Abstract:
The present inventions relate generally to tower systems, utility poles, and power transmission poles; and more particularly to a structure and method for implementing such poles and towers.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims priority to (i.e., is a non-provisional of) U.S. Pat. App. No. 62/211,358 entitled “Multi-Material Composite Pole”, and filed Aug. 28, 2015 by Barker et al. The entirety of the aforementioned application is incorporated herein by reference for all purposes. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present inventions relate generally to tower systems, utility poles, and power transmission poles; and more particularly to a structure and method for implementing such poles and towers. 
         [0003]    Masts used in the erection of towers, utility poles, power transmission poles, and other construction projects must offer great stability and durability. To this end, the state of the art has been to construct such towers and poles from steel or wood. However, use of such materials result in a combination of components that together are heavy, heavy, cumbersome, and difficult to transport. To address this, some attempts have been made to construct poles from lighter composite materials, however such attempts have failed due to overly complicated and expensive tooling and materials. 
         [0004]    For at least the aforementioned reasons, there exists a need in the art for more advanced pole and tower components and systems. 
       BRIEF SUMMARY OF THE INVENTION 
       [0005]    The present inventions relate generally to tower systems, utility poles, and power transmission poles; and more particularly to a structure and method for implementing such poles and towers. 
         [0006]    This summary provides only a general outline of some embodiments according to the present invention. Many other objects, features, advantages and other embodiments of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings and figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    A further understanding of the various embodiments of the present invention may be realized by reference to the figures which are described in remaining portions of the specification. In the figures, similar reference numerals are used throughout several drawings to refer to similar components. In some instances, a sub-label consisting of a lower case letter is associated with a reference numeral to denote one of multiple similar components. When reference is made to a reference numeral without specification to an existing sub-label, it is intended to refer to all such multiple similar components. 
           [0008]      FIG. 1  depicts a tower system constructed of multi-layered pole structures in accordance with various embodiments of the present inventions; 
           [0009]      FIG. 2  depicts a single multi-layered pole structure that is tapered in accordance with one or more embodiments of the present inventions; 
           [0010]      FIG. 3  shows a two-layer pole structure in accordance with some embodiments of the present inventions; 
           [0011]      FIG. 4  illustrates a three-layer pole structure where the three layers are repeated to form a six-layer pole structure in accordance with some embodiments of the present inventions; 
           [0012]      FIG. 5  shows a pole made of one or more multi-layered pole structures, and having a metal accessory mounted to the pole in accordance with particular embodiments of the present inventions; 
           [0013]      FIG. 6  is a flow diagram showing a method for manufacturing a multi-layered pole structure in accordance with various embodiments of the present inventions; and 
           [0014]      FIG. 7  is a flow diagram showing a method for implementing a pole using two or more multi-layered pole structure in accordance with some embodiments of the present inventions. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]    The present invention is related to monitoring movement, and in particular to systems and methods for supporting target monitoring. 
         [0016]    Various embodiments of the present inventions provide pole components that include two or more different fibrous materials formed within layers in a polymer matrix (resin) to remedy current weight, handling, and corrosion limitations while maintaining structural integrity. 
         [0017]    Various embodiments provide pole structures that include a tube formed of at least a first composite material layer defining an outer surface of the tube and a second composite material layer defining an inner surface of the tube. The first composite material layer is formed of a first composite material and the second composite material layer is formed of a second composite material. The first composite material is a glass fiber material. The second composite material may be one of: a carbon fiber material, a boron fiber material, an aramid fiber material, a first hybrid material including at least boron fibers and carbon fibers, a second hybrid material including at least boron fibers and aramid fibers, a third hybrid material including at least boron fibers and glass fibers, a fourth hybrid material including at least carbon fibers and aramid fibers, a fifth hybrid material including at least carbon fibers and glass fibers, or a sixth hybrid materials including at least aramid fibers and glass fibers. 
         [0018]    In some instances of the aforementioned embodiments, the carbon fiber material is a carbon fiber reinforced resin, the boron fiber material is a boron fiber reinforced resin, the aramid fiber material is an aramid fiber reinforced resin, and the glass fiber material is a glass fiber reinforced resin. In various instances of the aforementioned embodiments, the pole structure further includes at least one intermediate layer between the first composite layer and the second composite layer. The at least one intermediate layer is formed of a third composite material that may be one of: a carbon fiber material, a boron fiber material, an aramid fiber material, a first hybrid material including at least boron fibers and carbon fibers, a second hybrid material including at least boron fibers and aramid fibers, a third hybrid material including at least boron fibers and glass fibers, a fourth hybrid material including at least carbon fibers and aramid fibers, a fifth hybrid material including at least carbon fibers and glass fibers, or a sixth hybrid materials including at least aramid fibers and glass fibers. 
