US20180223556A1 - Modular pole sections using pole splice - Google Patents
Modular pole sections using pole splice Download PDFInfo
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- US20180223556A1 US20180223556A1 US15/887,738 US201815887738A US2018223556A1 US 20180223556 A1 US20180223556 A1 US 20180223556A1 US 201815887738 A US201815887738 A US 201815887738A US 2018223556 A1 US2018223556 A1 US 2018223556A1
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- 230000008878 coupling Effects 0.000 claims description 5
- 238000010168 coupling process Methods 0.000 claims description 5
- 238000005859 coupling reaction Methods 0.000 claims description 5
- 239000002184 metal Substances 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910000831 Steel Inorganic materials 0.000 description 6
- 230000008569 process Effects 0.000 description 6
- 239000010959 steel Substances 0.000 description 6
- 238000013461 design Methods 0.000 description 4
- 238000009434 installation Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000007246 mechanism Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012856 packing Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 238000004873 anchoring Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000000116 mitigating effect Effects 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 230000011664 signaling Effects 0.000 description 1
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H12/34—Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
- E04H12/342—Arrangements for stacking tower sections on top of each other
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04H—BUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
- E04H12/00—Towers; Masts or poles; Chimney stacks; Water-towers; Methods of erecting such structures
- E04H12/02—Structures made of specified materials
- E04H12/08—Structures made of specified materials of metal
Definitions
- the present application relates to utility poles, and more particularly to lighting poles constructed using modular pole segments.
- poles are used to support elevated lighting, of various thickness and contour.
- relatively thin poles e.g., 4 inches wide
- wide poles e.g., several feet across
- relatively short poles e.g., 99 inches tall, including the light
- tall poles e.g., 20 to 40 or more feet tall.
- Straight lighting poles are typically made of metal that has been rolled into a cylindrical, conical or pyramidal shape.
- lighting poles with curved contours Lighting poles can serve a decorative purpose in addition to their lighting function.
- FIG. 1 shows an example of a straight lighting pole 100 .
- a lighting fixture 102 is attached to a unitary pole shaft 104 using a tenon top.
- a luminaire is mounted on the light fixture.
- FIG. 2 shows an example of a utility pole 200 (a power line-supporting pole) with a modular design.
- an example modular utility pole comprises conical or pyramidal sections 202 , tapering at their respective tops, that are then stacked and bolted together. The top portion of a lower section 202 is inserted into the hollow bottom portion of the next higher section, and so on. Seams 204 between stacked sections 202 are easily visible.
- FIG. 1 shows an example of a straight lighting pole.
- FIG. 2 shows an example of a utility pole with a modular design.
- FIG. 3A schematically shows an example of an assembled lighting pole.
- FIG. 3B schematically shows an example of a base pole section.
- FIG. 3C schematically shows an example of an upper-most pole section.
- FIG. 3D schematically shows an example of a pole splice.
- FIG. 3E schematically shows an example of a perspective view of a pole splice.
- FIG. 4 shows an example process for manufacture of pole sections used to make an assembled lighting pole.
- FIG. 5 shows an example process for creating an assembled lighting pole using pole sections.
- the present application discloses new approaches to design and manufacture of lighting poles that enable easier and lower-cost warehousing, packing, shipping, and assembly and installation of lighting poles, as well as superior appearance.
- FIG. 3B schematically shows an example of a base pole section 304 .
- “pole section” 302 refers to the pole shaft 308 and the other components integrated therein prior to final assembly of multiple pole sections 302 into a lighting pole 300 .
- a base pole section 304 comprises a base plate 306 , a pole shaft 308 , a hand hole 310 (a wiring access port) and a pole splice 316 (also called a “splice assembly”) which is fixedly attached to the pole shaft 308 .
- the base plate 306 is preferably a flat metal plate fixedly attached to the pole shaft 308 of the base pole section 304 , e.g., using a circumferential weld on the top and bottom of the base plate 306 .
- the base plate 306 includes multiple anchor bolt holes for anchoring the base pole section 304 —and thus the assembled lighting pole 300 —to the ground.
- the base plate 306 will be used to anchor the lighting pole 300 to a secure foundation, such as a concrete foundation, through which wiring for the assembled pole 300 has been run.
- Pole shafts 308 of pole sections 302 and of the pole splice 316 are hollow, allowing wiring to be threaded through pole sections 302 and the pole splice 316 to luminaires which will be mounted on the assembled pole 300 .
- the hand hole 310 is essentially a window into the hollow interior of the base pole section 304 , and allows access to the wiring in an assembled lighting pole 300 .
- FIG. 3C schematically shows an example of an upper-most pole section 312 .
- an upper-most pole section 312 comprises a tenon top 314 (also called a tenon mount) for attaching one or more mounting structures for light fixtures and corresponding luminaires.
- a tenon top 314 also called a tenon mount
- FIG. 3D schematically shows an example of a pole splice 316 .
- the pole splice 316 preferably comprises a splice shaft 318 , multiple shims 320 fixedly attached to the splice shaft 318 (preferably at least four), and a bolt hole 322 for attaching the pole splice 316 to a receiving pole section.
