Abstract:
This invention is a modular pole assembly comprised of corner pieces and panel members. Panel members are slidably engaged to the corner pieces and are retained in a direction normal to the engagement direction by a track in each slot that nests within a groove in each panel member. Comer pieces may include multiple slots along each side, allowing for multiple layers of panel members along each side, thereby increasing strength and allowing an insulative and structural fill material to be added between panel member layers. The height of the modular pole may be increased by inserting splicing posts between consecutive, adjacent corner members and inserting splicing pieces between co-planar adjacent panel members. The modular nature of the pole assembly provides for simple packaging and shipment of the various components and easy assembly at or near the installation location.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     Not Applicable.  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable.  
       BACKGROUND OF THE INVENTION  
       [0003]     Field of the Invention. The present invention relates to poles and more specifically relates to poles formed from modular components made of a composite material.  
         [0004]     Description of the Related Art. The electric utility distribution pole market is dominated by standard, treated wood poles furnished by hundreds of wood preserving plants located throughout the United States. While relatively inexpensive in initial cost, wood poles face several issues ranging from the chemical preservatives with which they are treated to the structural soundness of newer poles.  
         [0005]     The wood treating industry comes under ever increasing attack from environmentalists and other public interest groups based on claims that the chemical preservatives used in the treatment of wood poles, which include a large quantity of pesticides, may cause public health problems.  
         [0006]     New poles are often constructed from “new growth” forests, which consist primarily of fast-growing hybrid species of trees. Some claim that the faster growing species may not be as strong as trees that are cultivated over many years from virgin forests.  
         [0007]     To address these issues, as well as to provide a more aesthetically-pleasing utility pole, poles have been developed from various metals and composites in a variety of structural assemblages.  
         [0008]     Prior art utility poles include:  
         [0009]     U.S. Pat. No. 466,012 issued to J. S. Seaman on Dec. 29, 1891, discloses a method for the manufacture of posts and poles utilizing welding as a joining process for the steel plates comprising the improved post and poles.  
         [0010]     U.S. Pat. No. 999,267 issued to E. E. Slick on Aug. 1, 1911, discloses a method of making tapering metal poles. This invention eliminates the requirements of inner webbing and a nested section required for vertical strength. The invention does not utilize mechanical bolting or welding as a means of fastening. The invention utilizes rolled blanks forming interlocking edges running vertically such that the rolled sections may be assembled.  
         [0011]     U.S. Pat. No. 3,196,990 issued to H. E. Handley on Jul. 27, 1965, discloses a tapered structural member and method of making same. This invention utilizes aluminum as the preferred material and incorporates welding as a method of fastening longitudinal peripheral portions.  
         [0012]     U.S. Pat. No. 3,276,182 issued to H. E. Handley on Oct. 4, 1966, discloses a taper structural member constructed from sectional vertical members coupled by tongue and groove fits. Internal bolting prevents rotation about the long axis of the vertical member.  
         [0013]     U.S. Pat. No. 3,291,437 issued to G. F. Bowden et al. on Dec. 13, 1966, discloses a flexible panel with abutting reaction shoulders under compression for use in a vertical load-bearing member.  
         [0014]     U.S. Pat. No. 3,557,422 issued to H. C. Pfaff, Jr. on Jan. 26, 1971, discloses a method of forming a pole base structure consisting of slotted panels arranged in a geometrically stable pattern. Each panel consists of a crimped edge, which is designed to be inserted into the slotted portions of the panels.  
         [0015]     U.S. Pat. No. 3,571,991 issued to Edward S. Doocy et al. on Mar. 23, 1971, discloses a tubular steel pole with pairs of sidebars and web members secured together by welds along the edges of the sidebars. Internal bracing exists at points where sidebars extend outward.  
         [0016]     U.S. Pat. No. 4,312,162 issued to Jonas Medney on Jan. 26, 1982, discloses a reinforced fiberglass pole suited for use in electric transmission systems. The invention utilizes reinforcing regions consisting of composite material made from pre-stressed longitudinally disposed fibers.  
         [0017]     U.S. Pat. No. 5,285,613 issued to W. Brandt Goldsworthy et al. on Feb. 15, 1994, discloses a pultruded joint system and tower structure including re-entrant slots which lock into place horizontal members used to support a vertical load.  
