Patent Publication Number: US-10760238-B2

Title: Protective pole cap

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 15/444,401, filed 28 Feb. 2017, now U.S. Pat. No. 10,227,747 the contents of which are incorporated herein by reference as if presented in full. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     The various embodiments of the present disclosure relate generally to protective devices for the tops of poles. More particularly, the various embodiments of the present invention may be directed to the tops of utility poles, pilings, fence posts, and the like. 
     BACKGROUND 
     The tops of wooden poles can deteriorate due to fungus decay or exposure of the wooden pole to weather elements. A primary cause of this deterioration is the entry of moisture at end surfaces of the poles due to the exposed end grains. Water can collect in slight depressions of an end of the pole, which can be caused by decay, and the water can cause wood fibers to shrink and swell and/or freeze and thaw. Cracks may develop which can eventually allow moisture and decay to travel beyond any original treatment to the wood, breaking down additional wood fibers. If wooden poles are neglected, decay may become severe enough to necessitate replacement of the pole. 
     Previous attempts to protect pole tops from deterioration include cover caps, such as those composed of polyvinylchloride (PVC) material. Installation of these cover caps generally requires them to be nailed to the tops of poles, which may prove dangerous, as use of a hammer and nails may be required near live electrical wires. Additionally, these cover caps are generally provided in different sizes to fit different size poles, requiring a stock of different sized cover caps to be carried in the field in order to accommodate a variety of pole sizes. 
     Another attempt requires a protective fluid to be poured over the top end of a utility pole, after which a flowable asphalt-based material must be applied to the top of the utility pole. The asphalt-based material must then be allowed to cure. This method may be cumbersome, time consuming, and messy. 
     Another method that attempts to protect pole tops from deterioration includes the on-site manufacture of a synthetic resin cap that includes an end plate covering the end surface of the pole and a skirt that extends downwardly from the end plate and around the pole. A foamed resin may also be applied between the cap and the pole to prevent entrance of moisture. This method may be difficult and time consuming. 
     Another attempt requires application of a preformed cap that is made of elastic and water-impervious material to the top of a pole. To accomplish this, however, a frame must be used to position and apply an outwardly stretched cap to the top end of the pole. To attach the cap to the top of the pole, the frame must then release the cap, allowing the cap to contract to attach the cap to the top of the pole. Such caps may not adequately seal to prevent the entrance of moisture to the top end of the pole. Furthermore, there may be an increased danger of accidentally touching live electrical wires due to the difficulty and awkwardness presented by the application method of these caps. 
     Another method is a moisture barrier comprising a sheet of moisture-adverse material that can be adhered to the top end of a pole. In such a method, the sheet is configured to fold about the edge of the pole&#39;s end. Existing methods, however, may not be configured to provide a tight fit to the end of the pole, creating a discrepancy between the geometry of the end of the pole and the geometry of the moisture barrier. Such a discrepancy may increase the likelihood of a breach in the seal of the moisture barrier, thus allowing the entrance of moisture to the top end of the pole. 
     Therefore, there is a desire for a protective pole cap that may be installed easily, quickly, and safely. Further, there is a desire for a single-sized pole cap that will snugly fit a variety of sizes of poles. Various embodiments of the present invention address these desires. 
     SUMMARY 
     The present invention relates to protective devices for the tops of poles, including utility poles, pilings, and fence posts. An example embodiment of the present invention provides a pole cap for covering an end of a pole. The pole cap can comprise a sheet that can include a central portion, a first strip, and a flap that comprises a slit. The central portion can be configured to cover a base surface of an end of a pole, and the first strip can be configured to fold over the edge of the end of the pole and circumferentially wrap around a portion of the curved surface of the pole. The flap can be configured to fold over an edge of the base surface. 
     In some embodiments of the present invention, the sheet may further comprise an adhesive. 
     In some embodiments of the present invention, the adhesive may be an adhesive film. 
     In some embodiments of the present invention, the flap may have a first portion located on one side of the slit and a second portion located on the other side of the slit. The first portion may be configured to overlap at least some of the second portion when the flap is folded over the edge of the base surface. 