- a “receiving pole section,” as used herein, is a pole section 302 into which the pole splice 316 is inserted, and to which the pole splice 316 is fixedly coupled (preferably using a bolt through the bolt hole 322 and through a matching bolt hole 334 in the receiving pole section, see FIG.
- a “splicing pole section,” as used herein, is a pole section 302 to which a pole splice 316 is fixedly coupled prior to final assembly of the lighting pole 300 .
- the splicing pole section is the base pole section 304
- the receiving pole section is the upper-most pole section 312 .
- the splice shaft 318 is preferably a short length of pole shaft 308 or tubing (short compared to a pole shaft 308 of a pole section 302 ).
- the splice shaft 318 is preferably long enough that the pole splice 316 can brace pole sections 302 to which the pole splice 316 is fixedly coupled against movement transverse to a long axis of the coupled pole sections 302 .
- a long axis 324 of the splice shaft 318 is parallel to (and in preferred embodiments, collinear with) a long axis 326 of the coupled pole sections 302 ; and the long axis 326 of the coupled pole sections 302 should be aligned (collinear) with each other.
- transverse directions” 328 refers to directions transverse to the long axis 326 of pole sections 302 and to the long axis 324 of the pole splice 316 in an assembled lighting pole 300 .
- a shim 320 preferably comprises a metal plate, with a same shape, in transverse directions 328 , as the hollow interior of a pole section 302 .
- the shim 320 is sized to fit snugly within the interior of the pole section 302 in the transverse directions 328 .
- a shim 320 has a hole disposed through it in a direction which is parallel to the long axis 324 of the splice shaft 318 when the shim 320 is fixedly coupled to the splice shaft 318 .
- the hole in the shim 320 is sized so that the splice shaft 318 can be inserted into the hole and fixedly coupled to the shim 320 using, for example, one or more welds.
- Pole splices 316 are preferably assembled prior to being fixedly coupled to pole sections 302 (as further described below).
- one pole splice 316 is coupled to a pole section 302 .
- a pole splice 316 is fixedly coupled to each pole section 302 that is not the upper-most pole section 312 .
- a pole splice 316 is contained within a splicing pole section (here, the base pole section 304 ) and a receiving pole section (here, the upper-most pole section 312 ).
- the splicing pole section sits beneath the receiving pole section in an assembled lighting pole 300 .
- a lower portion 330 of the pole splice 316 is preferably fixedly attached to and contained within the splicing pole section when the pole sections 302 are initially fabricated.
- An upper portion 332 of the pole splice 316 is inserted into the receiving pole section during lighting pole assembly 300 , and is preferably fixedly coupled to the receiving pole section using fastening and alignment mechanisms such as screws and bolts (e.g., sex bolts and set screws).
- a receiving pole section (here, the upper-most pole section 312 ) comprises a bolt hole 334 matching the bolt hole 322 in the pole splice 316 .
- a receiving pole section also comprises multiple screw holes 336 for aligning a receiving pole section to a pole splice 316 prior to—and thereby to a splicing pole section—and to mitigation flexion and other relative movement of pole sections 302 .
- a pole splice 316 preferably comprises at least four shims 320 , two disposed on the lower portion 330 of the pole splice 316 so that they will hold the pole splice 316 in place relative to the splicing pole section, and two disposed on the upper portion 332 of the pole splice 316 so that they will hold the pole splice 316 in place relative to the receiving pole section. That is, furthest-apart shims 320 in the lower portion 330 of the pole splice 316 are preferably disposed far apart while remaining within the splicing pole section and coupled to the lower portion 330 of the pole splice 316 .
- furthest-apart shims 320 in the upper portion 332 of the pole splice 316 are preferably disposed far apart while remaining within the receiving pole section and coupled to the upper portion 332 of the pole splice 316 .
- the farther apart shims 320 on the upper portion 332 of the pole splice 316 are, the better supported the pole splice 316 will be against movement in the transverse directions 328 relative to the receiving pole section.
- Preventing relative movement of the pole sections 302 and pole splice 316 helps to ruggedize the assembled lighting pole 300 against failures in connections between components, e.g., weld failures and screw breakages (and other failures of fastening mechanisms).
- the fixed coupling between the pole splice 316 and a pole section 320 preferably comprises welding.
- the shim 320 on the lower portion 330 of the pole splice 316 that will be nearest to an upper end of a corresponding pole section 302 can be welded to the corresponding pole section 302 .
- welds are disposed to avoid fully sealing pole sections.
- a plug weld hole can be drilled in the side of a pole section 302 near a corresponding shim 320 ; the shim 320 welded to the pole section 302 using the plug weld hole to provide access to the interface between the shim 320 and the pole section 302 ; the plug weld hole sealed shut, e.g., using a weld; and excess weld covering the plug hole ground smooth.
- the pole splice 316 is held so that the long axis 324 of the pole splice 316 is parallel to (preferably, collinear with) the long axis 326 of the pole section 302 .
- the pole splice does not affect the exterior cross section of a splicing pole section.
- Pole sections are designed to enable them to be palletized, transported and then stacked at their final assembly location.
- Pole sections can be, for example, 3′′, 4′′ or 5′′ round or square steel poles from approximately 8 feet to 12 feet in height.
- Assembled lighting poles can be, for example, 16 feet to 30 feet in height.
