Pole Cover

A pole cover assembly and a method for mounting the assembly onto a pole. The assembly includes a pole cover that has a first portion with a first longitudinal end. A base portion extends from the first portion and the base portion has a base portion depth and an inside diameter that is greater than an outside diameter of the first portion to accommodate a first longitudinal end of an adjacent pole cover therein and define a circumferential clearance gap around the adjacent pole cover. A longitudinal slit runs a length of the pole cover and separates axially extending arc segments of the pole cover. The arc segments overlap one another when disposed on the pole.

BACKGROUND OF THE INVENTION

Covers for poles and utility poles,

a) Field of the Invention

This invention relates to the utility poles or fixture poles that require coverings. In particular, poles for supporting communication hardware. The utility poles are constructed of materials such as aluminum, wood, concrete etc. Such poles may not be aesthetically pleasing and might not meet standards for the community requirements for the appearance of such. poles. The present invention pertains to a cover to cover such poles.

b) Description of the Related Art

It is well known to provide covers for poles. Gordin et al. (U.S. Pat. No. 7,607,276) discloses a pole cover or sleeve that is constructed for covering substantially tall poles. U.S. Patent Application Publication no.: 2009/0188207 to Gordin et al. discloses a set of covers or sleeves that are disposed to cover a 45 ft pole, where each sleeve is the same height. The sleeves are produced. from a flat sheet that has a trapezoidal shape, as is shown inFIG. 3(of the Gordin references), in order to have a tapered. shape to conform to the tapered pole. The ends of the vinyl sheets are bent and held together by extrusions once the covers are wrapped onto the pole and the extrusions are placed on the ends of the sheets and are rolled down to form a seam and close the covers onto the pole. The covers overlap one another in a longitudinal direction of the pole to cover the length of the pole. The covers are affixed at the top ends thereof, which is the underneath cover to allow the bottoms of the covers to expand and contract and accommodate thermal expansion due to temperature changes. This construction results in varying circumferential gaps where the seams overlap one another, as the covers move relative to one another due to thermal effects, as a result of the conical geometry. Furthermore, this construction results in two different materials extending the length of the covers, which can result in problems over time due to the thermal cycles.

SUMMARY OF THE INVENTION

The present invention is a pole cover assembly that provides for a pole cover that is easy to install and modify to cover poles of different lengths and that will accommodate structural elements such as mounting brackets that are mounted to the pole, where the structural elements must pass through the cover so that corresponding hardware can be mounted to the pole. The construction accommodates thermal expansion and contractions in a uniform way that provides for a constant circumferential relationship between the overlapping covers.

It is accordingly an object of the invention to provide a pole cover system that can conform to poles of various lengths, that is easy to install, replace and modify to length.

With the foregoing and other objects in view, there is provided, in accordance with the invention, a pole cover assembly for mounting onto a pole. The assembly includes a pole cover that has a first portion with a first longitudinal end. A base portion extends from the first portion and the base portion has a base portion depth and an inside diameter that is greater than the outside diameter of the first portion to accommodate a first longitudinal end of an adjacent pole cover therein and define a circumferential clearance gap around the adjacent pole cover. A longitudinal slit runs a length of the pole cover and separates axially extending arc segments of the pole cover. The arc segments overlap one another when disposed on the pole.

In accordance with another feature of the invention, the base portion has a free end with a circumferential lip that is directed radially inwards for closing the clearance gap.

In accordance with another feature of the invention, in one embodiment, a mounting fastener is disposed centrally with respect to a length of the pole cover. The mounting fastener passes through the pole cover into the pole for setting a height position of the pole cover on the pole. Alternately, in another embodiment, the inner diameter of the pole cover is substantially similar to the outer diameter of the pole, and the height position of the pole cover on the pole can be set and maintained by a frictional engagement between the pole cover and the pole.

In accordance with another feature of the invention, closing fasteners are provided along the length of the pole cover affixing the arc segments to one another.

