Modular Composite Utility Pole

Abstract

A modular composite utility pole has a plurality of sections, each with a tapered hollow tube having a plurality of plies, wherein a first end has a larger diameter than a second end, wherein each section is adapted to join at least one adjoining section at a joint wherein the first end of an upper section overlaps the second end of a lower section, the lower section having a ledge proximate to the second end of the lower section, with a fastener passing through the joint via apertures in the sections, and wherein, when the modular composite utility pole is erected, the joint is self-located by the joint features, and wherein substantially all vertical load is transferred between sections via the a surface of the second end of the upper section resting upon the ledge of the lower section. Also disclosed are individual sections and methods of making them.

1 . A section of a modular composite utility pole, comprising:
 a tapered hollow tube comprising a plurality of plies, a first end, and a second end, wherein the first end has a larger diameter than the second end;   at least one aperture proximate to an end and adapted to receive a fastener; and   a built-up ledge around the periphery of the tapered hollow tube and proximate to the second end thereof, the ledge comprising a plurality of plies having one or more filaments wound at an angle relative to a longitudinal axis of the tapered hollow tube.   
     
     
         2 . The section of  claim 1 , wherein said angle of the plies in the ledge is between 80 and 90 degrees relative to said longitudinal axis. 
     
     
         3 . The section of  claim 1 , wherein said tapered hollow tube comprises plies wound at an angle of about 85 to about 90 degrees, plies wound at an angle of about 40 to about 65 degrees, and plies wound at an angle of about 5 to about 25 degrees,
 wherein the degrees are measured relative to said longitudinal axis.   
     
     
         4 . The section of  claim 3 , wherein the plies are wound at an angle of about 85 degrees to about 90 degrees in the region corresponding to the area of the joint between pole sections, the plies are wound at an angle of about 65 degrees to about 40 degrees at a transition zone, and the plies are wound at an angle which varies from about 40 degrees to about 25 degrees or about 40 degrees to about 5 degrees until reaching the opposite end of the pole or pole section. 
     
     
         5 . The section of  claim 1 , wherein:
 (a) said tapered hollow tube comprises a wall having a thickness of about 0.2 to about 0.8 inches;   (b) said tapered hollow tube has a length of about 72 to about 224 inches; and/or   (c) said tapered hollow tube tapers at an angle of about 0.2 to about 0.8 degrees per side.   
     
     
         6 . The section of  claim 1 , wherein said tapered hollow tube comprises glass fiber filament and a polyester resin blend. 
     
     
         7 . A modular composite utility pole, comprising:
 a plurality of sections, each comprising a tapered hollow tube comprising a plurality of plies, a first end, and a second end, wherein the first end has a larger diameter than the second end,   wherein each section is adapted to join at least one adjoining section at a joint wherein the first end of an upper section overlaps the second end of a lower section, the lower section further comprising a ledge proximate to the second end of the lower section, the ledge comprising a plurality of plies having one or more filaments wound at an angle relative to a longitudinal axis of the tapered hollow tube,   wherein each section includes at least one aperture proximate to an end, the aperture being adapted to align with a corresponding aperture in the at least one adjoining section and to receive a fastener passing through the joint, and   wherein, when the modular composite utility pole is erected, substantially all vertical load is transferred between sections via the a surface of the second end of the upper section resting upon the ledge of the lower section.   
     
     
         8 . The modular utility pole of  claim 7 , comprising a top section comprising a sensor bay assembly. 
     
     
         9 . The modular utility pole of  claim 8 , wherein said sensor bay comprises a tubular insert and a top cap comprising a top flange. 
     
     
         10 . The modular utility pole of  claim 8 , wherein said sensor bay assembly contains one or more sensor or communications packages. 
     
     
         11 . The modular utility pole of  claim 7 , comprising a top section comprising a built-up area on said tapered hollow tube adapted for the attachment of heavy equipment. 
     