- pole sections can be small enough for distribution from a regional or local point of purchase to be performed by a small commercial truck rather than an 18 wheel truck.
- the cargo bed of a pickup truck e.g., a customer's work vehicle
- pole sections By using a pole splice, pole sections can be joined together so that the seam 338 between the joined pole sections is very difficult to see.
- the seam 338 between joined pole sections 302 can be invisible to the untrained and unassisted eye.
- Set screws can be used to align pole sections 302 —preferably, so that their main axes 326 are collinear and their edges are closely aligned—prior to using a sexbolt to rigidly couple the pole sections 302 .
- FIG. 3E schematically shows an example of a perspective view 340 of a pole splice 316 .
- the splice shaft 318 preferably has external measurements in the transverse dimensions 328 sized to fit within the pole sections 302 to be connected, with room to include shims 320 to fixedly couple the splice shaft 318 to a corresponding pole section 302 , and to hold the splice shaft 316 immobile with respect to pole sections 302 coupled together by the pole splice 316 .
- the splice shaft 318 preferably has internal measurements in the transverse dimensions 328 (i.e., the size of the hollow tube inside the splice shaft 318 ) sized to pass power and other cabling to be used in the lighting (or other application) to be mounted on the assembled lighting pole 300 .
- the walls 342 of the splice shaft 318 are preferably sufficiently thick (of sufficient gauge) to withstand stress in the transverse dimensions 328 which is transmitted by coupled pole sections 302 . Such stress may arise, for example, as a result of coupled pole sections 302 flexing or otherwise moving relative to each other due to environmental forces such as wind-related or precipitation-related forces.
- Shims 320 preferably have a notch 344 (cutout) to make room for the weld seam in the pole shaft 308 of the corresponding splicing pole section.
- FIG. 4 shows an example process 400 for manufacture of pole sections 302 used to make an assembled lighting pole 300 .
- Shims 320 and a strip of metal for forming into a splice shaft 318 are cut from sheet metal, the strip of metal is rolled and welded to form the splice shaft 318 , and the shims 320 and splice shaft 318 are welded together to form a pole splice 316 , in step 402 .
- Strips of metal are cut, rolled and welded to form pole shafts 308 in step 404 .
- a pole splice 316 is inserted into and held at a level within a splicing pole shaft so that a long axis 324 of the pole splice is aligned (parallel, and preferably collinear) with a long axis 326 of the splicing pole shaft; the pole splice 316 and splicing pole shaft are welded together; and a sex bolt hole 322 is drilled in the splice shaft 318 using a CNC (Computer Numeric Control) machine, in step 406 .
- CNC Computer Numeric Control
- Screw and sex bolt holes 334 , 336 Using a CNC machine enables screw and sex bolt holes 334 , 336 to be drilled into the same place on different splice shafts 318 , ensuring that the screw and sex bolt holes 334 , 336 on pole sections 302 and pole splices 316 will align. Screw holes for set screws 336 (to ensure that the receiving pole section and splicing pole section are properly aligned prior to installing a sex bolt) and a hole for the sex bolt 334 are drilled in a receiving pole section using a CNC machine, in step 408 .
- a base plate 306 and hand hole 310 are added depending on the intended function (e.g., base pole section 304 or upper-most pole section 312 ) of the particular pole section 302 , in step 410 .
- FIG. 5 shows an example process 500 for creating an assembled lighting pole 300 using pole sections 302 .
- a base pole section 304 is attached to a secure foundation through which wiring has been threaded for the lighting to be mounted on the assembled lighting pole 300 , in step 502 .
- a receiving pole section (which can be an upper-most pole section 312 ) is slid down over the pole splice 316 (splice assembly) of the base pole section 304 , so that the receiving pole section makes contact with the base pole section 304 , in step 504 .
- a sex bolt is inserted through the sex bolt holes 322 , 334 in the joint assembly; then set screws are inserted into the set screw holes 336 in the bottom of the receiving pole section and fastened to ensure that the base pole section and the receiving pole section are aligned (their main axes are collinear); then the sex bolt assembly is tightened to securely fasten the receiving pole section to the base pole section 304 , in step 506 .
- an additional pole section can be slid down over the receiving pole section's pole splice (that is, the receiving pole section can also be a splicing pole section), so that the additional pole section 302 makes contact with the receiving pole section (essentially, step 504 repeated).
- a sex bolt and set screws can then be used as in step 506 to securely fasten the additional pole section 302 to the receiving pole section. Steps 504 and 506 can be repeated in this way to continue adding pole sections 302 as required.