In accordance with another feature of the invention, the assembly includes the adjacent pole cover. In one embodiment, the mounting fastener is positioned in the pole to set a position of the pole cover so that the first longitudinal end of the adjacent pole cover is disposed at a middle of the depth of the bass portion. Alternatively, this is achieved through a frictional engagement between a pole cover and/or the adjacent pole cover and the pole.

In accordance with another feature of the invention, a cap portion is disposed at the first end of the pole cover and overlaps the pole cover.

In accordance with another feature of the invention, the base portion depth is at least as great as a sum of the amount of thermal expansion at a desired high temperature limit above 70° F. for a length of the pole cover in a desired service temperature range of the pole cover plus the amount of thermal contraction at a desired low temperature limit below 70° F. for the length of the pole cover in the desired service temperature range of the pole cover.

In accordance with still another feature of the invention, the pole cover has longitudinally extending corrugations that have a height at least as great as a wall thickness of the pole cover to define a space next to the pole to accommodate an underlying arc segment of the arc segments.

In accordance with still yet another feature of the invention, a corrugation peak defines an overlying arc segment of the arc segments.

Additionally, there is provided, in accordance with. the invention a method for covering a pole with a pole cover. The method includes to provide a plurality of pole covers. Each of the pole covers have: a first portion with a first longitudinal end, a base portion that extends from the first portion and the base portion has a base portion depth and an inside diameter greater than the outside diameter of the first portion, a longitudinal slit runs a length of the pole cover and separates axially extending arc segments of the pole cover. Opening a first pole cover at the slit and spanning the slit to fit over a diameter of the pole. Placing the first pole cover into a position where the arc segments overlap and inserting closing fasteners into the arc segments. Axially positioning the first pole cover on the pole and securing the first pole cover on the pole, for example, by inserting a mounting fastener through. the pole cover into the pole for mounting the first pole cover onto the pole or by taking advantage of a frictional engagement between the pole cover and the pole. Opening a second pole cover at the slit and spanning the slit to fit over a diameter of the pole into a position above the first pole cover where the arc segments of the second pole cover overlap and inserting closing fasteners into the arc segments of the second pole cover. Axially positioning and securing the second pole cover on the pole with the base portion. overlapping the first pole cover with the first longitudinal end of the first pole cover disposed at a middle of the depth of the base portion of the second pole cover. The second pole cover being secured on the pole, for example, by frictional engagement with the pole, or by inserting a second mounting fastener through the pole cover into the pole for mounting the second pole cover onto the pole.

Other characteristic features of the invention are set forth in the appended claims.

Although the invention is illustrated and described herein. as embodied in a pole cover assembly, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.

The construction of the invention, however, together with additional objects and advantages thereof will he best understood from. the following description of specific embodiments when read in connection with the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

The figures show a pole cover1, which alone or in multiples defines a pole covering system200. As can be seen, the circumferential profile of the cover is fluted and produced by molding of plastic, preferably rotary molding and has the characteristics of being rotary molded. The preferred material for the pole cover1is polyethylene and the length of the covers is approximately eight (8) feet in length, but is in no way limited to such dimension as the cover can be longer or shorter. As seen inFIG. 26, when the pole cover is removed from the tool upon completion of the molding cycle, there are three different longitudinal portions of the pole cover1. There is a cap portion30at one longitudinal end and a base portion50at the opposite longitudinal end, and a middle portion10between the base portion50and the cap portion30. The cap portion30and the base portion50have an expanded diameter relative to the middle portion10.

During post mold processing the cap portion30is removed from the middle portion10by being cut from the middle portion10so that multiple pole covers1can be mounted along a length of a pole100without the cap portion30interfering with the base portion50of an overlapping cover1. The pole cover1can include guides in the form of circumferential grooves, steps, and/or shoulders for providing a cutting guide between the cap portion30and the middle portion10. Once the cap30is cut from the middle portion10, a cut end10A of the middle portion10exists and can ha fit into the open end of the base portion50as shown inFIG. 24. As shown inFIG. 11the OD of the middle portion10and the ID of the base portion50are designated. This results in the circumferential clearance gap CC between the OD of the middle portion and the ID of the base portion shown inFIG. 24.