         [0019]    In one or more instances of the aforementioned embodiments, the tube is tapered from a top of the tube to a bottom of the tube. In some such instances, the tube exhibits a flared region near the bottom of the tube. In other instances of the aforementioned embodiments, the tube is cylindrical in shape. In some such instances, the tube exhibits a flared region near a bottom of the cylindrically shaped tube. 
         [0020]    Other embodiments provide pole kits that include at least a first pole structure, a second pole structure, and a set of instructions. Both the first pole structure and the second pole structure are a tube formed of at least a first composite material layer defining an outer surface of the tube and a second composite material layer defining an inner surface of the tube, where the first composite material layer is formed of a first composite material and the second composite material layer is formed of a second composite material. The first composite material is a glass fiber material. The second composite material may be one of: a carbon fiber material, a boron fiber material, an aramid fiber material, a first hybrid material including at least boron fibers and carbon fibers, a second hybrid material including at least boron fibers and aramid fibers, a third hybrid material including at least boron fibers and glass fibers, a fourth hybrid material including at least carbon fibers and aramid fibers, a fifth hybrid material including at least carbon fibers and glass fibers, or a sixth hybrid materials including at least aramid fibers and glass fibers. 
         [0021]    In various instances of the aforementioned embodiments, the pole kit further includes a metal mounting bracket capable of being attached to at least one of the first pole structure and the second pole structure such that a metal portion of the metal mounting bracket is in contact with the first composite material layer. In some instances of the aforementioned embodiments, the first pole structure is connectable to the second pole structure such that the connected first pole structure and second pole structure makes a pole assembly. In some cases, the first pole structure and the second pole structure are identical. 
         [0022]    In some instances of the aforementioned embodiments, the carbon fiber material is a carbon fiber reinforced resin, the boron fiber material is a boron fiber reinforced resin, the aramid fiber material is an aramid fiber reinforced resin, and the glass fiber material is a glass fiber reinforced resin. In various instances of the aforementioned embodiments, both the first pole structure and the second pole structure further include at least one intermediate layer between the first composite layer and the second composite layer. The at least one intermediate layer is formed of a third composite material that may be one of: a carbon fiber material, a boron fiber material, an aramid fiber material, a first hybrid material including at least boron fibers and carbon fibers, a second hybrid material including at least boron fibers and aramid fibers, a third hybrid material including at least boron fibers and glass fibers, a fourth hybrid material including at least carbon fibers and aramid fibers, a fifth hybrid material including at least carbon fibers and glass fibers, or a sixth hybrid materials including at least aramid fibers and glass fibers. 
         [0023]    In one or more instances of the aforementioned embodiments, the tube is tapered from a top of the tube to a bottom of the tube. In some such instances, the tube exhibits a flared region near the bottom of the tube such that a top portion of the second pole structure mates to a bottom portion of the first pole structure to form a pole assembly. In other instances of the aforementioned embodiments, the tube is cylindrical in shape. In some such instances, the tube exhibits a flared region near a bottom of the cylindrically shaped tube such that a top portion of the second pole structure mates to a bottom portion of the first pole structure to form a pole assembly. 
         [0024]    Turning to  FIG. 1 , a tower system  100  is depicted that is constructed of three multi-layered pole structures  110 ,  120 ,  130  in accordance with various embodiments of the present inventions. An antenna array  140  is mounted atop tower system  100  using a mounting bracket  145  that wraps around pole structure  130 . Pole structure  110  is connected to pole structure  120  at a joint  115 , and pole structure  120  is connected to pole structure  130  at a joint  125 . 
         [0025]    An expanded view  150  of joint  125  is shown where a portion of pole structure is cut away to show an interior region  160  defined as an area within an inner surface of pole structures  110 ,  120 ,  130 . In some embodiments, a base of pole structure  130  is flared at a lower region  170 . Lower region  170  begins where a bottom portion of pole structure  130  extends out  155  and continues until the bottom of pole structure  130  which corresponds to the location indicated for joint. Such a flare allows for easy assembly of tower system  100  including two or more pole structures designed to be installed atop one another. In the embodiment shown, a kit may be provided that includes all of pole structures  110 ,  120 ,  130 . In the embodiment, each of the pole structures is progressively tapered from the bottom to the top. In such an embodiment, the top of pole section  110  has a circumference that is greater than that of the top of pole section  120 ; and the top of pole section  120  has a circumference that is greater than that of the top of pole section  130 . In such a case, the kit of pole structures  110 ,  120 ,  130  includes three different pole structures designed for assembly in a particular order from bottom to top. 
         [0026]    It should be noted that while embodiments herein are shown as being based upon tapered pole structures, that in other embodiments the pole structures are not tapered, but do include a flare joint similar to that shown in expanded view  150 . In such a case, a kit of pole structures may include a number of pole structures that are interchangeable and may be assembled from bottom to top in any desired order. 
