Patent ID: 7329444

Claim:
A method of making a composite pole with an integral mandrel therein, comprising the steps of: a) shaping at least one integral mandrel to a desired internal configuration of the composite pole, wherein the at least one integral mandrel comprises expanded insulating foam, and wherein said shaping comprises shaping the outer contour of the at least one integral mandrel and cutting at least one longitudinal passage through the at least one integral mandrel; b) applying a plurality of layers of composite material to said at least one integral mandrel, wherein said composite material comprises a reinforcing material and a matrix, wherein the composite pole formed from said composite material is integrally bound to said at least one integral mandrel; c) allowing said at least one integral mandrel to remain within said pole to form a finished pole, such that the finished pole contains the at least one longitudinal passage passing through the pole; d) after the finished pole is formed, inserting at least one object through the entire length of the finished pole through the at least one longitudinal passage; and e) wherein said at least one integral mandrel comprises a plurality of integral mandrels butted together end to end, such that the at least one longitudinal passage is in alignment relationship among the plurality of integral mandrels.