The pole cover1is provided with a longitudinal cutting guide in the form of a groove, step, and/or shoulder that provides a linear guide for cutting the length of the pole cover1. As can be seen inFIG. 26, there is a connection at the cutting seam CS that extends radially, which once removed by cutting, allows two arc segments11to overlap and be fastened to one another by the insertion of fasteners12along the length of the middle portion10as is shown inFIG. 10. To this end, the pole cover1can be formed with pilot holes15on the underneath arc segment11and with counterbores16on the outer arc segment11, where the counterbores16corresponds to the head of the selected fastener12, so that the head of the fastener12is flush as shown inFIG. 11at the base portion50, where the overlap of the arc segments11also applies. Upon installation upon the pole100, the arc segments11are aligned in the overlapped position so that the pilot holes15and the counterbores16are aligned and the fasteners12are inserted and secured.

FIG. 24shows the fasteners14are provided to attach respective pole covers10to the outer surface of the pole100when the fasteners14are fastened to the pole. The fasteners14are selected for the corresponding pole material and construction (hollow or solid).

The base portion50is defined by an expanded collar52, the collar52has an increased diameter relative to the middle portion10that allows the base portion50to fit over a cut end10A of the middle portion10, once the pole cover1is cut to the appropriate height. As shown inFIG. 24, the base portion50has a minimum depth d in the longitudinal direction to a shoulder53between the middle portion10and the base portion50. The collar52accommodates the thermal expansion in the longitudinal direction of the adjoining pole covers1over an expected temperature range for the environment in which the pole covers1are employed.

FIG. 3shows the pole cover1has a corrugated profile with longitudinally extending corrugations and the fasteners14are provided at respective bases B of the corrugation where opposite corrugation bases correspond to the diameter of the pole100so the bases can contact the outer surface of the pole100when the fasteners14are fastened to the pole100. The corrugations have a height h. The height h provides clearance from the outer surface of the pole100for the overlapping arc segments11to overlap and be fastened to one another without interference with the outer surface of the pole100. Particularly, a gap or space is defined to the outer surface of the pole100for the inner or underlying arc segment11to be beneath the outer arc segment11. As such, the corrugation height h is at least as great as a wall thickness of the pole cover1to allow space for the inner arc segment11of the overlapping arc segments11under the outer arc segment11. The outer arc segment11may be defined by a corrugation peak P with respect to the pole surface.

This means that the shoulder53is of a depth d required per unit length of the pole cover that will allow expansion of the pole covers relative to one another, with consideration of the expansion of the pole100, so that the cut end10A of the middle portion10does not abut against the shoulder53of the base portion50to result in a buckling. Likewise, the depth d is also sufficient so that over the temperature range a linear contraction of the pole covers does not result in circumferential gaps between pole covers, which could cause buckling upon expansion if there is circumferential misalignment and the cut end abuts against the end of the base portion50upon increasing temperature and expansion. In light of these factors, the base portion, depth d is at least as great as a sum of the amount of thermal expansion at a desired high temperature limit above 70° F. for a length of the pole cover in a desired service temperature range of the pole cover plus the amount of thermal contraction at a desired low temperature limit below 70° F. for the length of the pole cover in the desired service temperature range of the pole cover. The baseline of 70° F. is used as this is the temperature at which the length of pole cover is at a steady state length. The relationship of the overlapping part of the covers1of system is shown enlarged inFIG. 24.

Example calculation for the minimum depth d for a service temperature range between 10° F. and 140° F. for a polyethylene 96 inch cover:

