Background Art [2] Traditional utility poles have distinct disadvantages. Wooden, concrete and steel utility poles are the most common poles used today. Wooden utility poles are probably the most common utility pole in use today. Wooden utility poles are susceptible to rot or destruction because of weather and bug infestation. To prevent the destruction of the poles, many wooden poles are soaked in creosote. Creosote is a highly toxic substance that has possible links to cancer in humans. The creosote leeches out of the pole and often enters the water table where it pollutes drinking water. Even with the creosote application, wooden poles still have a limited life span. Wooden poles need extensive maintenance and routine replacement.

[3] Concrete poles have been used in place of wood in some places. Unfortunately, concrete poles are extremely heavy. These concrete poles often require a crane or special machinery to assemble the pole in the field. Also, these poles are not good for remote locations because the weight of the pole requires the use of heavy trucks to transport the poles.

[4] Steel poles are lighter than concrete, but remain burdensome. The steel poles still are susceptible to environmental factors, like rust. In addition, steel poles are highly electrically conductive. Thus, steel poles present a danger to people working on or near the poles.

Disclosure of Invention Technical Problem [5] A need exists for a pole system made of lightweight and strong material but that is capable of meeting strength requirements.

Technical Solution [6] The present invention relates to z-direction reinforced panels and pole structures made from the panels. In addition, the present invention relates to methods of building the poles from the panels.

[7] An embodiment of a composite panel is disclosed. In this embodiment, the panel comprises at least one first skin ; at least one second skin; at least one layer of core material sandwiched between the at least one first skin and the at least one second skin, said core extending in more than one plane; and one or more support rovings int erspersed inside the core and connecting the at least one first skin to the at least one second skin.

[8] In another embodiment, a composite pole is disclosed. In this embodiment, the pole comprises two or more panels connected together, wherein the panels comprise a first skin forming an inner surface; a second skin forming an outer surface; a core separating the first skin and the second skin; one or more support rovings interspersed inside the core and connecting the first skin and the second skin; a first coupling device on a first edge of the panel; and a second coupling device on a second edge of the panel; wherein the panels are mechanically connected by inverting one panel with respect to another panel and interlocking the first coupling device on a first panel to the second coupling device of another panel.

[9] In another embodiment, hardware for a composite pole is disclosed. The hardware comprises, an end cap fitted to the pole, wherein the end cap may cover a bottom or top of a pole section; and a collar fitted to the pole, further comprising a first sleeve and a second sleeve that form a cavity to accept a top part of a bottom pole section; and an end plate connected to the first and second sleeves, wherein the end plate rests atop the top part of the bottom pole section; wherein, the hardware functions to mate one pole section to another pole section.

[10] In yet another embodiment, a nested composite pole is disclosed, comprising a first bottom pole section comprised of two or more panels mechanically connected by a first coupling device on a first panel and a second coupling device of another panel, the panels comprising: a first skin forming an inner surface; a second skin forming an outer surface; a core separating the first skin and the second skin; one or more support rovings interspersed inside the core and connecting the first skin and the second skin; a first coupling device on a first panel and a second coupling device on a second edge of the panel; and one or more connecting sections that mate with the first bottom pole section to increase the height of the nested pole.

[11] In a further embodiment, a method is disclosed for constructing a composite pole.

The method comprises providing at least one panel having a first side edge comprising a first coupling device, a second side edge comprising a second coupling device designed to connect with a first coupling device; providing at least one second panel having a first side edge comprising a first coupling device, a second side edge comprising a second coupling device designed to connect with a first coupling device; wherein the first and second edges of the at least one second panel comprise sub- stantially the same dimensions as the at least one first panel; inverting the at least one second panel relative to the at least one first panel; connecting the first coupling device of the at least one first panel with the second coupling device of the at least one second panel; and completing the circumference of the pole with additional panels if required.

Description of Drawings [12] FIG. 1 shows one embodiment of a pole comprised of two fiber reinforced panels formed in more than one plane and one embodiment of the male and female couplers.

[13] FIG. 2 shows one embodiment of a panel preform construction.

[14] FIG. 3A shows a side view of one embodiment of a multiple layered panel.

[15] FIG. 3B shows a side view of two embodiments of a panel having different fiber reinforcement arrangements.

[16] FIG. 4 shows an end view of a series of nested fiber reinforced poles.

[17] FIG. 5 shows a cross sectional view of one embodiment of a telescoping pole and the attachment hardware.

[18] FIG. 6 shows one embodiment of a single cross-member design in a composite pole system.

[19] FIG. 7 shows a cut-away view of one embodiment of a triple cross-member design in a composite pole system.

[20] FIG. 8 shows a cut-away view of one embodiment of a climbing system design in a composite pole system.