         [0018]     U.S. Pat. No. 5,319,901 issued to Goldsworthy et al. on Jun. 14, 1994, discloses a technique for connecting a cross member brace between a column and another cross member. A dovetailed shoulder fit facilitates the interlocking connection.  
         [0019]     U.S. Pat. No. 5,617,692 issued to Johnson et al. on Apr. 8, 1997, discloses composite structure made entirely from interlocking pultruded composite members. The interlocking members found in this invention are non vertical strengthening members locate to give the vertical structure rigidity.  
         [0020]     U.S. Pat. No. 5,644,888 issued to David W. Johnson on Jul. 8, 1997, discloses a heavy construction system using composite members, which are interfit using a dovetailed shoulder fit with other composite members to form a rigid post and beam or beam and brace.  
         [0021]     U.S. Pat. No. 5,864,998 issued to Weston R. Loomer on Feb. 2, 1999, discloses modular structure members disposed in adjacent co-acting positions so that a selected number of modules assembled together form a peripherally enclosed modular structural member.  
         [0022]     U.S. Pat. No. 6,094,881 issued to William D. Lockwood on Aug. 1, 2000, discloses a modular fiberglass reinforced polymer pole system comprising at least two corner pieces, each corner piece having two ends, and having a continuous channel and further comprising at least two tapered panel pieces, each panel piece designed to be glued into the slot of corner piece when said panel piece is fully inserted into said corner slot.  
         [0023]     U.S. Pat. No. 6,286,281 issued to David W. Johnson on Sep. 11, 2001, discloses a tubular tapered composite pole for supporting utility lines formed from elongated panels made of pultruded composite material. The elongated panels are trapezoidal in shape featuring a tongue and groove fit along its mating surface with the adjacent elongated panel. The panels interlock to form a closed loop giving the vertical pole rigidity.  
         [0024]     It would be an improvement in the art to have a pole that meets utility pole structural standards and that does not require treatment with pesticides and other potentially harmful chemical preservatives.  
         [0025]     It would further be an improvement in the art to have a modular configuration that simply and easily allows for additional reinforcement pursuant to calculated strength desired.  
         [0026]     It would further be an improvement in the art to have a modular fiberglass reinforced polymer pole, the components of which are easily packaged and shipped, and that may be simply assembled on or near the installation site rather than as a final product.  
         [0027]     It would further be an improvement in the art to have a modular pole in which the interface of the modular components provides additional strength to the pole.  
       BRIEF SUMMARY OF THE INVENTION  
       [0028]     Accordingly, the objects of this invention is to provide, inter alia, a modular utility pole assembly that: 
        does not require the use of pesticides and chemical preservatives;     has a modular structure that allows for additional reinforcements, as desired for calculated strength;     the modular components are easily packaged and shipped;     has few components to assemble;     can be assembled on or near the installation site; and     meets the structural requirements for utility poles.        
 
         [0035]     Other features and advantages of the invention will be apparent from the following description, the accompanying drawing and the appended claims.  
         [0036]     This invention is a modular pole assembly comprised of corner pieces and panel members. Panel members are slidably engaged to the corner pieces and are retained in a direction normal to the engagement direction by a track in each slot that nests within a groove in each panel member. Corner pieces may include multiple slots along each side, allowing for multiple layers of panel members along each side, thereby increasing strength and allowing an insulative and structural fill material to be added between panel member layers. The height of the modular pole may be increased by inserting splicing posts between consecutive adjacent corner members and inserting splicing pieces between co-planar adjacent panel members. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0037]      FIG. 1  is a side view of assembled modular pole.  
         [0038]      FIG. 2  is a cross sectional view of a corner piece.  
         [0039]      FIG. 3  is perspective view of a corner piece.  
         [0040]      FIG. 4  is a cross sectional view of receiving slot detail.  
         [0041]      FIG. 5  is a cross sectional view of a side.  
         [0042]      FIG. 6  is a front view of a panel member.  
         [0043]      FIG. 7  is an assembled modular pole proximate the base of the pole.  
         [0044]      FIG. 8  is an assembled modular pole proximate the top of the pole.  
         [0045]      FIG. 9  is a corner splicing post.  