- a modular utility support system comprising: a connector pole and a receiver pole, the connector and receiver poles each comprising a pole shaft having a hollow interior and with a long axis in an axial direction, directions perpendicular to the axial direction being transverse directions; the connector pole further comprising a pole splice, the pole splice comprising: a pipe section with a long axis parallel to the axial direction, a portion of the pipe section located within and having a same size in the transverse directions as the hollow interior of the pole shaft of the connector pole, and a remainder of the pipe section having a same size in the transverse directions as the hollow interior of the pole shaft of the receiver pole; and multiple shims fixedly connected to the pipe section, one or more of the shims located on the portion and having a same size in the transverse directions as the hollow interior of the pole shaft of the connector pole, at least one of the shims on the portion fixedly connected to the hollow
- a method for assembling a utility support pole comprising: a) inserting a pole splice into an interior of a receiving pole, said pole splice extending out of an interior of a splicing pole, said pole splice comprising a pole shaft fixedly coupled to multiple shims, multiple ones of the shims located in the interior of the splicing pole, at least one of the shims fixedly coupled to the interior of the splicing pole, multiple ones of the shims located in the interior of the receiving pole after the inserting, the shims sized to prevent movement of the pole splice lateral to a long axis of the splicing pole or a long axis of the receiving pole, the inserting being performed so that the splicing pole and the receiving pole section meet; and b) fixedly coupling the receiving pole to the pole splice.
- Pole sections can be joined without visible seams by inserting a pole splice fixedly connected to an interior of a first pole section into an interior of a second pole section and then fixedly connecting the second pole section to the pole splice.
- the pole splice is preferably a length of pole fixedly attached on its exterior to shims with dimensions closely matching the dimensions of pole section hollow interiors (transverse to a long axis of the pole sections), such that the pole splice contacts the interiors of first and second pole sections in multiple substantially separated locations to thereby prevent lateral movement of the pole sections with respect to each other.
- the pole shaft of the base pole section can be a square custom 8 foot shaft made from 7 gauge steel (approximately 3/16 inch thick) that is designed to match a typical exterior profile of a pole made from 11 gauge steel.
- two pole splices are fixedly coupled to a pole section that is then coupled, using the pole splices, to two other pole sections.
- methods other than screws can be used to attach a receiving pole section to a pole splice.
- shims can be fixedly connected to a splice shaft otherwise than by using welds.
- pole sections can be 10 to 30 feet tall.
- assembled poles can be taller or shorter than those described herein (e.g., a multiple of 10 to 30 foot pole section lengths).
- a CNC machine is used to drill plug weld holes in pole shafts to be used as splicing pole sections, so that plug weld holes are drilled in the same location on different pole shafts.
- pole splice components are cut and assembled using an automatically controlled jig and a structural DOM (drawn over mandrel) splice; e.g., to assist in meeting tolerances to assure interchangeability of parts and consistency of style and design.
- modular poles as described herein can be used to mount applications other than lighting, such as signaling (e.g., signal lights), communications lines or power lines.
- signaling e.g., signal lights
- communications lines e.g., communications lines
- power lines e.g., power lines
- a pole shaft can be formed by welding a round pole section to a pole splice at, e.g., shims, with o-rings and/or bands fixedly connected to the portion of the pole splice to be held within and bolted to another pole section (pole shaft or other pole section).
- set screw holes are located so that set screws inserted into set screw holes in a receiver pole shaft will push on a shim In some embodiments, set screw holes are located so that set screws inserted into set screw holes in a receiver pole shaft will push on the pole shaft of the pole splice.
- three or more pole sections are used, pairs of pole sections being joined together by a pole splice.
- one or more pairs of pole sections is joined together by a pole splice and one or more pairs of pole sections are joined together using other means.
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Abstract
Description
- This application is a non-provisional of, and priority is claimed from, U.S. Provisional App. No. 62/454,448, filed on Feb. 3, 2017, titled “Modular Pole Sections Using Pole Splice”, which is hereby incorporated by reference.
- The present application relates to utility poles, and more particularly to lighting poles constructed using modular pole segments.
- Various types of poles are used to support elevated lighting, of various thickness and contour. There are relatively thin poles (e.g., 4 inches wide) and wide poles (e.g., several feet across); and relatively short poles (e.g., 99 inches tall, including the light) and tall poles (e.g., 20 to 40 or more feet tall). Straight lighting poles are typically made of metal that has been rolled into a cylindrical, conical or pyramidal shape. There are also lighting poles with curved contours. Lighting poles can serve a decorative purpose in addition to their lighting function.
-
FIG. 1 shows an example of astraight lighting pole 100. A lighting fixture 102 is attached to a unitary pole shaft 104 using a tenon top. A luminaire is mounted on the light fixture. -
FIG. 2 shows an example of a utility pole 200 (a power line-supporting pole) with a modular design. As shown inFIG. 2 , an example modular utility pole comprises conical orpyramidal sections 202, tapering at their respective tops, that are then stacked and bolted together. The top portion of alower section 202 is inserted into the hollow bottom portion of the next higher section, and so on.Seams 204 between stackedsections 202 are easily visible. - The disclosed inventive scope will be described with reference to the accompanying drawings, which show important sample embodiments and which are incorporated in the specification hereof by reference, wherein:
-
FIG. 1 shows an example of a straight lighting pole. -
FIG. 2 shows an example of a utility pole with a modular design. -
FIG. 3A schematically shows an example of an assembled lighting pole. -
FIG. 3B schematically shows an example of a base pole section. -
FIG. 3C schematically shows an example of an upper-most pole section. -
FIG. 3D schematically shows an example of a pole splice. -
FIG. 3E schematically shows an example of a perspective view of a pole splice. -
FIG. 4 shows an example process for manufacture of pole sections used to make an assembled lighting pole. -
FIG. 5 shows an example process for creating an assembled lighting pole using pole sections. - The numerous innovative teachings of the present application will be described with particular reference to presently preferred embodiments by way of example, and not of limitation. The present application describes inventive scope, and none of the statements below should be taken as limiting the claims generally.