         [0027]    Turning to  FIG. 2 , a single multi-layered pole structure  200  is shown that is tapered in accordance with one or more embodiments of the present inventions. As shown, the shape of pole structure  200  is generally cylindrical. A top  210  of pole structure  200  exhibits a diameter  250  that is smaller than a diameter  255  of a bottom of pole structure  200  such that pole structure exhibits a taper along its height  260 . 
         [0028]    Turning to  FIG. 3 , a cut-away side view  335  and a cross-sectional view  310  are provided of a two-layer pole structure  300  in accordance with some embodiments of the present inventions. As shown, two-layer pole structure  300  includes an outer layer  310  and an inner layer  325 , and is formed in a generally cylindrical shape leaving a void  330  in a center area circumscribed by inner layer  325 . Two-layer pole structure  300  is formed of a first composite layer  315  formed over a second composite layer  320 . Second composite layer  320  may be formed of a first composite material that provides a desired weight/strength ratio. First composite layer  315  may be formed of a second composite material that provides both a desired weight/strength ratio, and also is compatible with metal accessories that may be mounted to a pole made of two or more two-layer pole structures  300 . First composite layer  315  and second composite layer  320  are integral to each other such that one or more desired physical characteristics such as high strength, rigidity, impact resistance, corrosion resistance, and weight are achieved. 
         [0029]    In some embodiments, first composite layer  320  may be, but is not limited to, a carbon fiber material, a glass fiber material, an aramid fiber material, a boron fiber material, and any hybrid of the aforementioned materials. The carbon fiber material may be, for example, a carbon fiber reinforced resin; the glass fiber material may be, for example, a glass fiber reinforced resin; the boron fiber material may be, a boron fiber reinforced resin; and the aramid fiber material may be an aramid fiber reinforced resin. Similarly, second composite layer  315  may be, but is not limited to, a carbon fiber material, a glass fiber material, an aramid fiber material, a boron fiber material, and any hybrid of the aforementioned materials. In some particular embodiments, first composite layer  315  is formed of a glass fiber material such as, for example, fiber glass that does not exhibit a high degree of chemical reactivity with metal including, but not limited to, galvanic corrosion. In addition to reducing chemical reactivity with metals, use of a glass fiber material for first composite layer  315 , use of such a glass fiber material provides resistance to physical impacts. In those same embodiments, second composite layer  320  is formed of one of a carbon fiber material, an aramid fiber material, a boron fiber material, and a combination material including one or more of carbon fibers, glass fibers, aramid fibers and boron fibers. In one particular embodiment, first composite layer  315  is formed of a glass fiber material and second composite layer  320  is formed of a carbon fiber material. 
         [0030]    Turning to  FIG. 4 , a cut-away side view  435  and an expanded view  405  of a layer stack  430  are provided of a six-layer pole structure  400  in accordance with some embodiments of the present inventions. An outer surface  410  of pole structure  400  is formed of an outer composite layer  470   b,  and an inner surface  425  of pole structure  400  is formed of an inner composite layer  460   a.  Four other composite layers (a first composite layer  465   a,  a second composite layer  470   a,  a third composite layer  460   b,  and a fourth composite layer  465   b  are formed between inner composite layer  460   a  and outer composite layer  470   b  as shown in expanded view  405 . As shown, inner composite layer  460   a  and third composite layer  460   b  are formed of the same material; first composite layer  465   a  and fourth composite layer  465   b  are formed of the same material; and second composite layer  470   a  and outer composite layer  470   b  are formed of the same material. Based upon the disclosure provided herein, one of ordinary skill in the art will recognize other numbers of material layers that may be used in relation to different embodiments of the present invention. Further, based upon the disclosure provided herein, one of ordinary skill in the art will recognize other orders which layers may be ordered. For example, both inner composite layer  460   a  and outer composite layer  470   b  may be of one particular material, while the other composite layers  465   a,    470   a,    460   b,    465   b  may be of different materials from that of inner composite layer  460   a  and outer composite layer  470   b.    
         [0031]    Inner composite layer  460   a,  first composite layer  465   a,  second composite layer  470   a,  third composite layer  460   b,  fourth composite layer  465   b  and outer composite layer  470   b  may be formed of composite materials each selected to achieve a desired weight/strength ratio when combined together in pole structure  400 , and for outer composite layer  470   b,  selected to be compatible with metal accessories that may be mounted to a pole made of two or more of pole structures  400 . 