         [0046]      FIG. 10  is a corner splicing post in a corner piece.  
         [0047]      FIG. 11  is a panel splicing piece.  
         [0048]      FIG. 12  is a panel splicing piece between two adjacent panel members.  
     
    
     DESCRIPTION OF THE INVENTION  
       [0049]     Referring to  FIG. 1 , the inventive assembled modular pole  10  is depicted. The modular pole comprises a plurality of corner pieces  20  and a plurality of sides  80 . Each side  80  includes at least two panel members  82 , as shown in  FIG. 5 , arranged in parallel, and slidably engaged to corner pieces  20 . Modular pole  10  has a pole height  16 , defined as the distance between a pole base  12  and a pole top  14 .  
         [0050]     Referring to  FIGS. 2 and 3 , corner piece  20  is depicted. Each corner piece  20  has a corner length  21 , which may be less than or equal to pole height  16 . Corner splicing posts  100 , described in greater detail below, may adjoin adjacent corner pieces  20  when a pole height  16  greater than corner length  21  is desired.  
         [0051]     Each corner piece  20  has a cross sectional geometry defined by an outer corner surface  22 , an inner corner surface  24 , a first end  26  and a second end  28 . Outer corner surface  22  and inner corner surface  24  are separated by a corner width  25 . First end  26  and second end  28  are intermediate outer corner surface  22  and inner corner surface  24  along opposing ends of corner piece  20 .  
         [0052]     First end  26  includes a first center support  31  intermediate a first inner finger  34  and a first outer finger  30 , while second end  28  includes a second center support  35  intermediate a second inner finger  36  and a second outer finger  32 . A gap between first outer finger  30  and first center support  31  defines a first outer receiving slot  42 . A first inner receiving slot  46  is defined by a gap between first center support  31  and first inner finger  34 . Along second end  28 , a second outer receiving slot  44  is defined by a gap between second center support  35  and second outer finger  32  and a second inner receiving slot  48  is defined by a gap between second center support  35  and second inner finger  36 .  
         [0053]     In an alternate embodiment, first and second ends  26 ,  28  each include a plurality of inner fingers (not shown) defining additional slots (not shown) therebetween.  5  First outer receiving slot  42  is parallel with first inner receiving slot  46  and second outer receiver slot  44  is parallel with second inner receiving slot  48 . First inner and outer receiving slots  42 ,  46  are at a corner angle  40  relative to second inner and outer receiving slots  44 ,  48 . Corner angle  40  is less than 180°, with the dimension being defined by the number of sides  80  of modular pole  10 . The value of corner angle  40  is dependent upon the predetermined number of sides modular pole  10  is to have. For example, corner angle  40  will range from 0° for a two-sided pole (not shown) to 60° for a three-sided pole (not shown) to 135° for an eight-sided pole (not shown). A four-sided modular pole  10  is depicted in  FIGS. 1, 7  and  8 , having a corner angle  40  that is 90°. Modular pole  10  may have any number of sides with the value of corner angle  40  being defined by the equation: 
 
Corner angle  40 =180°−(360°/(number of sides)). 
 
 The value of corner angle  40  may be slightly different due to various causes, including minor twisting corner pieces  20  during the formation of such pieces. 
 
         [0054]     As shown in  FIG. 4 , receiving slots  42 ,  44 ,  46 ,  48  have U-shaped slot surfaces  50  defined by finger wall  52  and side wall  54 , separated by a slot width  56 . Each receiving slot  42 ,  44 ,  46 ,  48  has a slot depth  58 .  
         [0055]     A track  60  protrudes from each finger wall  52  of slot surface  50  and extends towards side wall  54  along the entire distance of corner length  21 . Track  50  has a track width  61 , which is the width of the protuberance of track  60  along finger wall  52  between an inner track side  62  and an outer track side  64 . Track  60  also has a track depth  66 , which is the distance track  60  extends from finger wall  52  toward side wall  54 . Track  60  may have an arcuate cross sectional shape. The location of track  60  may be along finger wall  52  such that outer track side  64  abuts a finger end  38 . Alternatively, a finger extension (not shown) may separate outer track  64  from finger end  38 . The distance from inner track side  62  to a point on slot surface  50  farthest from finger end  38  defines slot location  68 .  