- The present application discloses new approaches to design and manufacture of lighting poles that enable easier and lower-cost warehousing, packing, shipping, and assembly and installation of lighting poles, as well as superior appearance.
- The disclosed innovations, in various embodiments, provide one or more of at least the following advantages. However, not all of these advantages result from every one of the innovations disclosed, and this list of advantages does not limit the variously claimed inventive scope.
- Pole shafts used to construct assembled pole can be palletized;
- Enables compact shipping;
- Modules are lighter than assembled poles, enabling easier packing, unpacking and assembling;
- Enables cheaper deployment and assembly;
- Easy to assemble;
- Enables a seamless appearance;
- Lower cost shipping;
- Individual pole shaft modules are relatively inexpensive;
- Easy to warehouse;
- Enables rabid shipping and deployment without specialized or large-factor transport;
- Enables assembly using relatively light assembly equipment; and
- Rugged over long-distance shipping, including across poorly-paved roadways.
- Some exemplary parameters will be given to illustrate the relations between these and other parameters. However it will be understood by a person of ordinary skill in the art that these values are merely illustrative, and will be modified by scaling of further device generations, and will be further modified to adapt to different materials or architectures if used.
- Inexpensive, durable, relatively small and lightweight (due to relatively small size)
metal pole sections 302 can be used to form fully assembled poles 300, as further described below with respect toFIGS. 3A through 5 .Pole sections 302 are typically made (e.g., by steel shaft vendors) on fabrication equipment known as “roll forming” equipment. The roll forming process takes a flat section of steel and forms it into a round or square tube that is then seam welded to connect the long adjacent edges of the steel section, resulting in apole shaft 308 which can be used to make apole section 302. -
FIG. 3A schematically shows an example of an assembled lighting pole 300. A lighting pole 300 preferably comprises two ormore pole sections 302. -
FIG. 3B schematically shows an example of abase pole section 304. As used herein, “pole section” 302 refers to thepole shaft 308 and the other components integrated therein prior to final assembly ofmultiple pole sections 302 into a lighting pole 300. For example, as shown inFIG. 3B , abase pole section 304 comprises abase plate 306, apole shaft 308, a hand hole 310 (a wiring access port) and a pole splice 316 (also called a “splice assembly”) which is fixedly attached to thepole shaft 308. Thebase plate 306 is preferably a flat metal plate fixedly attached to thepole shaft 308 of thebase pole section 304, e.g., using a circumferential weld on the top and bottom of thebase plate 306. Thebase plate 306 includes multiple anchor bolt holes for anchoring thebase pole section 304—and thus the assembled lighting pole 300—to the ground. Typically, thebase plate 306 will be used to anchor the lighting pole 300 to a secure foundation, such as a concrete foundation, through which wiring for the assembled pole 300 has been run.Pole shafts 308 ofpole sections 302 and of thepole splice 316 are hollow, allowing wiring to be threaded throughpole sections 302 and thepole splice 316 to luminaires which will be mounted on the assembled pole 300. Thehand hole 310 is essentially a window into the hollow interior of thebase pole section 304, and allows access to the wiring in an assembled lighting pole 300. -
FIG. 3C schematically shows an example of anupper-most pole section 312. Preferably, anupper-most pole section 312 comprises a tenon top 314 (also called a tenon mount) for attaching one or more mounting structures for light fixtures and corresponding luminaires. -
FIG. 3D schematically shows an example of apole splice 316. Thepole splice 316 preferably comprises asplice shaft 318,multiple shims 320 fixedly attached to the splice shaft 318 (preferably at least four), and abolt hole 322 for attaching thepole splice 316 to a receiving pole section. A “receiving pole section,” as used herein, is apole section 302 into which thepole splice 316 is inserted, and to which thepole splice 316 is fixedly coupled (preferably using a bolt through thebolt hole 322 and through amatching bolt hole 334 in the receiving pole section, seeFIG. 3C ), to thereby fixedly couple the receiving pole section to a splicing pole section. A “splicing pole section,” as used herein, is apole section 302 to which apole splice 316 is fixedly coupled prior to final assembly of the lighting pole 300. As shown inFIGS. 3A, 3B and 3C , the splicing pole section is thebase pole section 304, and the receiving pole section is theupper-most pole section 312. - The
splice shaft 318 is preferably a short length ofpole shaft 308 or tubing (short compared to apole shaft 308 of a pole section 302). Thesplice shaft 318 is preferably long enough that thepole splice 316 can bracepole sections 302 to which thepole splice 316 is fixedly coupled against movement transverse to a long axis of the coupledpole sections 302. When coupled topole sections 302, along axis 324 of thesplice shaft 318 is parallel to (and in preferred embodiments, collinear with) along axis 326 of the coupledpole sections 302; and thelong axis 326 of the coupledpole sections 302 should be aligned (collinear) with each other. Herein, “transverse directions” 328 refers to directions transverse to thelong axis 326 ofpole sections 302 and to thelong axis 324 of thepole splice 316 in an assembled lighting pole 300. - A
