Technical Field

The present invention relates to poles, and more specifically, to lateral strengthening of poles.

Background Art

Poles are used for various purposes, such as supporting elements at particular heights, such above ground. Such a use includes that of a utility pole (also known as a "telephone pole"). One end of a utility pole can be buried underground to expose a substantial portion of the pole length above ground. At or near the other end of such a pole, wires such telephone and/or electrical wires are mounted. This arrangement facilitates the distribution of telephone networks and/or electrical infrastructures.

Public safety and network/infrastructure integrity is also achieved by locating wires and other elements high above the ground. Inadvertent or otherwise undesired access to such wires is minimized.

Disclosure of Invention

It is, therefore, an object of the present invention to provide lateral strengthening of poles.

In an exemplary embodiment, the present invention can be embodied in a method of laterally strengthening a utility pole having an exterior surface, with the method comprising the following steps: providing a sheet of carbon-fiber, said sheet having an inner side and an outer side; applying an adhesive to at least one of the exterior surface of the target utility pole, the inner side of said sheet, and the outer side of said sheet; placing said sheet against the exterior surface of the target utility pole such that the inner side is facing the exterior surface; and after said step of placing, allowing said adhesive to cure to form, in conjunction with said sheet, a strengthening layer; where the strengthening layer covers at least a portion of the exterior surface of the target utility pole.

According to an exemplary aspect of the present invention, the sheet of carbon fiber can be formed of woven carbon fiber strands.

According to another exemplary aspect of the present invention, the step of applying can include dipping at least a portion of the sheet into the adhesive. According to a further exemplary aspect of the present invention, the sheet can be placed at an angle of 0° to 90°.

According to yet another exemplary aspect of the present invention, the adhesive can be applied after the step of placing. According to still yet another exemplary aspect of the present invention, the adhesive can be a liquid, a solid, or a powder.

According to still yet a further exemplary aspect of the present invention, the strengthening layer can be at least one ring substantially coaxial with the pole.

According to an additional exemplary aspect of the present invention, the strengthening layer can cover a substantial portion of the exterior surface.

Additionally, the present invention can be embodied in a laterally strengthened pole produced by any of the methods disclosed herein.

Brief Description of Drawings The present invention is illustrated by way of example, and not in limitation, in the figures of the accompanying drawings, in which:

Figure 1 illustrates an exemplary utility pole post-installation, and having various elements attached thereto.

Figure 2 illustrates an exemplary utility pole pre-installation. Figure 3 illustrates exemplary method steps of an exemplary embodiment of the present invention.

Figure 4 illustrates a section of an exemplary utility pole that has been laterally strengthened according the present invention.

Figure 5 illustrates a cross section of an exemplary utility pole that has been laterally strengthened according to the present invention.

Best Modes for Carrying Out the Invention

The invention will now be described in more detail by way of example with reference to the embodiments shown in the accompanying figures. It should be kept in mind that the following described embodiments are only presented by way of example and should not be construed as limiting the inventive concept to any particular physical configuration, shape, size, or order.

It should be noted that the present invention expressly contemplates the lateral strengthening of any sized or shaped pole, and further, a pole of any material. Therefore, it should be understood that any description herein directed to any particular sized or shaped pole or pole of particular material is merely for illustrative puiposcs, and is not to be construed as limiting the present invention to any particular size, shape, or material. Figure 1 illustrates an exemplary utility pole 100 that has been installed and configured at a desired location. As illustrated, one end of pole 100 is positioned under a surface, and optionally, secured with a foundation 1 10, such as one formed of concrete, to provide additional stability to the pole. Various elements can be mounted to pole 100. As illustrated, such elements can include distribution lines 120, at least one transformer 130, secondary lines 140, and communication lines 150. Distribution lines 120 can carry high voltage current (e.g., 23,000 volts) and can be positioned about 40 feet above ground. Transformers 130 can reduce high voltage to low voltage distributed to secondary lines, and can be positioned about 35 feet above ground. Secondary lines 140 can carry 120/240 volt current to homes or businesses, and can be positioned about 32 feet above ground. Communication lines 150 can carry low current for various communication systems, such as telephone, cable, and fiber, and can be positioned about 20 feet above ground.

A major consideration in the configuration of a utility pole is public safety. Accordingly, the various elements secured by utility poles are generally positioned at particular heights above ground according to the amount of risk they pose to public safety. Distribution lines 120 are generally positioned at the highest level (about 40 feet above ground) to minimize the risk of inadvertent contact, which would likely cause serious injury or death; while communication lines 150 are positioned at the lowest level (about 20 feet above ground). Concurrently, infrastructure integrity is also a concern, and is illustrated by the positioning of communication lines 150 20 feet above ground, which reduces the risk of damage thereto from persons, vehicles, etc. at ground level. As also illustrated in Figure 1 , a cross member 120 can be mounted near the peak of pole 100 to provide additional distance between elements. A utility pole can vary in shape and size, and be constructed from various materials, including a combination of materials. It is common for utility poles to be formed of wood or concrete. However, the present invention contemplates the use of any material that serves the purpose of forming a utility pole. Further, utility poles arc commonly formed to be cylindrical in shape, but similarly, the present invention contemplates any shaped utility pole the serves the purpose of the same. External forces, independently or in any combination, may cause utility poles to fail or break. Exemplary external forces include wind, water (from floods, humidity, and precipitation), degradation from environmental conditions, vehicular accidents, etc., for example and not in limitation. Failure of a utility pole can cause serious risks of injury and damage, directly and indirectly. A failed utility pole can cause dangerously high voltage lines to be near or at ground level, creating a zone of danger. Further, broken pieces of a utility pole can become projectiles during high- velocity wind storms. Additionally, damage to electrical and communication networks can cause additional damage to businesses and other public needs relying upon uninterrupted electrical and/or communication service. Moreover, utility poles and portions thereof can cause damage and injury due to the physical force they carry when falling, and moreover, can become dangerous obstacles in roadways and walkways. Further, failed utility poles can require substantial costs due to repair and downtime costs associated with such failures. Additionally, failed utility poles can initiate a "domino effect" with adjacent utility poles failing. Where one or more common lines are connected to one or more utility poles adjacent to one that fails, the weight of the failed pole can cause, independently or in combination with one or more other external forces, the one or more of the adjacent poles to also fail. These subsequently failed poles can in turn, independently or in combination with one or more other external forces, cause respectively adjacent utility poles to fail. While a single failed utility pole can cause substantial injury, damage, and costs, multiple failed utility poles arising from this "domino" effect can be exponentially harmful. As further described below, the present invention produces an unexpected, beneficial result in this regard. Notably, a laterally strengthened pole according to present invention can break, but not fail. Specifically, such a pole can be bent to the point that the pole itself breaks (i.e., the wood, concrete, or other material with which the pole is internally formed), but with the external layer having a degree of flexibility such that it bends, but does not break. The result is that a utility pole that may have otherwise failed and triggered a "domino effect" causing plural utility poles to fail can be secured to avoid this result.

Additionally, the risk that a failed utility pole produces a dangerous or otherwise harmful projectile or obstacle is reduced or otherwise avoided altogether. In an exemplary embodiment, the present invention provides a method of laterally strengthening a utility pole having an exterior surface, with the method comprising the following steps: providing a sheet of carbon-fiber, said sheet having an inner side and an outer side; applying an adhesive to at least one of the exterior surface of the pole, the inner side of said sheet, and the outer side of said sheet; placing said sheet against the exterior surface of the pole such that the inner side is flat against the exterior surface; and after said step of placing, allowing said adhesive to cure to form, in conjunction with said sheet, a strengthening layer; wherein the strengthening layer covers at least a portion of the exterior surface.

Providing Sheet of Carbon Fiber

In an exemplary embodiment of the present invention, carbon fiber is utilized as a component of an external strengthening layer. According to an exemplary aspect of the present invention, a carbon fiber sheet (also known as graphite fiber, graphite fibre, and carbon graphite) is a material consisting of a plurality of carbon fibers. For example, and not in limitation, such a fiber can measure about 0.0002-0.0004 inches (0.005-0.010 mm) in diameter and be composed primarily of carbon atoms, which are bonded together in microscopic crystals that arc generally aligned parallel to the long axis of the fiber. This crystal alignment renders the fiber extremely strong for its size and weight. Plural carbon fibers can be combined together (such as twisted together, for example and not in limitation) to form a yarn, which may be used independently or woven into a fabric. Further, carbon fibers can be woven in plural weave patterns. Therefore, a carbon fiber sheet, according to the present invention, includes a plurality of carbon fibers. Optionally, the carbon fibers can be combined to form a yarn and/or woven together to form a fabric. In another exemplary aspect of the invention, a sheet can be provided in varying sizes. For example, and not in limitation, a sheet can have a width and length such that it can be placed against a target utility pole's length and/or circumference, in whole or in part, one or more times. In still yet another exemplary aspect of the present invention, a sheet can be provided in a roll, such that it can be unrolled as needed. Further, a sheet can be any particular thickness desired, such that it can be formed over at least a portion of the exterior surface of a utility pole.

Figure 2 illustrates an exemplary target utility pole 200 having an exemplary sheet 260 having a length less than the length of the target utility pole. Illustratively, in this example, sheet 260 has a width substantially equal to the circumference of pole 200, and accordingly, when combined with an adhesive, which is subsequently allowed to cure, creates a strengthening layer in the form of a ring substantially coaxial with the target utility pole. Notably, plural "rings" can be provided insofar as desired. Also notably, by providing one or more sheets having lengths and/or widths less than the respective length and/or width of a target utility pole, the present invention can be utilized on target utility poles having pre-existing elements already mounted to the pole. Accordingly, a particular sheet size (length and/or width) can be provided based on pre-existing elements mounted to a target utility pole.

Figure 3a illustrates an exemplary sheet 360a and pole 300a prior to the sheet being placed against the exterior surface of the pole. As illustrated, sheet 360a can have a length and width substantially equal to that of the respective length and circumference of target utility pole 300a. Figure 3b illustrates an exemplary sheet 360b after the sheet has been placed against the exterior surface of target utility pole 300b. As illustrated, after sheet 360b has been so placed, a substantial portion of the exterior surface of pole 300b can be covered by the sheet.

Applying Adhesive

In an exemplary aspect of the present invention, an adhesive is applied to one or more of the exterior surface of a target utility pole, the inner side of a sheet of carbon fiber, and the outer side of the sheet. Thus, according to the present invention, an adhesive can be applied before, during, and/or after the sheet of carbon fiber is placed against the exterior surface of a target utility pole. Further, application can optionally include plural application steps. For example, and not in limitation, application can be effectuated by the sheet being dipped into a trough filled with adhesive, by spraying, brushing, or pouring the adhesive onto the pole or sheet; or by any physical manner that effectively applies the adhesive onto the pole or sheet. According to an exemplary aspect of the present invention, any type of adhesive (also referred to as "cpoxy") can be utilized. However, optionally, particular adhesives can be utilized based on one or more of the physical characteristics of the adhesive. For example, and not in limitation, exemplary characteristics can include Ultra-Violet Light (or "UV") Resistance, Temperature Resistance, Water Resistance, Non-Conductive, Post-Curing Flexibility and/or Crack-Resistance.

Sheet Placement

According to another exemplary aspect of the present invention, a sheet of carbon fiber can be placed against the exterior surface of a target utility pole. Notably, such placing can include the placement of one or more same, similarly, or differing sized and/or symmetrically or asymmetrically shaped sheets of carbon fiber against the exterior surface of a utility pole. Further, a sheet can be less than, equal to, or greater than the length and/or circumference of a utility pole. Also, a sheet can be placed around a utility pole such that one or more layers of carbon fiber are provided and cover at least a portion of the exterior surface of the pole.

In yet another exemplary aspect of the present invention, a sheet of carbon fiber can be placed against the exterior surface of a utility pole in one or more orientations. For example, and not in limitation, a sheet can be placed around a utility pole at an angle from 0° to 90°, with or without overlapping of the sheet in whole or in part. It should be noted that the recitation of the range of 0° to 90° covers all possible angles of placing, as an angle of application can be measured based on a clockwise or counterclockwise manner. Further, it should be noted that the angle of application can change or remain constant during placing.

Reference is now made to Figure 4a, which illustrates an exemplary placing of an exemplary sheet 460a against a target utility pole 400a, in which placement is at an angle of about 22°. As illustrated, as sheet 460a is placed at an angle in which no overlapping of the sheet occurs. Alternatively, as illustrated by Figure 4b, sheet 460b can be placed at an angle in which overlapping of the sheet does occur as the sheet is "wrapped" around a target utility pole 400b.

Moreover, application can optionally include manually pressing the sheet against the exterior surface, which can assist in removing air within the prc-curcd strengthening layer.

Post-Placement Curing

In still yet another exemplary aspect of the present invention, at some point after the sheet is placed against the exterior surface of the target pole, the adhesive is allowed to cure. Notably, as mentioned above, the adhesive can be applied before, as, and/or after the sheet is placed. This allowance will require a period of time that depends on the particular adhesive utilized, and potentially, environmental factors, such as temperature and humidity levels, for example and not in limitation. Accordingly, the amount of time required will be apparent to one of ordinary skill in the art given the particular adhesive utilized. Upon curing, the adhesive, in combination with the sheet of carbon fiber, will create a strengthening layer that covers at least a portion of the external surface and provides the pole with greater lateral strength. It will be apparent to one of ordinary skill in the art that the manner of making and using the claimed invention has been adequately disclosed in the above-written description of the exemplary embodiments and aspects taken together with the drawings.

It should be understood, however, that the invention is not necessarily limited to the specific embodiments, aspects, arrangement, and components shown and described above, but may be susceptible to numerous variations within the scope of the invention.

Accordingly, the specification and drawings are to be regarded in an illustrative and enabling, rather than a restrictive, sense. Therefore, it will be understood that the above description of the embodiments of the present invention are susceptible to various modifications, changes, and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.