opening to a second opening includes a plurality of flexible, tubular, corrugated sections, each defining at least a portion of the conduit passage therethrough. A plurality of tubular, non-corrugated sections are merged with at least one of the corrugated sections and define at least a portion of the conduit passage therethrough. The plurality of corrugated sections and the plurality of non-corrugated sections are arranged in alternating relation.

That which is claimed is:  
     
         1 . A conduit defining a continuous conduit passage and comprising: 
 a) a flexible, tubular, corrugated section defining at least a portion of the conduit passage therethrough;    b) wherein at least the corrugated section is formed of CPVC.    
     
     
         2 . The conduit of  claim 1  further including: 
 a) a tubular, non-corrugated section merged with the corrugated section at an end of the corrugated section;  
 b) wherein the non-corrugated section defines a second portion of the conduit passage.  
 
     
     
         3 . The conduit of  claim 2  wherein the non-corrugated section is formed of CPVC.  
     
     
         4 . The conduit of  claim 2  wherein the non-corrugated section has a nominal wall thickness of at least 0.068 inch.  
     
     
         5 . The conduit of  claim 2  wherein the non-corrugated section has a nominal inner diameter of at least 0.489 inch.  
     
     
         6 . The conduit of  claim 2  wherein the non-corrugated section has a length of at least about 2 inches.  
     
     
         7 . The conduit of  claim 2  including: 
 a) a second tubular, non-corrugated section merged with the corrugated section at a second end of the corrugated section;  
 b) wherein the second non-corrugated section defines a third portion of the conduit passage.  
 
     
     
         8 . The conduit of  claim 7  including a second tubular, corrugated section merged with the second non-corrugated section at an end of the second non-corrugated section opposite the first corrugated section.  
     
     
         9 . The conduit of  claim 1  wherein the corrugated section has a nominal wall thickness of at least 0.068 inch.  
     
     
         10 . The conduit of  claim 1  wherein the corrugated section has a nominal inner diameter of at least 0.489 inch.  
     
     
         12 . The conduit of  claim 1  wherein the corrugated section has a length of between about 10 and 40 inches.  
     
     
         13 . The conduit of  claim 1  wherein the conduit has a burst pressure of at least 250 psi at 180° F.  
     
     
         14 . The conduit of  claim 1  wherein the conduit meets or exceeds ASTM F1970-01, revision 2001.  
     
     
         15 . The conduit of  claim 1  wherein the conduit is formed of CPVC having a modulus of elasticity of at least 360,000 psi.  
     
     
         16 . A conduit defining a continuous conduit passage and comprising: 
 a) a flexible, tubular, corrugated section defining at least a portion of the conduit passage therethrough;    b) wherein at least the corrugated section is formed of cross-linked polyethylene (PEX).    
     
     
         17 . The conduit of  claim 16  further including: 
 a) a tubular, non-corrugated section merged with the corrugated section at an end of the corrugated section;  
 b) wherein the non-corrugated section defines a second portion of the conduit passage.  
 
     
     
         18 . The conduit of  claim 17  wherein the non-corrugated section is formed of PEX.  
     
     
         19 . The conduit of  claim 17  wherein the non-corrugated section has a length of at least about 2 inches.  
     
     
         20 . The conduit of  claim 17  including: 
 a) a second tubular, non-corrugated section merged with the corrugated section at a second end of the corrugated section;  
 b) wherein the second non-corrugated section defines a third portion of the conduit passage.  
 
     
     
         21 . The conduit of  claim 20  including a second tubular, corrugated section merged with the second non-corrugated section at an end of the second non-corrugated section opposite the first corrugated section.  
     
     
         22 . A conduit defining a continuous conduit passage extending from a first opening to a second opening and comprising: 
 a) a plurality of flexible, tubular, corrugated sections each defining at least a portion of the conduit passage therethrough; and    b) a plurality of tubular, non-corrugated sections each merged with at least one of the corrugated sections and defining at least a portion of the conduit passage therethrough;    c) wherein the plurality of corrugated sections and the plurality of non-corrugated sections are arranged in alternating relation.    
     
     
         23 . The conduit of  claim 22  wherein each of the corrugated sections and the non-corrugated sections is formed of a thermoplastic.  
     
     
         24 . The conduit of  claim 23  wherein each of the corrugated sections and the non-corrugated sections is formed of CPVC.  
     
     
         25 . The conduit of  claim 24  wherein the conduit meets or exceeds ASTM F1970-01, revision 2001.  
     
     
         26 . The conduit of  claim 23  wherein each of the corrugated sections and the non-corrugated sections is formed of PVC.  
     
     
         27 . The conduit of  claim 26  wherein the conduit meets or exceeds ASTM D2241-00, revision 2000.  
     
     
         28 . The conduit of  claim 23  wherein each of the corrugated sections and the non-corrugated sections is formed of PEX.  
     
     
         29 . The conduit of  claim 22  wherein the conduit is formed of PVC or CPVC having a modulus of elasticity of at least 360,000 psi.  
     