shim 320 preferably comprises a metal plate, with a same shape, intransverse directions 328, as the hollow interior of apole section 302. Theshim 320 is sized to fit snugly within the interior of thepole section 302 in thetransverse directions 328. Ashim 320 has a hole disposed through it in a direction which is parallel to thelong axis 324 of thesplice shaft 318 when theshim 320 is fixedly coupled to thesplice shaft 318. The hole in theshim 320 is sized so that thesplice shaft 318 can be inserted into the hole and fixedly coupled to theshim 320 using, for example, one or more welds. - Pole splices 316 are preferably assembled prior to being fixedly coupled to pole sections 302 (as further described below). Preferably, one
pole splice 316 is coupled to apole section 302. Preferably, apole splice 316 is fixedly coupled to eachpole section 302 that is not theupper-most pole section 312. - As shown in
FIG. 3A , in an assembled lighting pole 300, apole splice 316 is contained within a splicing pole section (here, the base pole section 304) and a receiving pole section (here, the upper-most pole section 312). Preferably, the splicing pole section sits beneath the receiving pole section in an assembled lighting pole 300. Alower portion 330 of thepole splice 316 is preferably fixedly attached to and contained within the splicing pole section when thepole sections 302 are initially fabricated. Anupper portion 332 of thepole splice 316 is inserted into the receiving pole section during lighting pole assembly 300, and is preferably fixedly coupled to the receiving pole section using fastening and alignment mechanisms such as screws and bolts (e.g., sex bolts and set screws). As shown inFIG. 3C , preferably, a receiving pole section (here, the upper-most pole section 312) comprises abolt hole 334 matching thebolt hole 322 in thepole splice 316. A receiving pole section also comprises multiple screw holes 336 for aligning a receiving pole section to apole splice 316 prior to—and thereby to a splicing pole section—and to mitigation flexion and other relative movement ofpole sections 302. - As shown in
FIG. 3D , apole splice 316 preferably comprises at least fourshims 320, two disposed on thelower portion 330 of thepole splice 316 so that they will hold thepole splice 316 in place relative to the splicing pole section, and two disposed on theupper portion 332 of thepole splice 316 so that they will hold thepole splice 316 in place relative to the receiving pole section. That is, furthest-apartshims 320 in thelower portion 330 of thepole splice 316 are preferably disposed far apart while remaining within the splicing pole section and coupled to thelower portion 330 of thepole splice 316. Also, furthest-apartshims 320 in theupper portion 332 of thepole splice 316 are preferably disposed far apart while remaining within the receiving pole section and coupled to theupper portion 332 of thepole splice 316. Generally, the farther apart shims 320 on thelower portion 330 of thepole splice 316 are, the better supported thepole splice 316 will be against movement in thetransverse directions 328 relative to the splicing pole section. Also, generally, the farther apart shims 320 on theupper portion 332 of thepole splice 316 are, the better supported thepole splice 316 will be against movement in thetransverse directions 328 relative to the receiving pole section. Preventing relative movement of thepole sections 302 andpole splice 316 helps to ruggedize the assembled lighting pole 300 against failures in connections between components, e.g., weld failures and screw breakages (and other failures of fastening mechanisms). - The fixed coupling between the
pole splice 316 and apole section 320 preferably comprises welding. For example, theshim 320 on thelower portion 330 of thepole splice 316 that will be nearest to an upper end of acorresponding pole section 302 can be welded to thecorresponding pole section 302. (Preferably, welds are disposed to avoid fully sealing pole sections.) Alternatively, a plug weld hole can be drilled in the side of apole section 302 near acorresponding shim 320; theshim 320 welded to thepole section 302 using the plug weld hole to provide access to the interface between theshim 320 and thepole section 302; the plug weld hole sealed shut, e.g., using a weld; and excess weld covering the plug hole ground smooth. - Preferably, when a
pole splice 316 is welded to a corresponding pole section 302 (or other process to fixedly couple is performed), thepole splice 316 is held so that thelong axis 324 of thepole splice 316 is parallel to (preferably, collinear with) thelong axis 326 of thepole section 302. This helps to ensure that the pole splice will fit into the receiving pole during pole assembly, that screw holes in the receiving pole will align with screw holes in the pole splice, and that the assembled lighting pole will be straight. - Preferably, the pole splice does not affect the exterior cross section of a splicing pole section.
- Pole sections are designed to enable them to be palletized, transported and then stacked at their final assembly location. Pole sections can be, for example, 3″, 4″ or 5″ round or square steel poles from approximately 8 feet to 12 feet in height. Assembled lighting poles can be, for example, 16 feet to 30 feet in height. However, pole sections can be small enough for distribution from a regional or local point of purchase to be performed by a small commercial truck rather than an 18 wheel truck. In some embodiments, the cargo bed of a pickup truck (e.g., a customer's work vehicle) can be used to carry pole sections to an installation location.