     In some embodiments of the present invention, the slit may be a V-shaped cut. 
     In some embodiments of the present invention, the flap can overlap at least some of the first strip. 
     In some embodiments of the present invention, the sheet may comprise a second strip. The first strip and the second strip may both comprise a tab, and the second strip may be configured such that the tab of the second strip overlaps at least a portion of the tab of the first strip. 
     In some embodiments of the present invention, the sheet can be composed of a moisture-resistant material. 
     In some embodiments of the present invention, the sheet can be composed of a plastic. 
     In some embodiments of the present invention, the sheet can be composed of polyethylene. 
     In some embodiments of the present invention, the sheet can be composed of butyl rubber. 
     In some embodiments of the present invention, the pole cap can comprise a sheet that can include a central portion, a first strip, and a flap that comprises a slit. The central portion can be configured to cover a base surface of an end of a pole, and the first strip can be configured to fold over the edge of the end of the pole and circumferentially wrap around a portion of the curved surface of the pole. The sheet can include a first cutout that separates at least a part of the central portion and at least a part of the first strip. The flap can be configured to fold over an edge of the base surface. A pole cap for covering an end of a pole comprising: 
     In some embodiments of the present invention, at least a part of the first cutout can be angled inwardly toward the central portion. 
     In some embodiments of the present invention, the flap may comprise a slit. 
     In some embodiments of the present invention, the flap may comprise a V-shaped cut. 
     In some embodiments of the present invention, the sheet may comprise a second strip and a second cutout separating at least a part of the central portion and at least a part of the second strip. The first strip and the second strip may both comprise a tab, and the second strip may be configured such that the tab of the second strip overlaps at least a portion of the tab of the first strip. 
     These and other aspects of the present invention are described in the Detailed Description of the Invention below and the accompanying figures. Other aspects and features of embodiments of the present invention will become apparent to those of ordinary skill in the art upon reviewing the following description of specific, example embodiments of the present invention in concert with the figures. While features of the present invention may be discussed relative to certain embodiments and figures, all embodiments of the present invention can include one or more of the features discussed herein. Further, while one or more embodiments may be discussed as having certain advantageous features, one or more of such features may also be used with the various embodiments of the invention discussed herein. In similar fashion, while example embodiments may be discussed below as device, system, or method embodiments, it is to be understood that such example embodiments can be implemented in various devices, systems, and methods of the present invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following Detailed Description is better understood when read in conjunction with the appended drawings. For the purposes of illustration, example embodiments are shown in the drawings, but the subject matter is not limited to the specific elements and instrumentalities disclosed. 
         FIG. 1A  provides a plan view of a pole cap prior to installation, in accordance with an example embodiment of the present invention. 
         FIG. 1B  provides a plan view of a pole cap prior to installation, in accordance with an example embodiment of the present invention. 
         FIG. 1C  provides a plan view of a pole cap prior to installation, in accordance with an example embodiment of the present invention. 
         FIG. 2  provides an enlarged edge view, taken along line  2 - 2 , of a pole cap prior to installation, in accordance with an example embodiment of the present invention. 
         FIG. 3  provides a perspective view of a pole cap being installed on a pole, in accordance with an example embodiment of the present invention. 
         FIG. 4  provides a perspective view of a pole cap as installed on a pole, in accordance with an example embodiment of the present invention. 
         FIG. 5  provides an elevation view of an upper end of a pole with a pole cap being thereon, in accordance with an example embodiment of the present invention. 
         FIG. 6  provides a vertical sectional view of an upper end of a pole with a pole cap installed thereon, in accordance with an example embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     To facilitate an understanding of the principles and features of the present invention, various illustrative embodiments are explained below. To simplify and clarify explanation, the invention is described below as applied to protective covers for utility poles. One skilled in the art will recognize, however, that the invention is not so limited. Instead, as those skilled in the art would understand, the various embodiments of the present invention also find application in other areas, including, but not limited to, pilings, fence posts, and the like. 