     
         30 . A conduit system comprising: 
 a) first and second substantially rigid conduits; and    b) a third conduit interposed between the first and second conduits, wherein: 
 the third conduit includes a flexible, tubular, corrugated section; and  
 at least the corrugated section is formed of CPVC.  
   
     
     
         31 . A conduit system comprising: 
 a) first and second substantially rigid conduits; and    b) a third conduit interposed between the first and second conduits, wherein: 
 the third conduit includes a flexible, tubular, corrugated section; and  
 at least the corrugated section is formed of PEX.  
   
     
     
         32 . A method for forming a conduit, the method comprising: 
 a) extruding a tubular pre-form of PVC, CPVC, or PEX; and    b) forming a corrugated section in the pre-form.    
     
     
         33 . The method of  claim 32  wherein the pre-form is formed of CPVC.  
     
     
         34 . The method of  claim 32  wherein the pre-form is formed of PVC.  
     
     
         35 . The method of  claim 32  wherein the pre-form is formed of PEX.  
     
     
         36 . The method of  claim 32  wherein the conduit is formed to meet or exceed ASTM D1794-99A.  
     
     
         37 . The method of  claim 32  wherein the step of forming the corrugated section is performed in-line with the step of extruding the pre-form.  
     
     
         38 . The method of  claim 32  wherein said step of forming a corrugated section includes forming corrugations in the pre-form while the pre-form is plasticized.  
     
     
         39 . The method of  claim 38  wherein said step of forming a corrugated section includes: 
 a) compressing the pre-form with at least one mold adapted to form the corrugations; and  
 b) pressurizing an interior passage of the pre-form with a pressurizing fluid while the mold is compressing the pre-form to limit displacement of walls of the pre-form into the interior passage.  
 
     
     
         40 . The method of  claim 38  wherein said step of forming a corrugated section includes: 
 a) positioning at least one mold adjacent the pre-form, the mold being adapted to form the corrugations; and  
 b) applying a vacuum to draw at least a portion of the pre-form into the mold to thereby form the corrugations.  
 
     
     
         41 . A method for forming a conduit, the method comprising: 
 a) extruding a tubular pre-form of a thermoplastic;    b) forming a corrugated section in the pre-form; and    c) forming a non-corrugated section in the pre-form such that the non-corrugated section is merged with the corrugated section.    
     
     
         42 . The method of  claim 41  wherein the pre-form is formed of CPVC.  
     
     
         43 . The method of  claim 41  wherein the pre-form is formed of PVC.  
     
     
         44 . The method of  claim 41  wherein the pre-form is formed of PEX.  
     
     
         45 . A method for forming a conduit system, said method comprising: 
 providing a first conduit including a flexible, tubular, corrugated section defining at least a portion of the conduit passage therethrough, wherein at least the corrugated section is formed of CPVC;    coupling second and third substantially rigid conduits to opposed ends of the first conduit; and    bending the corrugated section to form a bend between the second and third conduits.    
     
     
         46 . The method of  claim 45  wherein the first conduit includes a second corrugated section connected to the first corrugated section by an integral non-corrugated section, and further including bending the second corrugated section to form the bend.  
     
     
         47 . The method of  claim 46  including cutting the first conduit from a conduit assembly including a third corrugated section, said step of cutting including separating the first conduit from the third corrugated section.  
     
     
         48 . A method for forming a conduit system, said method comprising: 
 providing a first conduit including a flexible, tubular, corrugated section defining at least a portion of the conduit passage therethrough, wherein at least the corrugated section is formed of PEX;    coupling second and third substantially rigid conduits to opposed ends of the first conduit; and    bending the corrugated section to form a bend between the second and third conduits.    
     
     
         49 . The method of  claim 48  wherein the first conduit includes a second corrugated section connected to the first corrugated section by an integral non-corrugated section, and further including bending the second corrugated section to form the bend.  
     
     
         50 . The method of  claim 49  including cutting the first conduit from a conduit assembly including a third corrugated section, said step of cutting including separating the first conduit from the third corrugated section.  
     
     
         51 . A method for forming a conduit system, the method comprising: 
 a) providing a corrugated conduit defining a continuous conduit passage and including: 
 a flexible, tubular, corrugated section defining a first portion of the conduit passage therethrough, the corrugated section being formed of a thermoplastic; and  
 a tubular, non-corrugated section merged with the corrugated section at an end of the corrugate section, the non-corrugated section defining a second portion of the conduit passage; and  
   b) installing the corrugated conduit in a building structure such that the corrugated conduit provides fluid communication between a supply of potable water and a dispenser.    
     
     
         52 . The method of  claim 51  wherein the corrugated section is formed of CPVC.  
     
     
         53 . The method of  claim 51  wherein the corrugated section is formed of PVC.  
     
     
         54 . The method of  claim 51  wherein the corrugated section is formed of PEX.  
     
     
         55 . The method of  claim 51  wherein the step of installing includes bending the corrugated section to form a bend.  
     
     
         56 . The method of  claim 51  further including connecting at least one substantially rigid conduit to the corrugated conduit such that the rigid conduit also provides fluid communication between the supply of potable water and the dispenser.