# US 9,518,685 B2 · Extruded encapsulated fillers to provide crush protection > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 9,518,685 B2 - Document ID: US9518685B2 - Status: Granted - Kind: B2 - Application number: 14/290,197 - Filed: 2014-05-29 - Published: 2015-02-05 - Granted: 2016-12-13 - Earliest claimed: 2013-08-02 - Assignees: Oceaneering International, Inc. - Applicants: Oceaneering International, Inc. - Inventors: Stephen Owen Mast; Fraser Hynd Thomson; Rosianita Balena; Flavio Vasconcelos - Web page: https://patentgrep.com/patent/US9518685B2 ## CPC - F16L 11/10: with reinforcements not embedded in the wall (F16L11/11 takes precedence) - F16L 9/12: of plastics with or without reinforcement (F16L9/16 - F16L9/22 take precedence) - F16L 11/22: Multi-channel hoses - G02B 6/441: {built up from sub-bundles (G02B6/4429, G02B6/4439, G02B6/4479 take precedence)} - G02B 6/4427: {Pressure resistant cables, e.g. undersea cables} - G02B 6/4488: {using metallic tubes} - H02G 3/0406: {Details thereof (installation or suspension of conduit channels and other supports H02G3/263)} - G02B 6/4483: {Injection or filling devices} - Y10T 29/49826: Assembling or joining - Y10T 29/49879: Spaced wall tube or receptacle - Y10T 29/4998: Combined manufacture including applying or shaping of fluent material - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL - G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS - H02G: INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract In various embodiments, a tubular comprises a tubular outer sheath defining an inner void; one or more core elements or assemblies disposed within the inner void; and a substantially solid filler in various embodiments disposed within and substantially filling the inner void, where the filler is adapted to give the tubular hoop strength in a crush situation and comprises a polymer with a density of at least 1.0. In some embodiments, these core assemblies comprise an extruded polymer layer typically extruded about core elements in a single pass, fitting about them without a sharp edge and defining an outer shape. The resulting tubular can comprise multiple regions which, though substantially filled, are filled with differing fillers densities. ## Claims ### Claim 1 A tubular, comprising: a. a tubular outer sheath defining an inner void; b. a core element disposed within the inner void; c. a substantially solid filler comprising a polymer, the polymer comprising a density of at least 1.0 and a predetermined hoop strength in a crush situation, the filler disposed within and substantially completely filling the inner void and in contact with and substantially completely surrounding the core element; and d. a tubular inner sheath having a circumference smaller than the tubular outer sheath, the tubular inner sheath disposed within the inner void and defining: i. a first space between an outer portion of the tubular inner sheath and an inner portion of the tubular outer sheath; and ii. a second space within the inner void inside the tubular inner sheath, the filler disposed within and substantially filling the second space. ### Claim 2 (depends on 1) The tubular of claim 1, further comprising ii. an armor wire disposed within the first space. ### Claim 3 (depends on 1) The tubular of claim 1, wherein the polymer comprises high density polyethylene. ### Claim 4 (depends on 1) The tubular of claim 1, wherein the polymer is configured to provide impact and fatigue protection for the core element. ### Claim 5 (depends on 1) The tubular of claim 1, wherein: a. the tubular comprises an umbilical cable adapted for use subsea; and b. the core element comprises a fluid hose. ### Claim 6 (depends on 1) The tubular of claim 1, wherein the core element comprises at least one of a fluid hose, an electrical conductor, and a fiber optic conductor. ### Claim 7 (depends on 1) The tubular of claim 1, wherein the tubular comprises a flexible tubular. ### Claim 8 A method of manufacturing a tubular, comprising: a. placing a tubular inner sheath within a protective outer sheath about a core element, an interior surface of the outer sheath defining an inner void with respect to the tubular inner sheath, the tubular inner sheath defining: i. a first space between an outer portion of the tubular inner sheath and an inner portion the protective outer sheath; and ii. a second space within an inner void inside the tubular inner sheath; b. disposing the core element and the filler within the second space; and c. using a substantially solid polymer filler, the substantially solid polymer filler comprising an impact and fatigue protection material comprising a polymer with a density of at least 1.0 that provides tubular hoop strength in a crush situation, the impact and fatigue protection material, to substantially completely fill the second space and surround the core element. ### Claim 9 (depends on 8) The method of manufacturing a tubular of claim 8, further comprising: a. disposing an inner sheath within the outer sheath; and b. disposing an armor in an armor void defined by an inner surface of the outer sheath and an outer surface of the inner sheath, the polymer filler substantially filling a void defined by an interior surface of the inner sheath. ### Claim 10 (depends on 9) The method of manufacturing a tubular of claim 9, further comprising using an armor comprising a metal adapted to provide tensile strength with a winding at low lay angles from around 8 degrees to around 20 degrees.