- By using a pole splice, pole sections can be joined together so that the
seam 338 between the joined pole sections is very difficult to see. In preferred embodiments, theseam 338 between joinedpole sections 302 can be invisible to the untrained and unassisted eye. Set screws can be used to alignpole sections 302—preferably, so that theirmain axes 326 are collinear and their edges are closely aligned—prior to using a sexbolt to rigidly couple thepole sections 302. -
FIG. 3E schematically shows an example of aperspective view 340 of apole splice 316. Thesplice shaft 318 preferably has external measurements in thetransverse dimensions 328 sized to fit within thepole sections 302 to be connected, with room to includeshims 320 to fixedly couple thesplice shaft 318 to acorresponding pole section 302, and to hold thesplice shaft 316 immobile with respect topole sections 302 coupled together by thepole splice 316. Thesplice shaft 318 preferably has internal measurements in the transverse dimensions 328 (i.e., the size of the hollow tube inside the splice shaft 318) sized to pass power and other cabling to be used in the lighting (or other application) to be mounted on the assembled lighting pole 300. Thewalls 342 of thesplice shaft 318 are preferably sufficiently thick (of sufficient gauge) to withstand stress in thetransverse dimensions 328 which is transmitted by coupledpole sections 302. Such stress may arise, for example, as a result of coupledpole sections 302 flexing or otherwise moving relative to each other due to environmental forces such as wind-related or precipitation-related forces.Shims 320 preferably have a notch 344 (cutout) to make room for the weld seam in thepole shaft 308 of the corresponding splicing pole section. -
FIG. 4 shows anexample process 400 for manufacture ofpole sections 302 used to make an assembled lighting pole 300.Shims 320 and a strip of metal for forming into asplice shaft 318 are cut from sheet metal, the strip of metal is rolled and welded to form thesplice shaft 318, and theshims 320 andsplice shaft 318 are welded together to form apole splice 316, instep 402. Strips of metal are cut, rolled and welded to formpole shafts 308 instep 404. Apole splice 316 is inserted into and held at a level within a splicing pole shaft so that along axis 324 of the pole splice is aligned (parallel, and preferably collinear) with along axis 326 of the splicing pole shaft; thepole splice 316 and splicing pole shaft are welded together; and asex bolt hole 322 is drilled in thesplice shaft 318 using a CNC (Computer Numeric Control) machine, instep 406. Using a CNC machine enables screw and sex bolt holes 334, 336 to be drilled into the same place ondifferent splice shafts 318, ensuring that the screw and sex bolt holes 334, 336 onpole sections 302 and pole splices 316 will align. Screw holes for set screws 336 (to ensure that the receiving pole section and splicing pole section are properly aligned prior to installing a sex bolt) and a hole for thesex bolt 334 are drilled in a receiving pole section using a CNC machine, instep 408. Additional features, such as abase plate 306 andhand hole 310, or atenon top 314, are added depending on the intended function (e.g.,base pole section 304 or upper-most pole section 312) of theparticular pole section 302, instep 410. -
FIG. 5 shows anexample process 500 for creating an assembled lighting pole 300 usingpole sections 302. Using anchor bolts, abase pole section 304 is attached to a secure foundation through which wiring has been threaded for the lighting to be mounted on the assembled lighting pole 300, instep 502. A receiving pole section (which can be an upper-most pole section 312) is slid down over the pole splice 316 (splice assembly) of thebase pole section 304, so that the receiving pole section makes contact with thebase pole section 304, instep 504. A sex bolt is inserted through the sex bolt holes 322, 334 in the joint assembly; then set screws are inserted into the set screw holes 336 in the bottom of the receiving pole section and fastened to ensure that the base pole section and the receiving pole section are aligned (their main axes are collinear); then the sex bolt assembly is tightened to securely fasten the receiving pole section to thebase pole section 304, instep 506. - If the receiving pole section includes a
pole splice 316, an additional pole section can be slid down over the receiving pole section's pole splice (that is, the receiving pole section can also be a splicing pole section), so that theadditional pole section 302 makes contact with the receiving pole section (essentially, step 504 repeated). A sex bolt and set screws can then be used as instep 506 to securely fasten theadditional pole section 302 to the receiving pole section.Steps pole sections 302 as required. - According to some but not necessarily all embodiments, there is provided: a modular utility support system, comprising: a connector pole and a receiver pole, the connector and receiver poles each comprising a pole shaft having a hollow interior and with a long axis in an axial direction, directions perpendicular to the axial direction being transverse directions; the connector pole further comprising a pole splice, the pole splice comprising: a pipe section with a long axis parallel to the axial direction, a portion of the pipe section located within and having a same size in the transverse directions as the hollow interior of the pole shaft of the connector pole, and a remainder of the pipe section having a same size in the transverse directions as the hollow interior of the pole shaft of the receiver pole; and multiple shims fixedly connected to the pipe section, one or more of the shims located on the portion and having a same size in the transverse directions as the hollow interior of the pole shaft of the connector pole, at least one of the shims on the portion fixedly connected to the hollow interior of the pole shaft of the connector pole, and one or more of the shims being located outside the pole shaft of the connector pole and having a same size, in the transverse directions, as the hollow interior of the pole shaft of the receiver pole; wherein the portion and the remainder are sized in the axial direction to prevent the connector pole and the receiver pole from moving with respect to each other in the transverse directions when the pole splice is inserted into the hollow interior of the pole shaft of the receiver pole; and wherein the remainder is configured to be contained within the receiver pole when the pole splice is inserted into the receiver pole.
