Patent ID: 7022270

Claim:
A method of manufacturing a composite pole comprising: providing a mold with an inner surface substantially resembling a pole; inserting a structural member centrally within the mold to define an annular cavity between the structural member and the inner surface; filling the annular cavity between the structural member and the inner surface with a curable, thermosetting urethane resin; adding pigmentation to the urethane resin; adding a filler to the urethane resin to improve the electrostatic resistance of the cured urethane resin; adding a filler to the urethane resin to improve the fire resistance of the cured urethane resin; curing the urethane resin to define an exterior surface substantially resembling a pole and to bond the urethane resin to the structural member; removing the cured urethane resin and structural member from the mold; and forming an exterior surface of the composite pole with the exterior surface of the cured thermosetting urethane resin.