[21] To clarify, each drawing includes reference numerals. These reference numerals follow a common nomenclature. The reference numeral will have three digits. The first digit represents the drawing number where the reference numeral was first used. For example, a reference numeral used first in drawing one will have a number like 1XX while a number first used in drawing five will have a number like 5XX. The second two numbers represent a specific item within a drawing. One item in FIG. 1 will be 101 while another item will be 102. Like reference numerals used in later drawing represent the same item. For example, reference numeral 102 in FIG. 3 is the same item as shown in FIG. 1.

Mode for Invention [22] The present invention includes a reinforced panel, and a pole and pole system created from the panels. Each of the preceding embodiments of the invention will be described in turn.

Composite Panels [23] Referring to FIG. 1A and FIG. 1B, the present invention relates to a panel 100. The panel may be formed by a first skin 106 (inner skin), a core 104, and a second skin 102 (outer skin). The composite laminate may have varying materials used for the first skin 106, the core 104, or the second skin 102. A skin 106 or 102 can also be formed from multiple layers of fibrous material and resin. The fibrous material may comprise organic or inorganic fiber types including for example, fiberglass, carbon, aramid, Kevlar, carbon nanofiber, or other types of fiber. The resin may comprise any ther- moplastic or thermosetting resin including for example, polyester, phenolic resins, polypropylene or other similar resins.

[24] The core 104 may also be formed by several types of materials. These materials may also comprise fibrous materials and resin. However, in an exemplary embodiment, the core 104 can made from an open cell or, more preferably, a closed cell foam material comprising for example, polyurethane, a phenolic foam, styrene, or other type foam. To reduce weight, the foam material may be any foam, for instance, a low density foam in the range of. 5 (8.33 kg/m3) to 5 Ibs/foot3 (83.3 kg/m3). The core materials may comprise variable lengths and variable panel thicknesses. For example, depending on the use of the panel, in various embodiments the core may comprise a thickness ranging from about 1/2 inch (1.25 cm) to about 5 inches (12.5 cm), more preferably from about /2 inch (1.25 cm) to about 4 inches (10 cm).

[25] The core 104 may also comprise a hollow cavity. This cavity may be formed by the placement of a substance between the skins 102 and 106 during the formation of the panel 100, and after the panel 100 is wetted and cured, the material is removed either by a chemical or physical process. Other materials may be used in the core 104. These materials may comprise for example, cementious substances, fire-proof materials, sound-dampening materials, elastomers, other rubber-like materials, plastic-type materials, or other types of materials that meet the physical properties of the final panel 100.

[26] The panel further comprises z-direction reinforcements 108. As used herein, z- direction reinforcements encompasses reinforcements perpendicular to the panel side as well as reinforcements ranging from close to 0° to close to 180° relative to the panel side. These reinforcements may also be made from varying materials. The materials may comprise for example, fibers, metals, composites, or natural materials (such as wood). In an exemplary embodiment, the reinforcements 108 comprise a composite formed from fiber and resin. The fibers may comprise for example, fiberglass, carbon, aramid, Kevlar, carbon nanofiber, or other types of fiber. The resin may be any ther- moplastic or thermosetting resin for example, polyester, phenolic resins, or other similar resins. As one skilled in the art will recognize, the materials used to form the panel 100 are immaterial to the invention.

[27] As shown in FIG. 1A, the panel 100 may be formed in more than one plane. In other words, the panel can have several sides. The embodiment of panel 100 has four sides 110,112, 114 and 116. Panel 100 can have equidistant sides, wherein each side has approximately the same length, or sides of unequal length depending on the desired shape of the final structure. In other embodiments, the sides may each comprise a length different from the other sides. In various embodiments, a panel 100 may have more or fewer than four sides 110,112, 114 and 116. A one sided panel with tufted reinforcements is possible, but this type of panel is not ideal for creating structures. The panel 100 shown in FIG. 1B also includes devices 802a and 802b to couple two or more panels together to form different structures. These coupling devices are not necessary, but a more detailed explanation of embodiments of the coupling devices 802a and 802b is given later.

[28] Reinforcements 108 are placed into each side 110,112, 114 and 116 of the panel 100. These reinforcements 108 may be placed into the panel in an arrangement with each side 110,112, 114 and 116 of the panel 100. For example, in FIG. 1A the rein- forcements 108 are not placed similarly into each side 110,112, 114 and 116 of the panel 100. Rather, the reinforcements 108 in panel 100 are placed perpendicularly to each side 110,112, 114 and 116 of the panel 100. In various embodiments, the rein- forcements may be placed at various angles relative to each side. These arrangements will be explained in more detail below.

[29] As shown in FIG. 2, the skins 102 and 106 may each be made of one or more layers. Each layer of fibrous material may be different or similar. These layers may comprise for example, woven sheets, other webbings, unidirectional rovings, multi- directional rovings, or fabrics. The embodiment shown in FIG. 2 includes three different layers 202,204, and 206. The first layer 202 is a woven fibrous material or fabric, the second layer 204 is a plurality of unidirectional rovings that are placed in the 0° orientation, and the third layer 206 is another plurality of unidirectional rovings placed in the 90° orientation. Every skin 102 or 106 may have fewer or more than three layers. Each layer 202,204, and 206 may be formed from different materials as mentioned earlier. One skilled in the art will recognize the different materials and ar- rangements that may be made with the skins 102 and 106.

[30] FIG. 1A, FIG. 1B and FIG. 2 showed the core 104 as being formed from a single homogeneous substance. However, the core 104 may have multiple layers and substances between the skins 102 and 106. The core 104 may be layered in the panel 100 in various arrangements to achieve the desired physical properties of the finished panel 100. FIG. 3A shows an example of a multiple skin design having four in- termediate core skins 314 and four core layers 316. Each core skin 314 may have different materials and one or more layers. Each core layer 316 may be made from different substances or several substances. One skilled in the art will recognize that the arrangement of layers 316 or 314 inside the core 104 is immaterial to the invention and will recognize other embodiments of the core 104 that are included in this invention.

[31] To aid in structural stability to the panel 100, a plurality of reinforcements 108 are placed into the panel 100. The reinforcements 108 may be placed through the panel 100 to resist delamination. Thus, the invention includes reinforcements 108 that are set between or through the skins 102 and 106. In an exemplary embodiment, the present invention may include reinforcements (hereinafter referred to as rovings or fibers) woven through the outside of one skin 102, through the core 104, and through the inner skin 106. This exemplary embodiment will be used to describe the rein- forcements 108 hereinafter. However, the present invention is not limited to that one embodiment. The rovings 108 may include any type of stitching, sewing or'tufting'.

Stitching types or sewing types may include, but are not limited to, chain stitching, knotted stitching, or patterned stitching. Generally, stitching uses single fibers and sewing mimics classic sewing in that a second fiber is introduced under the panel. One skilled in the art will recognize the different types of fiber or roving placements that may be used in the present invention.

[32] Referring now to the side view of the panel 100 in FIG. 3B, the rovings 108 may pass through the core 104 at any angle Thetaa 312, between near 180° to near 0°, to the plane 310 of the skins 102 and 106. The plane 310 is the two dimensional orientation of the skins 102 and 106. The rovings may take in plus or minus angle from a vertical position. However, the angle of insertion 312 is more preferably between 135° to 45°.

In an exemplary embodiment, the rovings 108 are placed into the panel perpendicular to the plane 310 of the skins 102 and 106. FIG. 3B shows a side view of the insertion of the rovings 108, but a front view (not shown) of the rovings 108 would also show that the rovings may also be inserted into the panel 100 at an angle relative to the plane 310 in that view also.

[33] Tufting is a specific type of stitch included in the invention. To tuft, a fiber or fibers are pressed through the first skin 102, the core 104, and the second skin 106. A loop of fiber 302 is left on the outside surface of the second skin 106. This loop 302 may remain intact or be cut into a bundle of separate fiber ends. The insertion device proceeds to the next insertion creating a new tuft. Thus, the tuft may have loops 302 on one side of the panel 100 and lengths 318 of fiber, on the other side of the panel 100, connecting the insertions 108 of the tufts. During the wet-out and forming process, the loop 302, whether cut or intact, may be wetted and pressed onto the skin 106 of the panel. Thus, the tufted fiber 108 may be bent over 90° to lock the skins 102 and 106 to the core 104. The tufting creates a panel 100 with very rigid properties that can resist delamination, buckling, and impact. Tufts 108 will be used to explain the rovings 108 hereinafter, but the invention is not limited to that one embodiment.

[34] The tufts 108 can be set along and into the panel 100 at various stitch densities.

The stitch density is explained using two measures-the gauge and stitch rate (pitch) of the tufts. Gauge is controlled by spacing of the needles or number of needles. The gauge describes the number of tufts along the width of the panel 100 and pitch is controlled by computer and is programmable. In various embodiments, the pitch can be programmed during fabrication of a panel to achieve variable pitch along the length of the panel 100. Generally, the higher the stitch density the more protection from impact. The gauge and pitch can be adjusted to any variation to create a panel 100 with the required physical properties.

[35] The present invention includes panels 100 that can have more than one side 110, 112,114 or 116. Each side 110,112, 114 or 116 of the panel 100 can be formed in a different plane. These different planes can be set at angles to each other. Referring again to FIG. 1A, sides 112 and 114 are set at an angle Phi 324 to each other. Side 112 is formed in plane 310 and side 114 is formed in plane 308. These two planes 310 and 308 are set at an angle Phi 324 to each other. Angle Phi 324 may be any angle from nearly 180° to nearly 0°. Preferably, angle Phi 324 is between 150° to 90°. Each side 112 or 114 can have a plurality of tufts 108. These tufts 108 have an angular re- lationship with the plane 310 or 308 of that side. For instance, tufts 108 in side 114 have an angular insertion Theta b 313 with respect to plane 308, while tufts in side 112 have an angular insertion Thetaa 312 with respect to plane 310. A set of tufts 108 placed in one side may have a different angular relationship than another side. As mentioned earlier, the tufts 108 may be set at any angle Theta to the plane of the side.

In other words, tufts 108 in one plane may be placed into the panel 100 at a per- pendicular angle while tufts 108 in another side may be placed in the panel 100 at a 45° angle. Any angle Theta of placement is possible, but the preferred angle Theta of placement is perpendicular to the plane of the side due to the ease of manufacture.

Each side has its own set of tufts 108 set into that side separately. Along with the angle Theta of insertion, each side may have a different stitch density. Thus, the panel 100 can create sides with the same, reduced, or enhanced strength characteristics depending on the side of the panel 100.

[36] While the FIG. 1A and 1B illustrate an eight sided pole one skilled in the art will recognize that a single panel 100 may have a plurality of sides, each side may be set at different or similar angle Phi 324 to each other side. Also, in some embodiments, the panel may assume shapes with two sides that are in parallel but separated by one or more other sides that are at an angle Phi 324 to the parallel sides. In various em- bodiments, the panel may comprise a plurality of geometrical configurations. For example a panel 100 may be formed into an arc or semi-circle. Alternatively, the panel 100 may comprise one or more sides, for example a square a triangle a pentagon, a hexagon, or a tetrahedron. One skilled in the art will recognize that the present invention can adjust this shape by providing a numerous array of tufts 108, wherein one tuft or a small set of tufts 108 are each placed perpendicular or nearly per- pendicular to a segment of the arc of the skin.

[37] Referring again to FIG. 3A, one embodiment of the panel is shown. In FIG. 3A, the loop 302 is shown on one side 106 of the panel 100, while the lengths of the fiber 318 are shown on the other side 102 of the panel 100. The loops 302 are shown with broken lines because they can be folded over the skin 106 during wet-out and die formation process. The fiber lengths 318 are shown in FIG. 3A as proceeding in a straight line. It is envisioned that the fiber lengths 318 may proceed in a pattern. For instance, the fiber lengths 318 may form a zigzag pattern. One skilled in the art will recognize other patterns that the fiber lengths 318 may form.

[38] Referring again to FIG. 1B, the panels 100 may be formed with a clamping, coupling, or connecting structure set on one or two side edges of the panel 100. In the embodiment shown in FIG. 1B, the two panels 100a and 100b are identical but inverted. These panels 100a and 100b each have four equidistant sides, and when coupled together, the panels can form an eight-sided or octagonal enclosed structure.

Each panel 100a and 100b has a coupling device 802a on one side edge 806 and a second coupling device 802b on a second side edge 804. The first coupling device 802a mates with the second coupling device 802b. An embodiment of the coupling device 802a is a female receptor. The female receptor or coupler 802a has a set of semi-flexible flanges 808 that extend from the edge 810 of the panel 100. These flanges 808 can be formed from one or more of the skins 102 or 106 of the panel 100.

The flanges 808 may be tufted or not tufted depending on the desired physical properties of the flanges 808. These flanges 808 can mate with a male end coupler 802b formed on an opposing side 804 of a different panel 100. This male end 802b can have the skins 102 and 106 and core 104 comprising the panel 100. This male end 802b may also be reinforced with tufts 108.

[39] Both the male coupler 802b and the female coupler 802b comprise a com- plementary shape to efficiently mate. The shape of either coupler 802a or 802b may be formed by a die during wet-out and die formation. In the embodiment shown, the flanges 808 are extend a distance from the side 810 of the panel 100. The distance the flanges 808 extend depends on the amount of flexibility and strength desired in the female coupler 802a. At the distal end of the flanges 808, is a knob or bead 812 formed along the length of the flange 808. The flanges 808 form a cavity or channel 814 along the side 806 of the panel 100. The matching male coupler 802b has a shape that can fit within the cavity 814 of the female coupler 802a. This male coupler 802b may have a width that is less than the panel 100 while the female coupler 802 may have flanges that are the same distance apart as the two skins 102 and 106 of the panel 100. At the proximal end of the male connector 802b, two grooves or channels 816 may be formed along the length of the connection between the male coupler 802b and the panel 100. The grooves 816 can accept the beads 812. The connection of the grooves 816 and beads 812 provides a lock for the couplers to prevent either the male 802b or female 802a coupler from disengaging. In addition, the distal end of the male coupler may have rounded corners 818. Along with rounded ends on the beads 812, the rounded corners 818 allow the flanges 808 to easily slide over the male coupler 802b.

Adhesive may be applied to the female side. The beads 812 slide into the female 802a and the beads 812 trap the adhesive. The female end 802a is also formed to parallel the direction of the opposing side 804 of the other panel. This arrangement of the female coupler 802a allows for two panels 100a and 100b to be used to form a structure. In other embodiments, the female 802a or male 802b coupler can have a different angular relationship to the panel to allow coupling of three or more panels to form a structure.

In addition, the angular relationship will also be affected by the number of sides desired in the final structure.

[40] To mate the couplers 802a and 802b, the female end 802a can slide over the male end 802b and be clamped to the male end 802b. To accomplish this mating, the male end 802b is forced into the cavity 814 of the female coupler 802a. Once the beads 812 on the flanges 808 contact the rounded corners 818 of the male coupler 802b, the flanges 808 flex outwardly. This flexing of the flanges 808 allows the beads 812 to pass over the sides 102 and 106 of the male coupler 802b. Once, the beads 812 reach the end of the male coupler 802b, the beads 812 drop into the grooves 816 and the flanges 808 stop flexing, locking the panel and applying pressure to the adhesive. With the beads 812 set in the grooves 816, the male end 802b is harder to pull away from the female end 802a. While the mechanical connection of the male 802b and female 802a coupler can provide a good mating of two panels 102a and 102b, further en- hancements to the couple may be made. For instance, an adhesive substance may line the cavity 814 and bond the flanges 808 to the sides 102 and 106 of the male couple 802b. Coating the cavity 814 is preferred to coating the sides 804 because the beads 812 would scrape off the adhesive material when the male couple is inserted into the female couple. Also, when the beads 808 drop into the grooves 816 and the flanges 808 stop flexing, the inside of the cavity 814 contacts the entire surface of the male couple 802b at the same time and prevents bonding of one part of the couple and not another. In addition, rivets, bolts or other fasteners may be set through the one side of the couple, though the first flange, the male couple, and the second flange to create another mechanical fastening point. Other coupling designs are possible and included in the invention.

Composite Poles [41] After the panels are coupled together, the panels can form structures. Hereinafter, the structure created by the coupled panels shall be a pole. However, the invention is not limited to that one embodiment, as the panels may be used to form other structures including, but not limited to, buildings, containers, or other vessels. An end view of an embodiment of the pole is shown in FIG. 4. While this pole has six sides and formed from two panels, other embodiments of the pole may be formed from three or more panels and have more or fewer than six sides. The pole may be any polygonal shape, circle, or oval. In addition, the pole may have varying heights and widths. The pole can be made to any height because the panels 100a and 100b are formed from a pultrusion process that allows the creation of panels 100 of unlimited length. The panel 100 only needs to be sawed or milled to the appropriate length for the desired pole height. The width may vary by producing panels 100 with sides of greater or lesser length. The width of the panels 100 may also change, and thus, the pole may have an outside diameter and inside diameter that is greater or lesser than the embodiment shown in FIG. 4.

[42] An example of some of the different diameters, pole sizes, and wall thicknesses of the poles 900a, 900b, 900c, and 900d is shown in FIG. 4. In this embodiment, each pole section 900a, 900b, 900c, and 900d has a similar shape (a hexagon formed from two panels). Each pole section can fit into the next pole section. For instance, pole section 900a fits into pole section 900b, such that the outside surface of pole section 900a either can touch or can nearly touch the inside surface of pole section 900b. This nesting relationship continues for pole sections 900b with 900c and 900c with 900d.

Thus, using some connecting hardware, poles of varying heights may be constructed using different pole section 900a, 900b, 900c, and 900d that can have different lengths. By using pole sections that can be nested, standard panels and poles can be created, but those standard parts can create several poles of varying height. One skilled in the art will recognize that the shape or construction of the panels or poles can change but the nesting relationship maintained.

[43] The pole sections 900a, 900b, 900c, and 900d can be made to mate with each other to form an nested pole system. Poles may be formed from one or more pole sections.

In nested pole embodiments, poles may be formed from two or more pole sections that extend longitudinally. For example, in FIG. 4, the widest section 900a functions as a base and sections 900b, 900c and 900d extend upwardly to form a pole of extended height. Accordingly, fully extended pole sections may form poles of standard heights, namely, 45', 60', 75', 90'and 120'. In alternate embodiments, the pole sections may be used to form poles of variable heights or that exceed 120'. One skilled in the art will recognize that panels may be cut to any length to form any height of pole and the panel sides may have any width to form poles of any diameter. Hereinafter, standard pole heights and diameters will be used to describe the invention, but the invention is not limited to that embodiment.

[44] For example a first pole section 900a may be 45'in length and have roughly a 14' radius. The next pole section 900b can have a 15'length and an 18. 4' diameter. In this example, the first pole section 900a can slide four feet into the next pole section 900b.

Once mated, the nested pole is 60'in height, has an outside diameter at the bottom of the pole of 18. 4', and has an outside diameter at the top of the pole of 14'. Similarly, a 75', a 90', or a 120'pole can be created by slipping the pole into the next pole section.

In the embodiment presented, a 49'pole is the first section 900a and no other section mates with the pole 900a to create the 49'pole. The 49'pole 900a is a standard pole height for most electrical distribution networks. This type of telescoping pole is discussed in PCT Application No. PCT/US2004/030271 titled, Composite Tower for a Wind Turbine and Method of Assembly, and is incorporated by reference herein.

[45] In another example, a 60'pole 900 has a first pole section 900a, which is the 45' pole section, and a second pole section 900b, which is a 15'section. When the section 900a and 900b are fit together, the finished pole is 60'. To install the pole in the ground, the pole must be one tenth plus two feet of its length into the ground (Depth of Installation =. IL +2'). Thus, the 60'pole is installed eight feet into the ground. This re- quirement for the installation of utility poles is standard and the same rule is applied for connecting one pole section to another pole section. For a 75'pole, the pole is put into the ground 9.5'and the 90'pole is installed 11'into the ground. One skilled in the art will recognize that the depth of installation may be changed depending on the re- quirements of the pole. In addition, one skilled in the art will recognize that the pole system can be changed to provide a pole of a certain height above the ground with a certain depth below ground. These changes may be made by changing the length of the pole sections or adding more pole sections to the pole system.

[46] To mate the pole sections, some type of mating hardware can be used. This hardware may comprise any type of mechanical or adhesive connection. The mechanical hardware may be made from any rigid material comprising for example, metals, composites, plastics, or laminates. Referring to FIG. 5, one embodiment for the pole section mating hardware 1300 is shown. The embodiment may include an end cap 1302 to place on the bottom 1304 or top 1310 of the pole sections being inserted into another pole section and a ring or collar 1306 placed around the top 1308 of the pole section that has a pole section inserted into it. FIG. 5 shows a cut away view of a pole including both the bottom cap 1302 and the collar 1306.

[47] In the embodiment shown, the collar is constructed of a composite laminate similar to the skins 102 and 106 of the pole. However, the collar 1306 may comprise other materials for example other composites, other laminates, metals, or other rigid materials. The collar 1306 generally can have a first sleeve 1402 that can fit over the bottom pole section. The inside diameter of the bottom sleeve 1402 matches the outer diameter of the bottom pole section. A second sleeve 1404 can attach to the upper section of the pole section. The inside diameter of the second sleeve 1404 can attach to the outside diameter of the upper pole section. In the embodiment shown, the first sleeve 1402 and second sleeve 1404 can form a cavity 1406 that can accept the top part of the bottom pole section. An end plate 1408 can rest atop the top of the bottom pole section. The width of the cavity 1406 can match the width of the panels 100 comprising the bottom pole section. In addition, the collar 1306 can have the same polygonal shape of the pole sections. In this way, a strong mechanical couple of the collar to the bottom pole section is made. The second sleeve 1404 can be attached to the upper pole section at any point to create a nested pole of a certain height. To stabilize the upper pole section and provide better rigidity against lateral movement in the upper pole section, a series of gussets 1410 may be placed around the collar 1306.

These gussets 1410 can sit atop the plate 1408 and astride the outside of the second sleeve 1404. This design helps add rigidity to the upper part of the second sleeve 1404.

One skilled in the art will recognize other embodiments of the collar, which are included in this invention.

[48] In one embodiment, the end cap 1302 may have a bottom plate 1502 and a plurality of side walls 1504. The end cap 1302 can be slipped over the bottom or top of a pole section. Thus, the inside surface of the side walls 1504 can attach to the outside diameter of a pole section. The end cap 1302, when placed at the top 1310 of a pole, can prevent the penetration of water into the interior of the pole. At the bottom 1312 of the pole, the end cap 1302 can prevent the penetration of ground water, cement, soil, or other substances into the interior of the pole. One embodiment of the end cap 1302 is shown in FIG. 5. In an alternate embodiment of the end cap 1302 the cap may comprise an end cap sleeve 1314 that can be attached to a projection of the bottom plate 1502. The second sleeve 1314 can attach to inside surface of a bottom pole section. Like the collar 1306, this embodiment of the end cap 1302b can provide added rigidity to the pole system. One skilled in the art will recognize other embodiments of the end cap 1302 that are included in this invention.

[49] The end cap 1302 and the collar 1306 can either be attached to the inserted pole section or to the pole section having the pole inserted into it. In other words, the end cap 1302 can be attached to either the upper or bottom pole section before mating the pole section, and the collar 1306 can be attached to either the upper or bottom pole section before mating. The end cap 1302 and collar 1306 may be attached to the same pole section first or to different pole sections first. The attachment may be done by glue, adhesive, or epoxy, or by some mechanical fastener such as a rivet, coupling pin 1320 or bolt. Also, the attachment of the mating hardware can be done at a factory before the pole sections are sent into the field for installation or the installers could attach the mating hardware.

[50] After the pole sections are mated and ready for installation, the poles can be set into the ground. For example, for shorter poles or single pole sections, the pole may be set into the ground without any preparation. In this embodiment, a hole may be dug or drilled into the ground, the pole would be set in the hole, and the dirt compacted around the pole to stabilize the pole. In another example, a larger hole may be dug or drilled into the ground. A material may be placed at the bottom of the hole. The bottom pole section can be set onto the material. Then, more material may be placed around the pole section. The material may be any substance that gives the pole a solid and rigid footing in the ground. For instance, the substance may include, but is not limited to, concrete, other cementious materials, polymer concrete, diatomaceous earth, other compatible soils, expandable materials, hardened materials, or preformed materials.

[51] In another embodiment, the pole may be set at the bottom of the hole without any material placed under the pole. The material may then be placed around the pole. In yet another embodiment, an even larger hole may be dug into the ground. A first lining for the hole may be made of a first material. This lining may be made from similar materials as the preceding example. However, a second material lining may be placed inside the first lining and around the bottom of the pole. This second lining may be made from the same or different materials than those already mentioned. For instance, this lining may be made from substances including, but not limited to, diatomaceous earth, elastomers, plastics, rubber-like materials, polymer concrete, vibration dampening substances, or cementious materials. The elastomers or other vibration dampening materials could help stabilize the poles during earthquakes or against other environmental forces. It will be recognized by one skilled in the art that any of the in- stallation methods may be used with any height pole. Further, one skilled in the art will recognize other modifications to the installation methods that are included in the present invention.

Constructing Reinforced Panels [52] In various embodiments, two or more reinforced panels may be snapped or connected together to form a pole. Referring to FIG. 1B, a first panel section 100a is presented comprising end coupling devices or connector portions 802a and 802b. A second panel section 100b mirroring the first panel section 100a is presented. Second panel section 100b is inverted with respect to first panel section 100a as shown in FIG. 1B. Section 802b is inserted into section 802a and secured by the knobs 812 at the ends of section 802a (as described earlier). The connections may further be secured by use of an adhesive or an additional mechanical implement through both connectors 802a and 802b (not shown). These are only examples and one skilled in the art will recognize various ways to further secure the connections.

[53] Once the pole is constructed, the pole may further be coupled with additional pole segments to form an extended or telescoping pole structure of variable dimensions. For example, a pole of a certain height may be constructed from two or more sections of a nested pole system. A height for the pole is predetermined. Two pole sections are presented and mating hardware is attached to one or both of the sections. The upper pole section is slid into the lower pole section until the mating hardware mates with both sections. Any attachment of the pole sections, including, but not limited to, adhering, bolting, or riveting the sections, or using some other attachment, is con- templated. Some pole heights require more pole sections to meet the desired height, and therefore, it is determined whether another pole section is required. If another pole section is required, that next pole section is presented, mated, and attached. If no other pole section is needed, then the pole is complete and the process ends.

[54] FIG. 6, FIG. 7, and FIG. 8 show embodiments of cross-member 800 used to install electrical cables 804 on the composite poles 806. The cross-members 800 may be made of any rigid material that is capable of holding the cable and the insulators or other parts used to hold the cable. These materials may comprise for example, wood, metals such as steel or aluminum, or concrete. In the present embodiment, the cross- members 800 can be pultruded beams of a composite material. The composite cross member may be similar to the composite pole wall or can be hollow. Thus, the cross- member 800 may have an inner skin and an outer skin with a core set between the two skins. The cross-member 800 may be tufted also. In some embodiments, the cross- member 800 may be formed from two or more panels that are connected together. A composite cross-member 800 may not be hollow but contain one outer skin and a core.

One skilled in the art will recognize other make ups of the composite cross-member 800. The cross-member 800 in the exemplary embodiment has a rectangular or square shape.

[55] While the cross-member 800 may be bolted or attached to the exterior of the composite pole 802, the exemplary embodiment sets the cross-member 800 through the composite pole 802. In other words, a set of holes 808 are created on opposite sides of the composite pole 802 in the panels. The holes 808 are similar to the shape of the cross-member 800. The cross-member 800 can be slid through the opposing holes 808.

A sleeve 806 may be used to anchor the cross-member 800 into place. The sleeve 806 or the cross-member 800 may be physically attached to the pole 802. Attaching the cross-member 800 or sleeve 806 may involve the use of attachment hardware including, but not limited to, bolts, screws, nails, or rivets. In other embodiments, an adhesive may be used to attach the sleeve 806 to the pole 802 and cross-member 800 or the cross-member 800 to the pole 802. One skilled in the art will recognize other methods and means of attaching the cross-member 800 to the pole 802.

[56] The cross-member may further comprise end caps 810. These end caps 810 can prevent environmental forces (such as rain or soil) from penetrating the cross-member 800 and effecting the cross-member 800 physically. These end caps 810 may be made from any material that can attach to the cross-member 800 and prevent the intrusion of the physical forces. In the exemplary embodiment, the end caps 810 are formed from a molded composite made from a fibrous material and resin. The end caps 810 may be attached by adhering the end caps 810 to the cross members 800. However, in other embodiments, the end caps 810 may be riveted, nailed, bolted, screwed, or welded to the cross-member 800.

[57] In the exemplary embodiment, the cross-members 800 may further comprise one or more holes 812 to allow the attachment of the insulators 814. The holes 812 may be drilled or formed in the cross-member 800. The insulator 814 can have a elongated bolt of neck that feeds through the cross-member 800 and is coupled to a nut on the other side of the cross-member 800. The insulators 814 are standard in the industry and will not be explained further. However, if the cross-member 800 and the pole 802 are composite material, this insulator 814 may actually be a conductive material. FIG. 7 shows a cross sectional view of an example configuration for a pole 802 comprising three cross-members 800. One skilled in the art will recognize that the cross-member 800 can be arranged into any standard configuration of cross members used in the industry. In addition, one skilled in the art will recognize other configurations that the cross-member 800 may form.

[58] FIG. 7 further illustrates a pole cap 816 that can be placed atop the hollow pole 802. The end cap 816 may assume various shapes. However, in the exemplary embodiment the end cap 816 is formed into a peak. The end cap 816 has a bottom sleeve 818 that can slip over the sides of the pole 802. This design ensures that water that hits the top of the pole 802 is directed down the end cap 816 and over the outside walls of the pole 802. Thus, water does not pool on the end cap 816 nor does the water penetrate the interior of the pole 802. The end cap 816 may be made from various materials such as metals, plastics, wood, or composites. One skilled in the art will recognize other embodiments of the end cap 816 that are contemplated for this invention.

[59] Electrical workers or other technicians often need to scale the utility poles to install electrical cables, preform maintenance, or accomplish other sundry tasks. With wooden poles, the technicians could use a strap and a set of boot spikes to climb the pole. Unfortunately, composite poles have side walls that preclude the use of boot spikes. The spikes usually cannot puncture the rigid and dense side walls of the composite walls, and any hole left by the spikes may cause deterioration in the pole.

Thus, a climbing system is needed for the composite pole. A cherry picker or some other crane device may be used, but these devices are expensive, may not be able to access the pole in some remote areas, and sometimes cannot reach the heights of the poles. Some of the prior art pole designs included scaling systems. These systems were often hardware used by the technician in place of the strap and boot spikes. These devices are shaped to conform to the shape of the pole. The present invention does not include any specific shape, and therefore, designing one set of climbing hardware is not possible. Thus, the present invention provides simple climbing hardware that can be attached to a pole according to the present invention.

[60] Referring to FIG. 8, the climbing hardware includes a J-bolt 1000 and a nut 1002.

The J bolt 1000 and nut 1002 may be formed from any rigid material that is strong enough to hold the weight of a technician and the technician's equipment. These materials include, but are not limited to, metals, such as steel or aluminum, plastics, or composite thermoplastic or thermoset materials. In the exemplary embodiment, the J bolt 1000 is a composite material formed from a plurality of fibers set in a hardened resin. The J bolt 1000 has a sleeve 1020 on one end and threads on the other end 1004.

The sleeve may have one or more teeth 1006. The J bolt 1000 is placed through the pole 802 by inserting it into a set of holes 1008 placed into the opposite sides of the pole 802. The sleeve 1020 prevents the J bolt 1000 from sliding to far into the holes 1008. The nut 1004 prevents the J bolt 1000 from sliding out of the holes 1008. The teeth 1006 can prevent the J bolt 1000 from rotating inside the set of holes 1008. The nut 1004 may be replaced by a pin or some other device. The J bolt 1000 and nut 1004 are only exemplary, and one skilled in the art will recognize other embodiments of the climbing hardware that can be included in this invention.

Industrial Applicability [61] Panels comprise composite materials that are nonconductive, light weight and envi- ronmentally resistant. Poles assembled from such panels are also nonconductive, light weight and environmentally resistant. In various embodiments, the pole construction and materials enable non-burdensome assembly of poles of increasing or telelesoping heights.