     The components, steps, and materials described hereinafter as making up various elements of the invention are intended to be illustrative and not restrictive. Many suitable components, steps, and materials that would perform the same or similar functions as the components, steps, and materials described herein are intended to be embraced within the scope of the invention. Such other components, steps, and materials not described herein can include, but are not limited to, similar components or steps that are developed after development of the invention. 
     As shown in  FIG. 1 , an example embodiment of the present invention provides a protective pole cap  10  that can be applied to the top end  12  of a utility pole  14 , providing a moisture barrier for the upper end surface  16  of the utility pole  14 . In certain embodiments, the pole cap  10  may include a first layer  20  and a second layer  22 , which are preassembled such that the pole cap  10  can be quickly and easily applied to the top end  12  of a utility pole  14 . Alternatively, the pole cap  10  may be formed from a single layer. 
     In certain embodiments, the first layer  20  may be composed of a moisture-resistant material. The moisture-resistant material may provide protection from the effects of ultraviolet light. The first layer  20  can have a central portion  24 , which can overlay the upper end surface  16 , and flaps  42  that can be folded downwardly from the top of the utility pole  14 . The flaps  42  may assist in securing the pole cap  10  to the top end  12  of the utility pole  14 . 
     In some embodiments, the first layer  20  may be composed of an integral adhesive material, which may be elastomeric or rubber-like such that it is stretchable during application. For instance, an example embodiment comprises upper surface  26  and lower surface  28 , both of which are adhesive. In some embodiments, the first layer  20  is composed of an integral material or at least in part of an integral material. As used herein (unless otherwise noted), the term “integral” refers to a material that is not readily flowable or smearable. Accordingly, even an integral material such as an adhesive, which may be sticky, would not readily smear onto a person handling it. This is in contrast to asphalt or tar-based materials, which may readily smear onto a person handling them. In some embodiments, the integral material is butyl rubber, which is polyisobutylene to which isoprene is added during manufacture. 
     An example embodiment comprises a first strip  30 , which may extend from the central portion  24 . In certain embodiments, a second strip  31  may extend from the opposite side of the central portion  24 . The first strip  30  and second strip  31  may be foldable downwardly along fold lines  32 , such that the first strip  30  and second strip  31  can lie along, and adhere to, the curved, circumferential surface of the utility pole  14 . The first strip  30  and second strip  31  may comprise a central section  36  and a tab  38  on either side, or both sides, of the central section  36 . The tabs  38  may be wrapped around a portion of the circumference of the utility pole  14 , as illustrated by arrows  39  (see  FIG. 3 ). In some embodiments, some or all of the tabs  38  are adhered to the curved surface of the utility pole  14  such that the first strip  30  and/or second strip  31  are pulled taut along the circumference of the utility pole  14 . In some embodiments, the dimensions of the first strip  30  and/or second strip  31  are such that a tab  38  of the first strip  30  can overlap a tab  38  of the second strip  31  (or vice versa), as shown in  FIG. 4 . 
     In certain embodiments, a flap  42  may extend from the central portion  24 . In certain embodiments, the flap  42  has an arcuate edge. The flap  42  may comprise one or more notches or slits  47 , which may eliminate or reduce ripples or ridges in the flap  42  upon application of the pole cap  10  to the utility pole  14 . During application, the area of the flap  42  to one side of the slit  47  may first be applied, and the area of the of the flap  42  to the other side of the slit  47  may be subsequently applied, such that an overlap  51  may be formed, as shown in  FIG. 4 . 
     In certain embodiments, the slit  47  may be a straight cut that is generally perpendicular to the outermost tangent of to the edge of the flap  42 . Alternatively, the slit  47  may be a straight cut having an angle less than 90 degrees, such as an angle in the range of 5 to 20 degrees. Some embodiments may comprise an angle in the range of 21 to 45 degrees; some embodiments may comprise an angle in the range of 46 to 89 degrees. In some embodiments, the slit  47  may extend across the entire width of the flap  42 , such that the slit  47  extends from the edge of the flap  42  toward the central portion  24 . In some embodiments, the slit  47  extends only partially across the width of the flap  42 , such as one-half or three-fourths of the width of the flap  42 . 
     In some embodiments, the slit may be more substantial, forming a V-shaped cut  49 . Various embodiments may include various sizes and geometries of a V-shaped cut  49 , all of which are herein contemplated. For instance, the V-shaped cut  49  may extend across the entire width of the flap  42 , such that the V-shaped cut  49  extends from the edge of the flap  42  toward the central portion  24 . Alternatively, the V-shaped cut  49  extends only partially across the width of the skirt portion  76 , such as one-half or three-fourths of the width of the flap  42 . 
     The geometry of the V-shaped cut  49  may vary, depending on the embodiment. The V-shaped cut  49  may form a generally triangular shape having a vertex angle, which is defined as the vertex nearest the central portion  24 . The vertex angle may be a variety of angles. For instance, some embodiments may have a vertex angle that is acute. Certain embodiments may have a vertex angle in the range of 5 to 30 degrees, while some embodiments may have a vertex angle in the range of 31 to 60 degrees. Some embodiments may have a vertex angle in the range of 61 to 89 degrees. It should be noted that any variation in the degree of the vertex angle is herein contemplated. 
     By varying the distance that the slit  47  or V-shaped cut  49  cuts into the skirt portion  76  and/or the degree of the vertex angle, the amount of overlap  51  can be controlled. 
     In some embodiments, the flap  42  may include two V-shaped cuts  49 , such that a general M-shape is achieved. Some embodiments may include several V-shaped cuts  49 , such that a saw-tooth pattern is achieved at the edge of the flap  42 . 
     In certain embodiments, the flap  42  may include cuts of other shapes and geometries that provide the same overlapping effect as a slit  47  or V-shaped cut  49 . These shapes may include a cut that resembles a tooth of a ripsaw blade and a scalloped cut. 
     In some embodiments, a pair of flaps  42  extend from opposite sides of the central portion  24 . The flaps  42  may be foldable downwardly, as illustrated by arrows  44 , such that the flaps  42  overlay one or more tabs  38 . In some embodiments, at least one flap  42  adheres to one or more tab  38 . In some embodiments, one or more flaps  42  are folded downwardly first and the first strip  30  and/or second strip  31  is/are subsequently folded downwardly, such that at least one tab  38  overlays and is adhered to at least one flap  42 . Thus, the overlapping of the flaps  42  and tabs  38  may have the effect of covering or sealing seams to provide an effective moisture barrier and protective cover. 
     Certain embodiments, such as the one shown in  FIG. 1C , may comprise an angled cutout  25 . In some embodiments, the angled cutout  25  can be angled inwardly toward the central portion  24 . In some embodiments, the angled cutout  25  may meet the cutout  23  and can be angled with respect to the cutout  23 . Certain embodiments may have an angled cutout  25  with an angle in the range of range of 5 to 30 degrees, while some embodiments may have an angled cutout  25  with an angle in the range of 31 to 60 degrees. Some embodiments may have an angled cutout  25  with an angle in the range of 61 to 89 degrees. It should be noted that any variation in the degree of the angle of the angled cutout  25  is herein contemplated. Further, embodiments including an angled cutout  25  may comprise a “whole” flap  42  or may include a cut in at least one of the flaps  42 , such as a slit  47  or V-shaped cut  49 . 
     The first layer  20  may be composed of an elastomeric material such that the first layer  20  may be stretched during application. Such an elastomeric property may provide an effective moisture barrier for a utility pole  14 . The elastomeric property may also enable a single size first layer  20  to be applicable to a broad range of pole sizes. 
     In certain embodiments, a pole cap  10  may provide an effective moisture barrier that effectively protects against ultraviolet light damage without a second layer  22 . Some embodiments, however, may comprise a second sheet  22 . 