         [0056]     Corner piece  20  may include at least one channel  70  along corner length  21 . Additional side channels  72  and  74  may also be formed in corner piece  20  by including channel walls  76 ,  78  within channel  70 . Channel  70  and side channels  72 ,  74  may be filled with a type of foam (not shown) such as polyurethane closed cell foam to increase rigidity of modular pole  10  and to provide an improved basic insulation level. Alternatively, or in addition to the foam fill, wiring  140  (shown in  FIGS. 7 and 8 ) may be threaded through channel  70  and/or additional channels  72 ,  74 . Channel  40  has a channel width  77  and a channel depth  79 .  
         [0057]      FIGS. 5 and 6  depict modular panel members  82 . Panel members  82  may have a panel length  85  that is equal to or less than the length of pole height  16 . Panel splicing pieces  110 , described below, may adjoin co-planar, consecutive panel members  82  when a pole height  16  that is greater than panel length  85  is desired.  
         [0058]     Panel members  82  include a base edge  84  having a base width  83  and a top edge  86  having a top width  87 . Panel members  82  also include a first long edge  88  and a second long edge  89  intermediate base edge  84  and top edge  86 . Panel members  82  may be tapered in shape having base width  83  greater than top width  87 , thereby providing increased robustness to the assembled pole  10 . Base edge  84 , first long edge  88 , top edge  86 , and second long edge  89  border a grooved surface  90  and a flat surface  92  of each panel member  82 . The distance between grooved surface  90  and flat surface  92  is a panel thickness  91 .  
         [0059]     A first and second groove  93  and  94  are formed in grooved surface  90  of each panel member  82  along panel length  85 . First and second grooves  93 ,  94  are each bounded by an outer groove edge  95 , which is closest first or second long edge  88  or  89 , respectively, and an inner groove edge  96 , which is farthest from first or second long edge  88  or  89 , respectively. The distance between outer groove edge  95  and inner groove edge  96  of each of first and second groove  93  and  94  is a groove width  98 . The depth of each groove  93 ,  94  into panel member  82  from grooved surface  90  is a groove depth  99 . First and second grooves  93  and  94  may have an arc-shaped profile to match the profile of track  60 . First groove  93  extends along panel length  85  parallel to first long edge  88 . Second groove  94  extends along panel length  85  in a direction parallel to second long edge  89 . The distance from first long edge  88  or second long edge  89  to outer groove edge  95  defines a groove location  97 .  
         [0060]     Groove width  98  is sized to accommodate track width  61  and groove depth  99  is sized to accommodate track depth  66 , so that track  60  nests within first or second groove  93  or  94 . Slot depth  58  and groove location  97  are sized to align first and second grooves  93 ,  94  with their respective tracks  60 . Slot width  56  is wide enough to accept panel thickness  91 . Thus, panel members  82  are retained along first and second long edges  88  and  89  by receiving slots  42 ,  44 ,  46 , and  48  in corner piece  20  with track  60  fitting within first or second groove  93  or  94 .  
         [0061]     The plurality of panel members  82  of sides  80  increases the structural strength of modular pole  10 . A foam fill (not shown) such as polyurethane closed cell foam, may be added between panel members  82  on each side for additional rigidity and insulation.  
         [0062]     Referring to  FIGS. 9 and 10 , a corner splicing post  100  is depicted. Corner splicing posts  100  are used to adjoin consecutive corner pieces  20  until the sum of the corner lengths  21  of consecutive corner pieces  20  equals pole height  16 . Corner pieces  20  may be subdivided into corner piece sets  120 , depicted in  FIG. 1 . Each corner piece set  120  is adjoined with panel members  82  to form a tubular structure that makes up a segment of the entire modular pole  10 . To adjoin two adjacent corner piece sets  120 , corner splicing posts  100  are placed into channel  70  of each corner piece  20  in the lowest corner piece set  120  at what is or will be an upper end  18  of the corner pieces  20  of the lower corner piece set  19 . Each corner splicing post  100  has a post width  102  and a post depth  104 . Post width  102  and post depth  104  are sized to provide an interference fit with channel width  77  and channel depth  79 . Post width  102  and post depth  104  may be slightly smaller at each end of corner splicing post  100  to facilitate insertion into channel  70  of corner pieces  20  being adjoined. Corner splicing post  100  also has a post length  106 . When inserted into channel  70  of a corner piece  20 , approximately half of post length  106  is held within channel  70 . Channel  70  of a lower end  19  of corner pieces  20  in an adjacent corner piece set  120  are then placed over the free end of corner splicing posts  100 . The size of post length  106  of corner splicing post  100  is determined by the length of corner splicing post  100  to be held within channel  70  of each of the consecutive, adjacent corner pieces  20 . Upper end  18  of one corner piece set  120  abuts lower end  19  of another corner piece set  120  when properly adjoined by corner splicing posts  100 .  