The middle portion10is provided with fastener pilot holes13, as shown inFIG. 1. As shown inFIG. 24, in one embodiment of the invention, the middle of the pole cover1has fasteners14that are inserted through the holes13to fasten the pole cover1to the pole100. The middle location is the only location for fasteners14between the pole100and the pole cover1, as the fastened location is the origin (datum) of growth/contraction, as this position is fixed. The placement of the holes13are provided so that the expansion and contraction of pole cover1is substantially equal from the fasteners to the opposite ends of the cover1in the longitudinal direction of the cover1. Here, substantially means so that the tolerance is such that there is only a nominal difference in thermal expansion/contraction as measured from the fastening position of cover1at hole13, which the datum for the expansion/contraction, as this is where the pole cover1is fixed to the pole100. Alternatively, if desired, the fasteners14and holes13nay be omitted, and the pole cover1can be secured to the pole100by another securing mechanism, such as, via a frictional engagement between the pole cover1and pole100. For example, if the inner diameter of the pole cover1is made to be substantially equal to the outer diameter of the pole100, the pole cover1will be securely held in place on the pole100by friction, without sliding up or down the pole100, once it is wrapped around the pole100. Thus, the pole cover1can be secured at the desired position on the pole100through a frictional fit or frictional engagement between the pole cover1and the pole100, and/or the frictional fit between the pole cover1and an adjacent pole cover1, without the need for the fasteners14.

The cut cap portions30(shown inFIGS. 16-22) are removed and retained so that they can be assembled to a topmost pole cover1of the system. The cap portions30have the same construction with respect to requiring a longitudinal cut and fastener32once the corresponding arc segments31for the cover30are overlapped as seen inFIG. 22. Furthermore, the cap portions30can be provided with a pilot hole33for a further fastener that secures the cap portion30to the pole100. The cap portion30is removed from the middle portion10at a shoulder30A that defines an increase of the diameter of the cap portion30relative to the middle portion10. This construction allows the cap portion30to fit over the OD of the middle portion10as seen inFIG. 23.

When considering the end views or the cross-sectional profiles of the cover1, it is pointed out that as formed. In the tool the cover30will have an out or round profile defined by at least two different radii, this allows the pole cover to be substantially round upon being assembled with the respective overlapped arc segments11or31connected to one another by the fasteners12or32,

The base portion50has a turned in lip51at a free end thereof. The lip51is a reduction of the diameter of the base portion50and helps serve to limit dirt, water, and particles from penetrating the assembly of pole covers1. This helps to protect the pole100from elements that can have a negative effect on the pole100and a service life thereof. Also, the lip51provides structural strength and helps maintain the dimensional stability of the end of the base portion50.

The method of installation of the pole covers1onto a pole100is such that after molding of the covers1, the cap portion30is cut from the middle portion10. The cap portion30has a longitudinal end. face35and, similarly base portion50has a longitudinal end face, not shown. These end faces are removed to accommodate pole100. This allows the pole100to be accommodated within the portions10,50of the pole cover1. The portions10,50are longitudinally cut and. any projections are removed to allow the flush seating of the surfaces of the arc segments11against one another. This also apples to the arc segments31of cover30. The base portion50and the middle portion10, which are still connected are further processed to cut any openings for brackets or other hardware mounted. on the pole100to project through the pole cover1. The base portion50and the middle portion10are spread open longitudinally to an extent at which the pole cover1is spanned sufficiently to pass over the diameter of the pole100. The covers are each passed over the diameter of the pole100at which point the spring force of the pole cover and the memory of the pole cover1result in the arc segments coming back together with the pole100inside the pole cover1Once the arc segments11are aligned, the fasteners12can be installed and the pole cover1is a continuous cylinder surrounding the pole. If desired, the pole cover1is centrally fastened at openings13with the fasteners14to the pole100to allow for equal linear expansion from the mounting points. The correct number of pole covers1are added to the pole100to cover the length and the covers1are positioned with the cut end10A of the middle portions10disposed at the center of the overlapping base portion50(at a midpoint of the depth d of base portion50) and are fastened onto the pole100. This allows for the expansion, and contraction of the respective covers1within the depth d of the base portions50. Alternately, the pole cover1is secured to the pole100only by a frictional fit between the pole cover1, and the pole100and/or the pole cover1and adjacent pole covers1.

Upon the correct number of pole covers1being attached. to the pole100, the cap portion30is placed on the remaining cut end of the middle portion, also centrally aligned in the middle of the axial extent of the cap portion30. The fasteners32are fastened to the respective arc segments31of the cap portion30. The cap portion30is fastened to the pole100by a fastener (not shown) that passes through pilot hole33of the cap portion30and into the pole100.