- According to some but not necessarily all embodiments, there is provided: a method for assembling a utility support pole, comprising: a) inserting a pole splice into an interior of a receiving pole, said pole splice extending out of an interior of a splicing pole, said pole splice comprising a pole shaft fixedly coupled to multiple shims, multiple ones of the shims located in the interior of the splicing pole, at least one of the shims fixedly coupled to the interior of the splicing pole, multiple ones of the shims located in the interior of the receiving pole after the inserting, the shims sized to prevent movement of the pole splice lateral to a long axis of the splicing pole or a long axis of the receiving pole, the inserting being performed so that the splicing pole and the receiving pole section meet; and b) fixedly coupling the receiving pole to the pole splice.
- According to some but not necessarily all embodiments, there is provided: methods and systems for assembling a modular ornamental pole. Pole sections can be joined without visible seams by inserting a pole splice fixedly connected to an interior of a first pole section into an interior of a second pole section and then fixedly connecting the second pole section to the pole splice. The pole splice is preferably a length of pole fixedly attached on its exterior to shims with dimensions closely matching the dimensions of pole section hollow interiors (transverse to a long axis of the pole sections), such that the pole splice contacts the interiors of first and second pole sections in multiple substantially separated locations to thereby prevent lateral movement of the pole sections with respect to each other.
- As will be recognized by those skilled in the art, the innovative concepts described in the present application can be modified and varied over a tremendous range of applications, and accordingly the scope of patented subject matter is not limited by any of the specific exemplary teachings given. It is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
- Particular fabrication methods of the pole splice and pole shaft have been described hereinabove. It will be apparent to those of ordinary skill in the arts of manufacturing lighting poles that other methods of fabrication can be used.
- In some embodiments, the pole shaft of the base pole section can be a square custom 8 foot shaft made from 7 gauge steel (approximately 3/16 inch thick) that is designed to match a typical exterior profile of a pole made from 11 gauge steel.
- In some embodiments, two pole splices are fixedly coupled to a pole section that is then coupled, using the pole splices, to two other pole sections.
- In some embodiments, a pole section has no pole splices, and is coupled to one or two pole sections using pole splices fixedly coupled to the other pole section(s).
- In some embodiments, methods other than screws can be used to attach a receiving pole section to a pole splice.
- In some embodiments, shims can be fixedly connected to a splice shaft otherwise than by using welds.
- In some embodiments, larger or smaller pole widths and/or lengths than those described herein can be used. In some embodiments, pole sections can be 10 to 30 feet tall. In some embodiments, assembled poles can be taller or shorter than those described herein (e.g., a multiple of 10 to 30 foot pole section lengths).
- In some embodiments, a CNC machine is used to drill plug weld holes in pole shafts to be used as splicing pole sections, so that plug weld holes are drilled in the same location on different pole shafts.
- In some embodiments, modular poles with pole splices as described herein can be used for purposes other than to mount luminaires; for example, as flag poles or to mount utilities other than lighting.
- In some embodiments, pole splice components are cut and assembled using an automatically controlled jig and a structural DOM (drawn over mandrel) splice; e.g., to assist in meeting tolerances to assure interchangeability of parts and consistency of style and design.
- In some embodiments, modular poles as described herein can be used to mount applications other than lighting, such as signaling (e.g., signal lights), communications lines or power lines.
- In some embodiments, a pole shaft can be formed by welding a round pole section to a pole splice at, e.g., shims, with o-rings and/or bands fixedly connected to the portion of the pole splice to be held within and bolted to another pole section (pole shaft or other pole section).
- In some embodiments, set screw holes are located so that set screws inserted into set screw holes in a receiver pole shaft will push on a shim In some embodiments, set screw holes are located so that set screws inserted into set screw holes in a receiver pole shaft will push on the pole shaft of the pole splice.
- In some embodiments, three or more pole sections are used, pairs of pole sections being joined together by a pole splice. In some embodiments, in a single assembled lighting pole, one or more pairs of pole sections is joined together by a pole splice and one or more pairs of pole sections are joined together using other means.
- None of the description in the present application should be read as implying that any particular element, step, or function is an essential element which must be included in the claim scope: THE SCOPE OF PATENTED SUBJECT MATTER IS DEFINED ONLY BY THE ALLOWED CLAIMS. Moreover, none of these claims are intended to invoke paragraph six of 35 USC section 112 unless the exact words “means for” are followed by a participle.
- The claims as filed are intended to be as comprehensive as possible, and NO subject matter is intentionally relinquished, dedicated, or abandoned.
Claims (15)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US15/887,738 US20180223556A1 (en) | 2017-02-03 | 2018-02-02 | Modular pole sections using pole splice |
Applications Claiming Priority (2)
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US201762454448P | 2017-02-03 | 2017-02-03 | |
US15/887,738 US20180223556A1 (en) | 2017-02-03 | 2018-02-02 | Modular pole sections using pole splice |
Publications (1)
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US20180223556A1 true US20180223556A1 (en) | 2018-08-09 |
Family
ID=63038778
Family Applications (1)
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US15/887,738 Abandoned US20180223556A1 (en) | 2017-02-03 | 2018-02-02 | Modular pole sections using pole splice |
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