         [0032]    In some embodiments, inner composite layer  460   a  may be formed of, but is not limited to, a carbon fiber material, a glass fiber material, an aramid fiber material, a boron fiber material, and any hybrid of the aforementioned materials. The carbon fiber material may be, for example, a carbon fiber reinforced resin; the glass fiber material may be, for example, a glass fiber reinforced resin; the boron fiber material may be, a boron fiber reinforced resin; and the aramid fiber material may be an aramid fiber reinforced resin. Each of composite layers  465   a,    470   a,    440   b,    465   b,    470   b  similarly may be formed of, but are not limited to, carbon fiber materials, glass fiber material, aramid fiber materials, boron fiber materials, and any hybrid of the aforementioned materials. 
         [0033]    In some particular embodiments, outer composite layer  470   b  is formed of a glass fiber material such as, for example, fiber glass that does not exhibit a high degree of chemical reactivity with metal including, but not limited to, galvanic corrosion. In addition to reducing chemical reactivity with metals, use of a glass fiber material for outer composite layer  470   b,  use of such a glass fiber material provides resistance to physical impacts. In those same embodiments, one or more of inner composite layer  460   a,  first composite layer  465   a,  second composite layer  470   a,  third composite layer  460   b,  and fourth composite layer  465   b  is/are formed of a carbon fiber material. 
         [0034]    Turning to  FIG. 5 , a pole  510  made of one or more multi-layered pole structures, and having a metal accessory  515  mounted thereto is shown in accordance with particular embodiments of the present inventions. Metal accessory  515  includes a metal strap portion  530  extending around and in contact with an outer surface of pole  510 . Metal strap portion  530  is tightened using a tightening bolt  525 , and supports a mounting structure  520 . In some embodiments, the outer surface of pole  510  that is in contact with metal strap portion  520  is a fiber glass layer which is relatively nonreactive to the metal of metal strap portion  530  when compared with layers made of, for example, carbon fiber material. 
         [0035]    Turning to  FIG. 6 , a flow diagram  600  shows a method for manufacturing a multi-layered pole structure in accordance with various embodiments of the present inventions. Following flow diagram  600 , an inner fiber layer is formed in a tapered cylindrical form including a flare bottom portion (block  605 ). The tapered cylindrical form with the flared bottom portion may be similar to the shape of pole structure  200  discussed above in relation to  FIG. 2 . The inner fiber layer forms the general shape of the pole structure. The inner fiber layer may be formed of, but is not limited to, a carbon fiber material, a glass fiber material, an aramid fiber material, a boron fiber material, and any hybrid of the aforementioned materials. 
         [0036]    It is then determined whether any intermediate layers will be formed (block  610 ). An intermediate layer is any layer other than an inner layer and an outer layer of the pole structure. Where an intermediate layer is desired (block  610 ), an intermediate fiber layer is formed over the inner fiber layer (or over the last intermediate fiber layer where two or more intermediate fiber layers are to be formed) (block  615 ). The intermediate fiber layer may be formed of, but is not limited to, a carbon fiber material, a glass fiber material, an aramid fiber material, a boron fiber material, and any hybrid of the aforementioned materials. 
         [0037]    Where no additional intermediate layers are desired (block  610 ), an outer fiber layer is formed of a glass fiber material over either the inner fiber layer or the last formed intermediate fiber layer (block  620 ). By forming the outer fiber layer of a glass fiber material, the resulting pole structure is less reactive to metal structures attached thereto, and less susceptible to physical impacts. 
         [0038]    Turning to  FIG. 7 , a flow diagram  700  shows a method for implementing a pole using two or more multi-layered pole structure in accordance with some embodiments of the present inventions. Following flow diagram  700 , a pole kit is received (block  705 ). The Pole kit includes at least two multi-layer pole structures and a set of instructions. A first multi-layer pole structure from the pole kit is fitted to a second multi-layer pole structure from the same pole kit to yield an pole assembly (block  710 ). This may include inserting the top of a lower pole structure into a flared bottom end of an upper pole structure. Where the multi-layer pole structures are tapered, the lower pole structure includes an average circumference that is greater than the upper pole structure. In contrast, where the multi-layer pole structures are not tapered, they may be identical. 
         [0039]    It is determined whether another multi-layer pole structure is to be used (block  715 ). Where another multi-layer pole structure is to be used (block  715 ), another of the multi-layer pole structures from the pole kit is fit to the previously formed pole assembly to increase the length of the pole assembly (block  720 ). Where all of the multi-layer pole structures have been attached to the pole assembly (block  715 ), any accessories may be mounted to the pole assembly as part of deploying the pole (block  725 ). 
         [0040]    In conclusion, the present invention provides for novel systems, devices, and methods for implementing pole structures. While detailed descriptions of one or more embodiments of the invention have been given above, various alternatives, modifications, and equivalents will be apparent to those skilled in the art without varying from the spirit of the invention. Therefore, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims.