| JP11033472 | REVERSING MACHINE FOR COATING |
| WO/2001/053000 | POWDER COATING ARRANGEMENT AND COATING METHOD |
| JP3199320 | PROCESSING OF WORK |
Ralstin, Curtis G. (Route 2, Box 53 Craigmont, ID, 83523, US)
Holand, Dave (P.O. Box 6460, Bozeman, MT, 59771-6460, US)
| 1. | A method of reinforcing a wooden support comprising: providing a wooden support having a body which extends between a pair of spacedapart ends; forming a resin over the wooden support; and wrapping a reinforcing fabric material around the wooden support in a manner which covers the body and at least one of the ends. |
| 2. | The method of claim 1, wherein the wrapping covers both of the spacedapart ends. |
| 3. | The method of claim 1, wherein the wrapping completely encapsulates the wooden support with the reinforcing fabric material. |
| 4. | The method of claim 1, further comprising after the wrapping of the reinforcing fabric, coating portions of the wooden support which are covered with the fabric material with resin. |
| 5. | The method of claim 2, further comprising after the wrapping of the reinforcing fabric, coating portions of the wooden support which are covered with the fabric material with resin and curing the resin. |
| 6. | The method of claim 1, wherein the wooden support comprises a utility pole. |
| 7. | The method of claim 1, wherein the wooden support comprises a crossarm configured for use with a utility pole. |
| 8. | The method of claim 1, wherein the wooden support comprises a piling configured for use in a marine environment. |
| 9. | The method of claim 1, wherein the wrapping of the reinforcing fabric material comprises providing an integral expanse of fabric material and wrapping the integral expanse of fabric material in a manner which provides only one layer of fabric material around a substantial portion of the wooden support body. |
| 10. | The method of claim 1, wherein the wooden support generally tapers from one end to the other, and the wrapping of the reinforcing fabric material comprises initiating the wrapping at a narrower end. |
| 11. | A method of providing an encapsulated wooden support: providing an elongate wooden support; coating the entire wooden support with a first resin material; applying a reinforcing fabric material over the first resin material; after the applying of the reinforcing fabric material, coating the reinforcing fabric material with a second resin material; and curing the second resin material to encapsulate the wooden support. |
| 12. | The method of claim 11, wherein the applying of the reinforcing fabric material comprises utilizing a single expanse of material which is dimensioned to cover the entirety of the wooden support. |
| 13. | The method of claim 12, wherein the applying comprises spiral wrapping the single expanse along the wooden support. |
| 14. | The method of claim 11, wherein the applying comprises wrapping fabric reinforcing material in discrete units along the wooden support. |
| 15. | The method of claim 11, wherein the coating of the wooden support with the first resin material comprises: rotating the wooden support; and while rotating, spraying the wooden support with the first resin material. |
| 16. | The method of claim 15, wherein the coating of the wooden support with the second resin material comprises: rotating the wooden support; and while rotating, spraying the wooden support with the second resin material. |
| 17. | The method of claim 11, wherein the coating of the wooden support with the first resin material comprises: placing the wooden support in a mechanized rotation device; rotating the wooden support with the mechanized rotation device; and while rotating, spraying the wooden support with the first resin material. |
| 18. | The method of claim 17, wherein the spraying of the wooden support with the first resin material comprises: providing a mechanized spraying unit configured to spray the first resin material; placing the mechanized spraying unit proximate the wooden support; spraying first resin material through the mechanized spraying unit; and moving the mechanized spraying unit longitudinally along the wooden support while spraying the first resin material. |
| 19. | The method of claim 17, wherein the applying of the reinforcing fabric material comprises: rotating the wooden support with the rotation device; and while rotating the wooden support, applying the fabric reinforcing material over the first resin material. |
| 20. | The method of claim 17, wherein the applying of the reinforcing fabric material comprises: rotating the wooden support with the rotation device; and while rotating the wooden support, applying the fabric reinforcing material in discrete units over the first resin material. |
| 21. | A method of treating a wooden pole comprising: providing an elongate wooden pole which extends along a defined axis, the pole having an outer surface; dispensing resin material from a dispenser in a manner which coats the wooden pole; applying a layer of reinforcing material over the wooden pole's entire outer surface; and subjecting the wooden pole to conditions which are effective to harden the reinforcing material. |
| 22. | The method of claim 21 further comprising rotating the wooden pole relative to the defined axis while dispensing the resin material. |
| 23. | The method of claim 22, wherein the wooden pole has a first end and a second end, and the rotating of the pole comprises rotatably supporting at least one of the ends. |
| 24. | The method of claim 23, wherein the rotatably supporting comprises rotatably supporting the first and the second end. |
| 25. | The method of claim 21, wherein the dispensing of the resin material comprises: providing at least one stream of the resin material proximate the wooden pole's outer surface; and moving the at least one stream and the wooden pole's outer surface relative to one another to effect coating of the wooden pole with the resin material. |
| 26. | The method of claim 25, wherein the moving comprises: rotating the pole relative to the defined axis; and moving the dispenser longitudinally along the pole. |
| 27. | The method of claim 21, wherein the applying of the layer of reinforcing material over the wooden pole's outer surface comprises: providing a continuous length of reinforcing material; placing a portion of the continuous length of reinforcing material in a physical contacting relationship with the outer surface; and moving the continuous length of reinforcing material and the outer surface relative to one another to effect application of the reinforcing material. |
| 28. | The method of claim 21, wherein the applying of the layer of reinforcing material over the wooden pole's outer surface comprises: providing a continuous length of reinforcing material; placing a portion of the continuous length of reinforcing material in a physical contacting relationship with the outer surface; rotating the wooden pole to effect application of the reinforcing material to a subportion of the wooden pole's outer surface; moving the continuous length of reinforcing material to a next subportion of the wooden pole's outer surface; placing a portion of the continuous length of reinforcing material in a physical contacting relationship with the next subportion; and rotating the wooden pole to effect application of the reinforcing material to the next subportion of the wooden pole's outer surface. |
| 29. | A method of providing a utility pole comprising: providing an uninstalled utility pole at a location which is remote from a desiredtobeinstalled location; completely encapsulating the uninstalled utility pole with a rigidified coating of resincured material; moving the uninstalled utility pole to the desiredtobeinstalled location; and installing the utility pole at the desiredtobe installed location. |
| 30. | The method of claim 29, wherein the encapsulating of the un installed utility pole comprises forming a single layer of resincured material over a substantial portion of the utility pole. |
| 31. | The method of claim 30, wherein the forming of the single layer of resincured material comprises: spiral wrapping the utility pole with a single expanse of material; forming resin over the single expanse of material; and curing the resin over the single expanse of material to provide the rigidified coating. |
| 32. | A method of reinforcing a utility pole comprising: providing a utility pole rotation device defining a work area in which a utility pole can be processed; providing a resindispensing apparatus; providing a reinforcing material dispensing apparatus; mounting a utility pole on the utility pole rotation device and within the work area; rotating the utility pole with the utility pole rotation device; dispensing resin through the resindispensing apparatus and onto the utility pole; and applying reinforcing material onto the utility pole from the reinforcing material dispensing apparatus. |
| 33. | The method of claim 32, wherein the resindispensing apparatus and the reinforcing material dispensing apparatus comprise different apparatuses. |
| 34. | The method of claim 32, wherein the utility pole has a length, and the applying of the reinforcing material comprises applying the reinforcing material onto a subportion of the utility pole's length. |
| 35. | The method of claim 34 further comprising after the applying of the reinforcing material onto the subportion, moving the reinforcing material dispensing apparatus to a next subportion of the utility pole's length and applying reinforcing material to the next subportion. |
| 36. | A method of reinforcing a utility pole comprising: providing an elongate utility pole having first and second ends and a long axis which extends between the ends; providing a lathe apparatus having first and second support members for rotatably supporting a utility pole; the first and second support members defining a work area therebetween in which the utility pole can be supported by the first and second support members; providing a resindispensing apparatus operably proximate the lathe apparatus; the resindispensing apparatus being configured for reciprocation through the work area; providing a reinforcing material dispensing apparatus operably proximate the lathe apparatus; the reinforcing material dispensing apparatus being configured for reciprocation through the work area; mounting the utility pole on the lathe apparatus, the utility pole first end being supported by the first support member and the utility pole second end being supported by the second support member; spinning the utility pole generally about the long axis; dispensing resin through the resindispensing apparatus while spinning the utility pole with the lathe apparatus; moving the resindispensing apparatus through the work area; applying reinforcing material which is held by the reinforcing material dispensing apparatus to the utility pole; moving the reinforcing material dispensing apparatus through the work area; and exposing the utility pole to conditions which are effect to harden the reinforcing material and resin. |
| 37. | The method of claim 36 further comprising after the moving of the reinforcing material dispensing apparatus through the work area: dispensing resin through the resindispensing apparatus while spinning the utility pole with the lathe apparatus; and moving the resindispensing apparatus through the work area. |
| 38. | The method of claim 36, wherein the utility pole tapers from the second end to the first end; and the applying of the reinforcing material comprises initially applying the reinforcing material on the first end; and the moving of the reinforcing material dispensing apparatus comprises moving the apparatus through the work area toward the second end. |
| 39. | The method of claim 38, wherein the initial applying of the reinforcing material extends the reinforcing material past the first end in a direction away therefrom. |
| 40. | The method of claim 38, wherein the applying of the reinforcing material extends the reinforcing material past the second end in a direction away therefrom. |
| 41. | The method of claim 38, wherein: the reinforcing material comprises an integral sheet of reinforcing material; the initial applying of the reinforcing material extends the reinforcing material past the first end in a direction away from the second end; the applying of the reinforcing material extends the reinforcing material past the second end in a direction away from the first end, and further comprising: after the moving of the reinforcing material dispensing apparatus through the work area and prior to the exposing of the utility pole: dispensing resin through the resindispensing apparatus while spinning the utility pole with the lathe apparatus; and moving the resindispensing apparatus through the work area. |
| 42. | The method of claim 36, wherein the utility pole tapers from the second end to the first end; and the applying of the reinforcing material comprises initially applying the reinforcing material on the second end; and the moving of the reinforcing material dispensing apparatus comprises moving the apparatus through the work area toward the first end. |
| 43. | The method of claim 42, wherein the utility pole comprises a length which extends between the first and second ends, and the applying of the reinforcing material comprises applying discrete units of reinforcing material over subportions of the utility pole's length. |
| 44. | A reinforced wooden support comprising: a first end; a second end; an elongate body which extends between and joins with the first and second ends; and a rigidified expanse of fabric reinforcing material disposed over the elongate body and the first and second ends, the material generally encapsulating the wooden support. |
| 45. | The reinforced wooden support of claim ?, wherein the rigidified expanse of fabric reinforcing material is spirally disposed about the wooden support. |
| 46. | The reinforced wooden support of claim 45, wherein the rigidified expanse of fabric reinforcing material comprises a single layer of reinforcing material disposed over a substantial portion of the elongate body. |
| 47. | The reinforced wooden support of claim 44, wherein the rigidified expanse of fabric reinforcing material is dispensed in discrete subunits about the wooden support. |
| 48. | The reinforced wooden support of claim 44, wherein the fabric reinforcing material comprises a single layer of reinforcing material which is disposed over a substantial portion of the elongate body. |
| 49. | The reinforced wooden support of claim 44, wherein the wooden support comprises a utility pole. |
| 50. | A reinforced wooden support comprising: a first end; a second end; an elongate body which extends between and joins with the first and second ends; and a single, resincured, rigidified expanse of reinforcing material disposed over and defining a single layer of material over a substantial portion of the elongate body and the first and second ends in a manner which completely encapsulates the wooden support. |
| 51. | The reinforced wooden support of claim 50, wherein the wooden support comprises a utility pole. |
| 52. | The reinforced wooden support of claim 50, wherein the wooden support comprises a cross arm configured for use with a utility pole. |
| 53. | The reinforced wooden support of claim 50, wherein the expanse is fireresistant. |
| 54. | The reinforced wooden support of claim 50, wherein the expanse is UVresistant. |
| 55. | A utility pole processing system comprising: a rotation device defining a work area; the work area being dimensioned to accommodate an elongate utility pole; the device having features for rotatably supporting a utility pole which is received within the work area; a resindispensing apparatus mounted operably adjacent the work area and configured for dispensing resin within the work area and over a utility pole provided therewithin; and a reinforcing material dispensing apparatus mounted operably adjacent the work area and configured to dispense reinforcing material over a utility pole received within the work area. |
| 56. | The utility pole processing system of claim 55, wherein the rotation device comprises a lathe. |
| 57. | The utility pole processing system of claim 55, wherein the resin dispensing apparatus is configured for movement through the work area. |
| 58. | The utility pole processing system of claim 55, wherein the resin dispensing apparatus is configured for movement through the work area in a direction generally parallel with a utility pole long axis. |
| 59. | The utility pole processing system of claim 55, wherein the reinforcing material dispensing apparatus is configured for movement through the work area in a direction generally parallel with a utility pole long axis. |
| 60. | The utility pole processing system of claim 55, wherein the reinforcing material dispensing apparatus is configured to dispense a single, integral expanse of reinforcing material which is dimensioned to encapsulate a utility pole. |
| 61. | The utility pole processing system of claim 55, wherein the reinforcing material dispensing apparatus is configured to dispense a plurality of discrete reinforcing material units in a manner which encapsulates a utility pole. |
| 62. | A utility pole processing system comprising: a lathe apparatus having first and second support members for rotatably supporting a utility pole, the support members defining a work area therebetween in which a utility pole can be rotatably supported by the first and second support members; a resindispensing apparatus mounted operably adjacent the lathe apparatus; the reinsdispensing apparatus being configured for reciprocation through the work area; and a reinforcing material dispensing apparatus mounted operably adjacent the lathe apparatus; the reinforcing material dispensing apparatus being configured for reciprocation through the work area. |
| 63. | The utility pole processing system of claim 62, wherein at least one of the first and second support members is adjustable for varying the dimensions of the work area. |
| 64. | The utility pole processing system of claim 62, wherein the resin dispensing apparatus is configured to make a resindispensing pass through the work area, and the reinforcing material dispensing apparatus is configured to make a materialdispensing pass through the work area after the resindispensing pass. |
| 65. | The utility pole processing system of claim 64, wherein the resin dispensing pass through the work area constitutes a first resindispensing pass, and further, the resindispensing apparatus being configured to make a second resindispensing pass through the work area after the materialdispensing pass. |
| 66. | The utility pole processing system of claim 64, wherein the reinforcing material dispensing apparatus is configured to dispense reinforcing material in discrete subunits. |
| 67. | The utility pole processing system of claim 64, wherein the reinforcing material dispensing apparatus is configured to dispense reinforcing material in an integral expanse which is dimensioned to cover an entirety of a utility pole supported in the work area. |
Background Art Wooden supports such as utility poles are often treated with preservative materials before being placed in the ground. Such preservative materials or chemicals are useful in preventing decay which is associated with the abuses such poles are subjected to in the operating environment. Ground rot decay, ultra violet light damage, fire damage, insect damage, and animal damage (such as woodpecker damage) are just a few of the abuses to which such poles are subjected.
Referring to Fig. 1, and depicted generally at 10 are two utility poles 12, 14. Poles 12, 14 are shown installed in the ground and include respective portions 16, 18 which are installed below a ground line G. Each pole 12, 14 includes a respective exemplary cross arm 20, 22, and each cross arm supports a plurality of wires 24 which extend between and are supported by poles 12, 14. Utility poles typically have a wide variety of shapes and sizes.
Utility poles such as exemplary poles 12, 14, by virtue of their being mounted outside are subjected to many abuses which can significantly degrade the quality of the utility pole over an extended period of time. Wind, rain, and naturally occurring weather phenomena can significantly impact the lifetime of a particular utility pole. In addition, damage can be caused by fire, insects, or animals which necessitate in-field reparations. Woodpeckers, as mentioned above, can have a very significant impact on the life of a utility pole. For these reasons, protecting wooden supports such as utility poles is important if the lifetimes of such supports are not to be shortened.
A number of prior patents have addressed some problems associated with repairing portions of utility poles while such poles are in place in the field.
Reference is made to the following patents which disclose various schemes for
treating portions of a pole or wooden support: U.S. Patent No. 1,981,664 to Quarles; U.S. Patent No. 2,109,508 to Schmittutz; U.S. Patent No. 3,139,731 to Liddell; U.S. Patent No. 3,448,585 to Vogelsang; U.S. Patent No. 3,562,403 to Monahan; U.S. Patent No. 4,713,129 to Inhofe, Jr. et al.; U.S.
Patent No. 4,799,340 to Lichau et al.; U.S. Patent No. 5,138,806 to Marx et al.; and U.S. Patent No. 5,516,236 to Williams et al. These references are lacking in one respect in that less than the entire pole is treated thereby leaving exposed pole portions subjected to the abuses mentioned above.
Some of these and other references contemplate repairing and reinforcing utility poles by removing the ground material from around a damaged area of a utility pole (as in the case of ground rot) which has already been installed and in place for quite some time. This approach requires a repair crew to seek out damaged poles, excavate the area around the poles, and then administer the appropriate remedial treatment to the damaged area. Needless to say, this is quite time consuming and expensive. Additionally, it may not be readily apparent which poles require below-the-surface reparations. Hence, selection of the work pieces in need of repair is necessarily complicated. Moreover, less than the entire pole or support is treated which still leaves untreated portions exposed to the above-described abuses.
Other references contemplate reparation of utility pole portions which reside or are disposed above the ground line. Such methods can be difficult and are often very expensive to implement. For example, repair crews must actively seek out utility poles which may be in hard-to-access or remote areas in order to effectuate the appropriate repair. In addition, the portion of a pole to be repaired may be disposed far above the ground such that a crew must either utilize special machinery in order to elevate themselves to the repair area, or climb up the pole individually in order to access the area in need of repair.
With remotely located, or hard-to-access poles, repair can be very difficult to say the least.
Yet, utility companies and repair crews must often go to the added effort and expense of fixing such poles, for the alternative is even more costly, i.e., power outages caused by weakened or degraded poles collapsing and breaking the utility lines.
Other methods are disclosed which, while addressing some problems, leave others unaddressed or, in fact, create more problems. One such method is disclosed in U.S. Patent No. 5,326,410 to Boyles which discloses a complicated
treatment scheme which results in numerous layers of material being formed over a utility pole. Such contemplates several layers of resin impregnated fiberglass which are applied to a damaged area of a utility pole. Such methods are difficult to implement in the field because several different layers must be alternatively wrapped around a damaged area of the pole. Such is further complicated by the fact that the damaged area may be below the ground.
Moreover, less than the entirety of the pole is treated thereby leaving exposed pole portions subject to the abuses mentioned above.
This invention arose out of concerns associated with providing wooden support products, such as utility poles, which are reinforced in a manner which substantially extends their useful lifetime. This invention also arose out of concerns associated with providing methods of reinforcing wooden supports and apparatuses to facilitate the reinforcement of wooden supports to extend the useful lifetimes thereof.
Brief Description of the Drawings Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
Fig. 1 shows a pair of utility poles installed in the ground in an outside location.
Fig. 2 is a flow diagram which illustrates some methodical steps of the present invention.
Fig. 3 shows a processing system which is constructed in accordance with one aspect of the present invention.
Fig. 4 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 3 processing step.
Fig. 5 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 4 processing step.
Fig. 6 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 5 processing step.
Fig. 7 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 6 processing step.
Fig. 8 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 7 processing step.
Fig. 9 shows the Fig. 3 processing system at a processing step which is subsequent to the Fig. 8 processing step.
Fig. 10 show a processing system which is constructed in accordance with another aspect of the present invention.
Fig. 11 shows the Fig. 10 processing system at a processing step which is subsequent to the Fig. 10 processing step.
Fig. 12 shows the Fig. 10 processing system at a processing step which is subsequent to the Fig. 11 processing step.
Fig. 13 shows the Fig. 10 processing system at a processing step which is subsequent to the Fig. 12 processing step.
Fig. 14 shows a wooden support in the form of a utility pole which has been processed in accordance with methodical aspects of the present invention.
Fig. 15 is a view which is taken along line 15-15 in Fig. 14.
Fig. 16 is a view which is taken along line 16-16 in Fig. 14.
Fig. 17 is a view which is taken along line 17-17 in Fig. 1.
Best Modes for Carving Out the Invention and Disclosure of Invention Referring to Fig. 2, certain methodical aspects of the present invention are set forth in a flow diagram generally at 26. The methodical aspects of the invention enable treatment of a wooden support in a manner which provides a fortified support construction which is able to withstand operating environment abuses which are mentioned above. As used in this document, the term "wooden support" will be understood to include constructions which may or may not be entirely constructed of wood. Such constructions are ordinarily used in the operating environment to provide a support function relative to some other structure which may or may not itself comprise wood. It will be understood, however, the such is not necessarily required. Accordingly, a "wooden support" as such term is contemplated in this document may comprise a "stand alone" structure. Such will become more readily apparent below.
A wooden support is provided in accordance with step 28. The wooden support, as mentioned above, can be any suitable wooden support which is desired to be reinforced. In accordance with a preferred aspect of the invention, the wooden support constitutes a pole having first and second ends and a body which extends therebetween. Exemplary poles include utility poles and/or marine pilings which are suitable for use in marine environments. Also contemplated are wooden supports which include railroad ties and cross arms which are configured for use with utility poles.
In accordance with step 30, resin is formed over the wooden support.
Any suitable method or means can be used to form the resin over the wooden
support. Exemplary methods can include mechanized or mechanical methods, electromechanical, computer-controlled, computer-monitored, or manual application.
Preferably, such resin constitutes a first resin which is formed over the entirety of the wooden support, including the first and second ends thereof. Hence, the wooden support is completely covered with the first resin.
At step 32, reinforcing fabric material, e.g., fiberglass, is formed over the wooden support. A suitable material is a product called VectorPly-E-LTMP 1808 which is available through a company called Johnson Industries. Other products can, of course, be used. In accordance with a preferred aspect of the invention, the reinforcing fabric material is wrapped or otherwise provided over the entirety of the wooden support (including over the first and second ends). Accordingly, such reinforcing fabric material is preferably wrapped around the wooden support in a manner which covers the body of the wooden support and at least one of, and preferably both of the ends of the utility pole. In this manner, the utility pole is substantially, if not completely encapsulated with a single layer of reinforcing fabric material. Any suitable method or means can be employed to wrap or otherwise cover the pole with reinforcing fabric. To that end, mechanized or mechanical, electromechanical, computer-controlled, computer- monitored, or manual means can be used, to name just a few.
At step 34, and after the reinforcing fabric material has been suitably formed or otherwise wrapped over the wooden support, a second resin is formed over the reinforcing fabric material to provide a coating of resin thereover.
Such resin can be treated or have additives which provide fire resistant or UV resistant characteristics to the resin.
At step 36, a curing step is undertaken in order to facilitate hardening of the reinforcing fabric material and resin formed thereover. According to one aspect of the invention, the resin and fabric material are selected to achieve a rigidified, hardened outer coating over the body of the wooden support. By providing an encapsulated wooden support, the entirety of the pole, and not just a portion thereof, is protected from the environment. According to another aspect of the invention, as will become apparent below, the resin and fabric material are selected to provide an end product which is generally not meaningfully heavier than an untreated wooden support. The advantages of such, as are discussed below, include that the end product can be more easily transported. Moreover, in accordance with another aspect of the invention, and in the context of wooden support which comprises a utility pole, resin and
reinforcing material are selected to provide a pole which has desirable climb- ability features, i.e., it can be easily climbed for servicing and the like. Suitable resins and reinforcing fabric material which are sufficient to meet these and other objectives will be understood by those of skill in the art.
In accordance with a preferred implementation, and as will become apparent below, the reinforcing fabric material constitutes a single integral expanse of fabric material which, when cured in connection with the first and second resins, forms a single, rigidified, resin-cured expanse of reinforcing material which is disposed over, and defines a single layer of material over a substantial portion of the wooden support's body. In accordance with another implementation, the reinforcing fabric material constitutes a single layer of rigidified coating. Such provides only one layer of fabric material around a substantial portion of the wooden support body. By "substantial portion" is meant that at least a major portion of the outer surface area is covered with only one layer. It will be appreciated that there may be some overlap between portions of the fabric material as will be discussed below. However, such overlap is not meaningful insofar as occupying a fairly insubstantial area of the pole body.
First Processing System Embodiment Referring to Figs. 3-9, an exemplary and preferred first processing system or apparatus for effectuating the reinforcement of a wooden support is set forth generally at 38. It will be appreciated that such system or apparatus provides but one preferred, generally mechanized approach for implementing or providing a preferred encapsulated utility pole. Other methods, including manual methods can be used.
Apparatus 38 includes a work area 40 within which a work piece, such as a utility pole, can be received and supported for processing in accordance with the invention. A rotation device 42 is provided and defines work area 40.
The work area is preferably dimensioned to receive and support an elongate utility pole. Preferably, features are included on the rotation device which rotatably support a utility pole which is received within the work area. In a preferred implementation, rotation device 42 comprises a lathe apparatus which is defined by a first support member 44 and a second support member 46.
First and second support members 44, 46 rotatably support a work piece, preferably a utility pole, which is to be installed within work area 40.
Accordingly, work area 40 is defined between first and second support members 44, 46.
In accordance with one aspect of the invention, first support member 44 is, or can be selectively repositioned in the direction of the arrows shown thereapproximate, to effectively lengthen or shorten work area 40 between first and second support members 44, 46. Such is desirable, in some instances, to accommodate differently-dimensioned work pieces such as utility poles having varying lengths. Accordingly, a variably-adjustable work area is provided.
A pair of work piece engagement members 48, 50 are separately and respectively provided relative to first and second support members 44, 46. Such engagement members enable a work piece, such as a utility pole, to be engaged, and for rotational movement to be imparted thereto as will become apparent below. Engagement members 48, 50 can be any suitable engagement members which are able to be fixed onto, into or otherwise operationally engage a work piece and thereafter rotatably support the same.
In another aspect, apparatus 38 includes a resin-dispensing apparatus 51 which is preferably mounted operably adjacent or proximate work area 40 and is configured for dispensing resin within the work area and over a wooden support received therein. An exemplary resin-dispensing apparatus is a "Venus- Gusmer" brand Saturator Unit. Other apparatuses can, of course, be used.
Resin-dispensing apparatus 51, in a preferred aspect, includes a reservoir 52 of resin and a dispensing nozzle 54. Resin from reservoir 52 is preferably dispensed, under pressure, to provide at least one stream of resin material through dispensing nozzle 54, in a spray-like fashion, over a work piece which is mounted or contained within work area 40. Resin-dispensing apparatus 51 can be any suitable mechanized apparatus which is capable of performing as described above and below. In a preferred aspect of the invention, resin-dispensing apparatus 51 is movable relative to work area 40. In one implementation, resin- dispensing apparatus is mounted for reciprocation through work area 40 in a direction which is generally parallel to a long axis of an elongate utility pole which is received within the work area as will become apparent below. Such can be effectuated or implemented in one aspect by a suitable track 56 upon which resin-dispensing apparatus 51 is movably mounted. Other mounting schemes and movement regimes are possible to move the resin-dispensing apparatus through or within the work area.
Referring to Fig. 4, a work piece in the form of an elongate utility pole 58 is provided. Utility pole 58 is provided for exemplary purposes only.
Of course, other work pieces or wooden supports can be used. The exemplary utility pole 58 includes a first end 60, a second end 62, an outer surface 63, and a defined or long axis 64 which extends between ends 60, 62. In one aspect of the invention, wooden support or utility pole 58 generally tapers from one end to the other. In the illustrated example, second end 62 constitutes a wider end of pole 58, and first end 60 constitutes a narrower end of pole 58.
Accordingly, pole 58 tapers from second end 62 to first end 60.
Pole 58 is suitably mounted on rotation device 42 within work area 40, with first end 60 being supported by the preferred lathe's first support member 44, and second end 62 being supported by second support member 46.
The mounting of pole 58 in the work area can be manually performed or mechanically performed. Because mass processing of utility poles is contemplated by the present implementation, a somewhat continuous feed stream of poles (not shown) can be provided to ensure efficient, quick, and sequential processing of the poles. Thereafter, and with a utility pole fixedly mounted relative to the support members, rotational movement is imparted to the utility pole to spin, rotate, or otherwise cause the pole to revolve about the long axis 64.
Accordingly, rotation device 42 constitutes a mechanized rotation device into which utility pole 58 is placed and subsequently rotated.
Referring to Fig. 5, and in accordance with one aspect of the invention, while utility pole 58 is being rotated, resin-dispensing apparatus 51 is utilized to spray at least one stream of resin which coats the entire utility pole with a first resin material 66. In the illustrated example, the coating of the utility pole is effectuated by rotating the utility pole as shown, and spraying the first resin through resin-dispensing apparatus 51. It is possible, however, for utility pole 58 to be coated by rotating the source or stream of resin relative to the pole. In this manner, outer surface 63 is provided with a resin material which originates from at least one stream which is disposed proximate the outer surface. As shown, resin-dispensing apparatus 51 and the stream of resin provided thereby are moved. A preferred movement is longitudinally along pole 58 in a manner which effects coating of the entire pole. Accordingly, the resin-dispensing apparatus makes a first resin-dispensing pass through the work area. Other movements are, of course, possible.
Alternately considered, resin-dispensing apparatus 51 constitutes a mechanized spraying unit which is configured to spray the first resin material.
The mechanized spraying unit is placed proximate a wooden support which, in accordance with this example constitutes utility pole 58. First resin material is next sprayed through the mechanized spraying unit which is repositioned or moved longitudinally along the wooden support or pole while the first resin material is sprayed therethrough. Preferably, the wooden support is rotated while the first resin is sprayed.
Referring to Fig. 6, spraying or application of the first resin material is completed as resin-dispensing apparatus 51 has moved along track 56 to a position which is away from second end 62 of pole 58. In accordance with another preferred aspect of the invention, system 38 includes a mechanized, reinforcing fabric material-holding device or dispensing apparatus 68. Such is preferably provided operably proximate rotation device 42 as shown. In one aspect, the reinforcing material-holding device or apparatus is movable. In the illustrated example, dispensing apparatus 68 is mounted on track 56 and is configured for reciprocation or movement through work area 40 in a direction which is generally parallel with long axis 64 of utility pole 58. Such can, however, be separately mounted by other means. As shown, apparatus 68 is placed or positioned proximate utility pole 58.
Apparatus 68 preferably holds a supply of reinforcing material 70 which is next applied to the utility pole. In accordance with this aspect of the invention, reinforcing material 70 comprises a single length or integral sheet of material. Such preferably has a length and a width which is sufficient to accommodate spiral wrapping of the material along pole 58. More particularly, dispensing apparatus 68 comprises a continuous length of reinforcing material 70 which is resident thereon in the form of a spooled supply of reinforcing material. Reinforcing material 70 includes a leading edge 72 which is preferably placed in physical contacting relationship with outer surface 63 of utility pole 58 while the pole is being rotated by rotation device 42. The first resin is preferably, by this time, tacky or sticky enough to enable the leading edge of material 70 to stick thereupon. Other fastening means can be employed to fasten the leading edge of the material onto the pole. In a preferred aspect of the invention, leading edge 72 is placed proximate first end 60 in a manner which allows an overlap of reinforcing material 70 in a direction away from first end 60. Such overlap is, in accordance with a preferred aspect of the invention,
advantageous from a standpoint of providing excess material which can be folded over onto itself and end 60, and thereafter processed or fastened for encapsulating the top end of pole 58. A sufficient amount of material should be provided for the overlap, and 6"-12" of material has been found to be suitable. As will become apparent, the second end 62 is or can be similarly processed. Alternatively, suitable end caps can be provided over the ends of the utility pole in advance of the processing described just above. In this way, providing the overlapped or overextended reinforcing material can be avoided.
The reinforcing material dispensing apparatus is, at this point, ready for a material-dispensing pass through the work area.
Referring to Fig. 7, and with pole 58 being rotated by rotation device 42, dispensing apparatus 68 is moved longitudinally along pole 58 and through work area 40 thereby relocating itself and moving reinforcing material 70 therealong.
In accordance with one aspect of the invention, reinforcing material 70 and pole outer surface 63 are moved relative to one another to effectuate the application of the reinforcing material thereover. Other dispensing and/or application regimes are possible as will be described below in connection with Fig. 10-13.
Dispensing apparatus 68 is advanced in its material-dispensing pass, longitudinally along pole 58 in a manner which effectuates a spiral wrapping of reinforcing material 70 over the outer surface of the pole. As can be seen adjacent first end 60 of utility pole 58, leading edge 72 may be seen to define at least in part, the overlapping portion which extends away therefrom. It will be appreciated that the reinforcing material can be, and preferably is provided over the outer surface of pole 58 in a manner which provides a single layer of reinforcing material over at least a substantial portion of the outer surface. As mentioned above, there can be some overlap between adjacent spiral wraps.
However, in the preferred embodiment, such overlap is preferably reduced by ensuring that each successive winding is, to the extent possible, placed into registered alignment with the next adjacent winding. In this manner, a single, integral expanse of reinforcing material is provided and dimensioned to encapsulate the utility pole. The illustrated application of material 70 to pole 58 includes an initial application step which places the leading edge of material 70 proximate first end 60, and moves dispensing apparatus 68 away therefrom.
Referring to Figs. 8 and 9, dispensing apparatus 68 has been moved to a position which is away from second end 62 of utility pole 58 (and out of the
Fig. 8 view). Accordingly, such leaves, in the illustrated and preferred example, an overlap of reinforcing material 70 which extends away from second end 62.
Such overlap is defined in part by a trailing edge 74 which is disposed away from both ends. Accordingly, such constitutes moving dispensing apparatus 68 (Fig. 7) through work area 40. Both of the overlaps of material 70, as was mentioned above, enable the material to be later fastened into place over the respective end adjacent which each is disposed. Such provides for an encapsulated end product as will become apparent below. A suitable amount of material for the overlaps is between 6"-12".
In accordance with another aspect of the invention, resin-dispensing apparatus 51 is again moved through work area 40, on a second resin-dispensing pass after the above-described material-dispensing pass. Preferably, such is accomplished while pole 58 is being rotated or otherwise spun by rotation device 42. Accordingly, a second resin 67 is dispensed thereby which substantially, if not completely coats or covers reinforcing material 70 thereby impregnating the same.
Referring to Fig. 9, resin-dispensing apparatus 51 has been moved on its second resin-dispensing pass entirely through work area 40 in a manner which is sufficient to ensure that the entire surface of reinforcing material 70 is coated with a suitable amount of second resin material. In accordance with one aspect of the invention, the first resin material and second resin material constitute the same resin. Different resin materials can, of course, be used.
After the resin material and reinforcing fabric material have been suitably provided over the pole as described above, the pole is subjected or exposed to conditions which are effective to harden or cure the reinforcing material and resin. In one aspect of the invention, the cured fabric reinforcing material and resin provide a substantially hardened and rigidified single layer of material over the entirety of the pole. Of course, there may be some overlap between adjacent swaths of reinforcing material, but for the most part, a single layer is provided. Accordingly, pole 58 is, in accordance with this aspect of the invention, completely encapsulated with the resin and a single, integral length of reinforcing fabric material.
Second Processing System Embodiment Referring to Fig. 10, an alternate preferred embodiment of processing system 38 is shown. Like numbers from the first-described embodiment are utilized where appropriate.
In accordance with this aspect of the invention, reinforcing material is applied or otherwise formed over sub-portions of the utility pole's outer surface.
In a preferred implementation, the reinforcing material dispensing apparatus is configured to dispense a plurality of discrete reinforcing material units or sub- units in a manner which encapsulates the utility pole. Accordingly, resin- dispensing apparatus 51 is provided and makes a first resin-dispensing pass over the utility pole. Preferably, as in the first-described embodiment, the utility pole is rotated under the influence of rotation device 42 during the resin-dispensing pass. The illustrated resin-dispensing pass starts or initiates at or adjacent second end 62 and progresses toward first end 60.
Referring to Fig. 11 and after completion of the resin-dispensing pass, reinforcing material dispensing apparatus 68 is moved to a first position adjacent end 62 of pole 58. Reinforcing material is initially applied proximate second end 62. Accordingly, a first length of material 70 is provided over the pole's outer surface. In one implementation, an overlap of material 70 is provided which allows for subsequent encapsulation processing in accordance with the above discussion.
Referring to Fig. 12, a discrete unit or sub-unit 76 of reinforcing material 70 is shown disposed over the utility pole's outer surface, and more particularly a sub-portion thereof. A plurality of such discrete units or sub-units are dispensed and formed over the outer surface of the illustrated utility pole.
After one sub-unit of reinforcing material is wrapped or otherwise formed over the utility pole, the dispensing apparatus 68 moves or advances to a next adjacent sub-portion of the utility and dispenses another unit of reinforcing material. The illustrated reinforcing material dispensing apparatus 68 is shown advancing from an initial position proximate second end 62 toward first end 60.
Accordingly, the illustrated dispensing apparatus progresses from the thicker of the utility pole ends to the thinner of the utility pole ends.
During the above-described application of the discrete units of reinforcing material, pole 58 is rotated in accordance with the description of the first- described system. Such rotation can be continuous throughout the application of the discrete units, or, such rotation can be intermittent in a manner which rotates during application of the sub-unit, stops during the advancement of the dispensing apparatus, and then rotates again during application of the next adjacent sub-unit.
It will be appreciated that the above-described application of reinforcing material is preferably sufficient to provide enough reinforcing material so that the entire utility pole, including both ends 60, 62, are completely covered in a manner which encapsulates the utility pole. In a preferred aspect the utility pole is encapsulated with a single layer of reinforcing material disposed over a substantial portion of the utility pole's outer surface. Of course, there may be some overlap as between adjacent sub-units of reinforcing material and the reinforcing material which is disposed over the ends of the utility pole.
Referring to Fig. 13, and after discrete sub-units 76 have been applied over the utility pole, resin-dispensing apparatus 51 makes a second resin- dispensing pass along the utility pole and through work area 40. Accordingly, such dispenses resin over the reinforcing material which was previously applied.
In the illustrated example, the resin-dispensing apparatus begins its second pass adjacent end 60 and moves longitudinally along the pole in a direction away from the first end. It is to be understood that, as with the first-described embodiment, any suitable method by which the resin is provided over the utility pole can be used. The above is intended only to illustrate one preferred embodiment.
Referring to Fig. 14, a utility pole 58 is shown which has been processed in accordance with the first-described system. Accordingly, a reinforced utility pole is provided with a rigidified expanse of fabric reinforcing material which, in accordance with one aspect of the invention, substantially, if not completely encapsulates or coats the pole body. In accordance with one aspect of the invention, a single layer of reinforcing material is provided over a substantial portion of the utility pole. In one implementation, the single layer is defined by an integral expanse of reinforcing material which is spirally disposed around the body of the pole. In another implementation, the single layer is defined by a plurality of discrete sub-units of the reinforcing material.
Referring to Fig. 15, an end view of pole 58 is shown. End 60 of pole 58 is encapsulated with the reinforcing material 70. Such material, in one implementation is provided by a portion of reinforcing material 70 which overlaps first end 60 as described above. Subsequent processing before cure can include a folding step in which the overlapping portions are folded over onto themselves and suitably fastened into place as by staples and the like. Upon curing the resin material, a rigidified and generally encapsulated end results. As shown, the utility pole has a generally circular cross-section.
Referring to Fig. 16, a view along line 16-16 in Fig. 14 is shown. There, outer surface 63 of pole 58 can be seen to be covered with first resin 66, reinforcing fabric material 70, and second resin 67.
Referring to Fig. 17, a sectional view of a cross arm having a generally non-circular transverse cross section is shown. Such is preferably configured for use with a utility pole such as the one described immediately above. The cross arm has been treated in accordance with one aspect of the invention and, accordingly, is encapsulated with fabric reinforcing material 70. Such provides protection against the abuses in the operating environment mentioned above.
One particular advantage of the present invention, as such pertains to the above- described utility poles and cross arms, is that the reinforcing material can be, and preferably is electrically non-conductive. Hence, the treated utility poles and cross arms are suitably electrically insulated. This becomes important in the context of a utility line which may become separated from its supportive insulator and grounded against a cross arm of the pole or the pole itself. Previously, with untreated poles, a fire would most often result and burn either or both of the cross arm and the utility pole. Accordingly, such would require in-field repair by a line crew which, in turn, presents problems itself which are discussed above. One aspect of the present invention is that the cross arm is electrically insulated by the reinforcing material. In addition, the entire pole can be treated to provide an electrically insulated pole and cross arm. Accordingly, the risk of fire damage from a broken line is greatly reduced if not eliminated. As should be apparent, the risk of fire damage from other sources is reduced as well.
It will be appreciated that the cross arm can be processed utilizing either of the above-described processing systems, or other processing systems including manually performed processing systems in order to provide the finished rigidified, fiber-reinforced cross arm.
Industrial Applicabilitv In accordance with one aspect of the invention, a method of providing a reinforced wooden support or utility pole enables the pole to be reinforced at a location which is remote from a location where the pole is desired to be installed. In this manner, a plurality of wooden supports or utility poles can be pre-processed, at one time, prior to installation to expedite the provision of a supply of reinforced, rigidified and encapsulated utility poles. Accordingly, un- installed utility poles are provided, processed, and completely encapsulated in accordance with the methods and procedures described above. The un-installed
utility poles can then be moved to a location in which such are desired to be installed. Subsequently, the utility poles can be installed into the ground at the desired location. The substantially single layer of rigidified coating material results in a final product which is not meaningfully heavier than an untreated utility pole. Such facilitates transportation of the utility poles by conventional means. This represents an improvement over prior processing techniques for a number of different reasons. First, the entire pole can be treated and effectively encapsulated before installation into the ground. This results in a fortified construction which resists all of the previously-mentioned abuses in the operating environment. Additionally, by having only one layer of reinforcing material, the utility pole is not meaningfully heavier than those poles which are untreated.
Therefore, transportation and installation into field locations is not hampered.
Moreover, because the entire pole, including the ends thereof are treated as described above, the entire pole is resistant to the abuses commonly encountered in the operating environment. Furthermore, the single layer of reinforcing material provides a substrate which accommodates climbing by a linesman when necessary. For example, linesmen typically wear spiked climbing gear attached to their shoes to facilitate climbing a pole. A single layer of rigidified material is thin enough to allow penetration by a linesman's spikes, yet thick enough to afford protection relative to the above-discussed abuses. Additionally, the reinforcing material can be selected to provide a suitable degree of friction relative to the utility pole and a lineman's climbing gear. For example, a lineman can ascend and descend a utility pole using a belt which loops around the pole such that the pole is disposed between the belt loop and the linesman.
Textured reinforcing material can facilitate and enhance the engagement between the belt and the pole thereby assisting the linesman in climbing the pole.
Moreover, reinforcing material can be provided with ridges which are disposed around the diameter of the pole and longitudinally therealong in a manner which provides a ledge-like system of belt-engaging structures which assists in temporarily engaging a lineman's belt during climbing or servicing of a pole.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
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