         [0063]     Referring to  FIGS. 11 and 12 , panel splicing pieces  110  may adjoin co-planar panel members  82  until the sum of panel lengths  85  of consecutively adjoined panel members  82  equals pole height  16 . Panel members  82  may be subdivided into panel sets  182 . Each panel set  182  is used with a corner piece set  120  to form a tubular structure that makes up a segment of the entire modular pole  10 . Panel splicing pieces  110  are H-shaped, comprising two parallel plates  111  and  112  adjoined by a center member  113  to form two splicing slots  114  and  115 . The splicing slot width  116  between parallel plates  111  and  112  is sufficient to snugly receive panel thickness  91  of top edge  86  of the panel members  82  of the lower panel set  182  and panel thickness  91  of base edge  84  of the panel members  82  of the upper panel set  182 . Panel splicing pieces  110  have a splice piece width  117  sufficient to fit between corner pieces  20  with which adjoined co-planar panel members  82  engage. Parallel plates  111  and  112  may have slightly tapered outer edges  132  and  134  to correspond to the taper of adjoining panel members  82 , making the splice piece width  117  wider proximate top edge  86  of the lower panel members  82  than proximate bottom edge  83  of upper panel members  82 . Center member  113  of panel splicing pieces  100  has a center depth  118 . The size of center depth  118  of each panel splicing piece  110  is considered with panel length  85  of each panel member  82  along a side  80  to determine pole height  16 .  
         [0064]     Panel members  82  and corner pieces  20  may be made from a polymer with fiberglass reinforcement. Other possible materials include other fiberglass composites, other plastics, metals, and wood. Corner pieces  20  made from fiberglass composites, other plastics, or metals may be extruded.  
         [0065]     To assemble a modular pole  10 , first long edge  87  of one panel member  82  is slidingly inserted into first outer receiving slot  42  of a first corner piece  20  and second long edge  88  is slidingly inserted into second outer receiving slot  44  of a second corner piece  20 . Another panel member  82  is slidingly inserted into between the same two corner pieces  20 , with first long edge  87  inserted into first inner receiving slot  46  of the first corner piece  20  and second long edge  88  inserted into second inner receiving slot  48  of the second corner piece  20 .  
         [0066]     The first long edge  87  of two additional panels members  82  are inserted into first inner and first outer receiving slots  42  and  46  of the second corner piece  20 . Second long edge  88  of the additional panels  82  are inserted into second inner and second outer receiving slots  44  and  48  of a third corner piece  20 . This process is continued until two panel members  82  are inserted between corner pieces  20  such that the modular pole  10  has the number of sides  80  that was previously determined.  
         [0067]     There are some alternative embodiments to modular pole  10 . If a pole height  16  is desired that is greater than the length of panel members  82  and corner pieces  20 , panel splicing pieces  110  and corner splicing posts  100  are used as previously described. First end  26  and second end  28  may be formed with additional receiving slots (not shown) therein, thus permitting additional panel members  82  to be inserted between corner pieces  20 . Insulation or other material may be used to fill the space created within modular pole  10  bounded by panel members  82  retained by first and second inner retaining slots  46 ,  48 .  
         [0068]     Assembled modular poles  10  may be utilized to hold various types of electrical equipment, electrical wires, wireless communications equipment, lighting fixtures, traffic equipment or signs.  
         [0069]     The foregoing description of the invention illustrates a preferred embodiment thereof. Various changes may be made in the details of the illustrated construction within the scope of the appended claims without departing from the true spirit of the invention. The present invention should only be limited by the claims and their equivalents.