Weldless pole mounting structure and method of providing same

Abstract

A hollow pole having a flared lower end is matingly mounted in a base flange fitted over, and in facing contact with, the flared end portion of the pole and having a tubular wedge matingly fitted in the flared end of the pole so that the pole is bonded to the tubular wedge and the base flange solely by galling action. The assembly is effected by using relatively soft aluminum alloy from which the components are made but which is heat treated prior to assembly to increase hardness and tensile strength so that assembly of the pole, tubular wedge and base flange results in a galling action providing the sole bonding of the pole to the other parts.

What is claimed is:  
     
         1 . A pole assembly comprising: 
 a hollow pole having a main axis, an inner surface, and an outer surface, and an outwardly flared hollow mounting portion concentric to the main axis, and having a lower end surface defining the lower extent of the pole member;    a tubular wedge positioned in the outwardly flared mounting portion and having a lower end surface, and an outer flared surface concentric to the main axis and in mating facing contact with the inner surface of the pole;    a base flange having an inner flared surface matingly fitted over and in facing contact with the outwardly flared mounting portion of the pole and having a lower end surface; and    wherein the lower end surface of the pole member, the lower end surface of the tubular wedge and the lower end surface of the base flange are coplanar surfaces.    
     
     
         2 . A pole assembly as recited in  claim 1 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces.  
     
     
         3 . A pole assembly as recited in  claim 1 , wherein said base flange comprises a unitary structure formed of a conical tube in which the inner flared surface of the base flange is provided, and a connector plate extending outwardly radially of the conical tube.  
     
     
         4 . A pole assembly as recited in  claim 3 , wherein said base flange includes plural attachment permitting apertures in the connector plate for receiving retainers for connecting the pole assembly to a supporting foundation or footing.  
     
     
         5 . A pole assembly as recited in  claim 1 , additionally including a keeper plate having an upper surface engaging the lower end surface of the pole, the tubular wedge and the base flange for permitting support of pole assembly by the keeper plate.  
     
     
         6 . A pole assembly as recited in  claim 5 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces.  
     
     
         7 . A pole assembly as recited in  claim 6 , wherein the base flange comprises a unitary structure including a conical tube in which the inner flared surface of the base flange is provided and a connector plate extending outwardly radially of the conical tube.  
     
     
         8 . A pole assembly as recited in  claim 7 , wherein the base flange includes plural attachment permitting apertures in the connector plate for receiving retainers for connecting the pole assembly to a supporting foundation or footing.  
     
     
         9 . A pole assembly as recited in  claim 1 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces; and 
 wherein the base flange comprises a unitary structure formed of a conical tube in which the inner flared surface of the base flange is provided and a connector plate extending outwardly radially of the conical tube and includes plural attachment permitting apertures for receiving retainers for connecting the pole assembly to a supporting foundation or footing.    
     
     
         10 . A pole assembly as recited in  claim 1 , wherein the hollow pole is bonded to the tubular wedge and the base flange by galling contact with the tubular wedge and the base flange.  
     
     
         11 . A pole assembly as recited in  claim 10 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces.  
     
     
         12 . A pole assembly as recited in  claim 10 , wherein said base flange comprises a unitary structure formed of a conical tube in which the inner flared surface of the base flange is provided and a connector plate extending outwardly radially of the conical tube.  
     
     
         13 . A pole assembly as recited in  claim 12 , wherein said base flange includes plural attachment permitting apertures in the connector plate for receiving retainers for connecting the pole assembly to a supporting foundation or footing.  
     
     
         14 . A pole assembly as recited in  claim 10 , additionally including a keeper plate having an upper surface engaging the lower end surface of the pole, the tubular wedge and the base flange for permitting support of pole assembly by said keeper plate.  
     
     
         15 . A pole assembly as recited in  claim 14 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces.  
     
     
         16 . A pole assembly as recited in  claim 1 , wherein the hollow pole, tubular wedge and base flange are formed of aluminum alloy.  
     
     
         17 . A pole assembly as recited in  claim 16 , wherein the inner surface and the outer surface of the outwardly flared hollow mounting portion of the pole, the outwardly flared surface of the tubular wedge and the inner flared surface of the base flange are all conical surfaces.  
     
     
         18 . A pole assembly as recited in  claim 16 , wherein said base flange comprises a unitary structure formed of a conical tube in which the inner flared surface of the base flange is provided, and a connector plate extending outwardly radially of the conical tube.  
     
     
         19 . A pole assembly as recited in  claim 18 , wherein said base flange includes plural attachment permitting apertures in the connector plate for receiving retainers for connecting the pole assembly to a supporting foundation or footing.  
     
     
         20 . A pole assembly as recited in  claim 19 , additionally including a keeper plate having an upper surface engaging the lower end surface of the pole, the tubular wedge and the base flange for permitting support of pole assembly by the keeper plate.  
     
     
         21 . A pole assembly as recited in  claim 16 , wherein the hollow pole, tubular wedge and base flange are formed of aluminum alloy 6063-T6.  
     
     
         22 . A method of making a pole assembly comprising the steps of: 
 a) providing a tube, a tubular wedge and a base flange all of which are made of relatively soft aluminum machinable alloy having a relatively low tensile strength;    b) providing a flared end on the tube by machining one end of the tube to provide an outwardly flared end portion on the tube;    c) subjecting the flared tube, the tubular wedge and the base flange to heat to increase the tensile strength and hardness thereof;    d) matingly positioning the flared end portion of the tube over the tubular wedge with sufficient force to bond the tube to the wedge by galling; and    e) matingly positioning the base flange over the outer surface of the flared end portion of the tube with sufficient force to bond the tube to the base flange by galling.    
     
     
         23 . The method of  claim 22 , wherein step d) is effected by contacting an inner conical surface of the outwardly flared end portion of the tube in face-to-face contact with a conical outer surface of the tubular wedge.  
     
     
         24 . The method of  claim 23 , wherein step e) is effected by contacting an outer conical surface of the outwardly flared end portion of the tube in face-to-face relation with a conical inner surface of the base flange.  
     
     
         25 . The method of  claim 22 , wherein the relatively soft aluminum alloy of step a) is 6063-T4 alloy and wherein the alloy resultant from step c) is 6063-T6 alloy.  
     
     
         26 . The method of  claim 25 , wherein step d) is effected by contacting an inner conical surface of the outwardly flared end portion of the tube in face-to-face contact with a conical outer surface of the tubular wedge.  
     
     
         27 . The method of  claim 26 , wherein step e) is effected by contacting an outer conical surface of the outwardly flared end portion of the tube in face-to-face relation with a conical inner surface of the base flange.