     
         12 . The modular utility pole of  claim 11 , wherein said built-up area adapted for the attachment of heavy equipment comprises plies adapted to increase torsional stiffness and wound at about 40 to about 65 degrees and plies adapted to increase bending stiffness and wound at about 5 to about 25 degrees, wherein the degrees are measured relative to said longitudinal axis. 
     
     
         13 . The modular utility pole of  claim 7 , comprising a common impact point, wherein the pole sections and joints are configured such that, when the pole is buried in the ground, a first joint between a bottom buried section and the next section adjoining the bottom section is positioned outside the common impact point. 
     
     
         14 . The modular utility pole of  claim 7 , wherein said pole comprises three or more sections. 
     
     
         15 . The modular utility pole of  claim 7 , wherein a nominal gap of about 0.020 to about 0.060 inches exists in the joint between inner and outer peripheral wall surfaces of said adjoining sections. 
     
     
         16 . The modular utility pole of  claim 7 , wherein said angle of the plies in said ledge is about 80 to about 90 degrees relative to said longitudinal axis. 
     
     
         17 . The modular utility pole of  claim 7 , wherein said tapered hollow tube comprises plies wound at an angle of about 85 to about 90 degrees, plies wound at an angle of about 40 to about 65 degrees, and plies wound at an angle of about 5 to about 25 degrees,
 wherein the degrees are measured relative to said longitudinal axis.   
     
     
         18 . The modular utility pole of  claim 17 , wherein the plies are wound at an angle of about 85 degrees to about 90 degrees in the region corresponding to the area of the joint between pole sections, the plies are wound at an angle of about 65 degrees to about 40 degrees at a transition zone, and the plies are wound at an angle which varies from about 40 degrees to about 25 degrees or about 40 degrees to about 5 degrees until reaching the opposite end of the pole or pole section. 
     
     
         19 . The modular utility pole of  claim 7 , wherein:
 (a) each tapered hollow tube comprises a wall having a thickness of about 0.2 to about 0.8 inches;   (b) each tapered hollow tube has a length of about 72 to about 224 inches; and/or   (c) each tapered hollow tube tapers at an angle of about 0.2 to about 0.8 degrees per side.   
     
     
         20 . A method of making a section of a composite utility pole, the method comprising:
 (a) wetting a filament in resin;   (b) winding the wetted filament on a tapered mandrel;   (c) curing the wetted filament to create a tapered hollow tube comprising a plurality of plies, a first end, and a second end, wherein the first end has a larger diameter than the second end;   (d) machining an end of the tapered hollow tube at a predetermined position along the length of the tapered hollow tube; and   (e) creating an aperture through the tapered hollow tube at a predetermined distance from the machined end.   
     
     
         21 . The method of  claim 20 , further comprising:
 before said curing, winding one or more plies to build up a ledge,   wherein said curing further comprises curing the ledge, and   wherein the ledge is proximate to said second end of said tapered hollow tube and comprises plies wound at an angle relative to a longitudinal axis of said tapered hollow tube.   
     
     
         22 . The method of  claim 21 , wherein said winding one or more plies to build up said ledge comprises winding plies at an angle of about 80 to about 90 degrees relative to said longitudinal axis. 
     
     
         23 . The method of  claim 21 , further comprising forming a built-up area on a discrete portion of said tapered hollow tube adapted for the attachment of heavy equipment. 
     
     
         24 . The method of  claim 23 , wherein said forming the built-up area adapted for the attachment of heavy equipment comprises winding plies at an angle of about 40 to about 65 degrees and winding plies at an angle of about 5 to about 25 degrees,
 the degrees measured relative to a longitudinal axis of said tapered hollow tube.   
     
     
         25 . The modular utility pole of  claim 7 , wherein each tapered hollow tube comprises plies having a variable wind pattern. 
     
     
         26 . The section of the modular composite utility pole of  claim 1 , wherein the tapered hollow tube comprises plies having a variable wind pattern. 
     
     
         27 . The modular utility pole of  claim 13 , wherein pole sections are adapted to be disassembled and replaced.