     The second layer  22  may be thin relative to the first layer  20 . In some embodiments, the second layer  22  can be sized and disposed to cover certain areas of the first layer  20 , which may include the central portion  24  and the central sections  36  of the first strip  30  and/or second strip  31 . The second layer  22  can also have cutouts, identified in  FIGS. 1A and 1B  at  23 , which generally correspond to the shape and configuration of the first layer  20 . In certain embodiments, the second layer  22  is attached to the adhesive or sticky upper surface  26  of layer  20 . The second layer  22  may have a non-adhesive or non-sticky upper surface  46 , which could provide a non-sticky upper surface when the pole cap  10  is attached to a utility pole  14 . The width  48  of the second layer  22  may, in some embodiments, be at least as great as the diameter of the upper end surface  16  of a typical utility pole  14 . 
     In certain embodiments, the second layer  22  may be composed of a material that affords protection against ultraviolet light. In some embodiments, the second layer  22  is composed of polyethylene. 
     In some embodiments, the pole cap  10 , with or without the second layer  22 , is packaged as a generally planar article between a pair of backing or release sheets  50 , which may ease storage, transportation, and handling prior to and during installation. 
     During installation, a protective fluid may be applied to the top of the utility pole  14 . The pole cap  10 , may be applied by removing the release sheets  50  and positioning the pole cap  10  such that the central portion  24  overlays and covers the upper end surface  16  of the utility pole  14 . The lower surface  28  of the first layer  20  may then be adhesively attached to the upper end surface  16  by pressing upon the first layer  20 . The first strip  30  and/or second strip  31  may then be folded downwardly generally along fold lines  32 , and the central sections  36  may then be adhesively attached to the curved circumferential surface of the utility pole  14 . The tabs  38  may be stretched to overlap one another, which may provide a tighter seal against moisture. Each tab  38  may be adhesively attached to one another and/or the pole by pressing thereon. The flaps  42  may be fold downwardly, stretched, and adhesively attached to the respective tabs  38  and/or the curved surface of the utility pole  14  by pressing thereon. Thus, the flaps  42  may cover and seal seams between the tabs  38 . 
       FIG. 5  depicts an example embodiment in which a pole cap  60  comprises a flat sheet of adhesive material, similar to the material of which the first layer  20  is composed. The flat sheet of the pole cap  60  may be sized and dimensioned such that it covers the upper end surface  16  of the utility pole  14 . Such an embodiment may provide a less expensive option to protect the top of a pole due to a decrease in materials necessitated by its design. 
       FIG. 6  depicts an example embodiment in which a pole cap  70  comprises a flat sheet of adhesive material, similar to the material of which the first layer  20  is composed. The flat sheet of the pole cap  70  has a diameter greater than that of the pole  72  so as to provide a skirt portion  76 , which may be folded downwardly about the circumference of the pole  72  and adhered to the side of the top of the pole  72 . The skirt portion  76  may comprise one or more notches or slits  47 , which may eliminate or reduce ripples or ridges in the skirt portion  76  upon application of the pole cap  70  to the pole  72 . During application, the area of the skirt portion  76  to one side of the slit  47  may first be applied, and the area of the of the skirt portion  76  to the other side of the slit  47  may be subsequently applied, such that an overlap may be formed, similar to the overlap  51  depicted in  FIG. 4 . 
     It is to be understood that the embodiments and claims disclosed herein are not limited in their application to the details of construction and arrangement of the components set forth in the description and illustrated in the drawings. Rather, the description and the drawings provide examples of the embodiments envisioned. The embodiments and claims disclosed herein are further capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purposes of description and should not be regarded as limiting the claims. 
     Accordingly, those skilled in the art will appreciate that the conception upon which the application and claims are based may be readily utilized as a basis for the design of other structures, methods, and systems for carrying out the several purposes of the embodiments and claims presented in this application. It is important, therefore, that the claims be regarded as including such equivalent constructions. 
     Furthermore, the purpose of the foregoing Abstract is to enable the United States Patent and Trademark Office and the public generally, and especially including the practitioners in the art who are not familiar with patent and legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The Abstract is neither intended to define the claims of the application, nor is it intended to be limiting to the scope of the claims in any way. Instead, it is intended that the invention is defined by the claims appended hereto.