Filament wound structural columns for light poles

Abstract

A one-piece, unitary, elongate, tubular light pole. The elongate light pole defines a central axis and is constructed from a filament-wound composite of fiber-reinforced bonding agent and has a wall thickness of less than ¾ inch, and preferably ⅜ inch. The pole is configured and adapted to support a lighting structure thereon without failure of the composite, such that a twenty-foot section of the pole is capable of withstanding a lateral load transverse of the axis of at least 300 pounds without failure of the composite.

What is claimed is:  
     
         1 . A structural lighting pole comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent and having a wall thickness of less than 3 inch, wherein said tubular member is configured and adapted to support a lighting structure thereon without failure of the composite material, such that a twenty-foot section of said tubular member is capable of withstanding a lateral load transverse of the axis of at least 300 pounds without failure of said composite material.    
     
     
         2 . The lighting pole of  claim 1 , wherein the tubular member has a wall thickness of less than {fraction (1/2)} inch.  
     
     
         3 . The lighting pole of  claim 1 , wherein the tubular member is configured and adapted to bear flexure stress imposed by a lighting member when said lighting member is attached to said tubular member and extends outward from said tubular member in a sideways direction.  
     
     
         4 . The lighting pole of  claim 1 , further comprising: 
 means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light.    
     
     
         5 . The lighting pole of  claim 1 , wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 19.938 inches of deflection when a lateral load of at least 300 pounds is applied at an opposing end section of said tubular member in a transverse direction relative to the axis.  
     
     
         6 . The lighting pole of  claim 1 , wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 36 inches of deflection when a lateral load is applied at an opposing end section of said tubular member in a transverse direction relative to the axis and at a magnitude sufficient to induce failure of the composite.  
     
     
         7 . The lighting pole of  claim 1 , wherein the tubular member is configured and adapted to support a heavy lighting structure thereon and to bear lateral loads imposed by said lighting structure without failure of the composite, and wherein said tubular member is light weight having an average linear weight distribution of less than five pounds per foot and further having an average outer diameter of at least six inches.  
     
     
         8 . The lighting pole of  claim 1 , wherein the tubular member is characterized by a substantial absence of core material disposed therein for the purpose of providing structural reinforcement to said tubular member.  
     
     
         9 . The lighting pole of  claim 1 , wherein the tubular member is constructed of multiple, filament-wound layers, including an inner, circumferential hoop-wound layer, and at least one internal, helical-wound layer, and an external, circumferential hoop-wound layer.  
     
     
         10 . The lighting pole of  claim 9 , wherein the inner, circumferential hoop-wound layer comprises windings that form an angle within a range of 80-100 degrees with respect to the central axis of the tubular member.  
     
     
         11 . The lighting pole of  claim 10 , wherein the angle formed by the windings of the inner, circumferential hoop-wound layer is within a range of 85-90 degrees.  
     
     
         12 . The lighting pole of  claim 9 , wherein the at least one internal, helical-wound layer comprises windings that form an angle within a range of 10-20 degrees with respect to the central axis of the tubular member.  
     
     
         13 . The lighting pole of  claim 12 , wherein the angle formed by the windings of the at least one internal, helical-wound layer is approximately 15 degrees.  
     
     
         14 . A street light comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent and having a substantially constant exterior taper;    means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light.    
     
     
         15 . The street light of  claim 14 , wherein said tubular member is configured and adapted to support a lighting structure thereon without failure of the composite, such that a twenty-foot section of said tubular member is capable of withstanding a lateral load transverse of the axis of at least 300 pounds without failure of the composite.  
     
     
         16 . The street light of  claim 15 , wherein the tubular member has a wall thickness of less than {fraction (3/4)} inch.  
     
     
         17 . The street light of  claim 14 , wherein the tubular member has a wall thickness of {fraction (3/8)} inch or less.  
     
     
         18 . The street light of  claim 14 , wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 19.938 inches of deflection when a lateral load of at least 300 pounds is applied at an opposing end section of said tubular member in a transverse direction relative to the axis.  
     
     
         19 . The street light of  claim 14 , wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 36 inches of deflection when a lateral load is applied at an opposing end section of said tubular member in a transverse direction relative to the axis and at a magnitude sufficient to induce failure of the composite.  
     
     
         20 . The street light of  claim 14 , wherein the tubular member is configured and adapted to support a heavy lighting structure thereon and to bear lateral loads imposed by said lighting structure without failure of the composite, and wherein said tubular member is light weight having an average linear weight distribution of less than five pounds per foot and further having an average outer diameter of at least six inches.  
     
     
         21 . The street light of  claim 14 , wherein the tubular member is characterized by a substantial absence of core material disposed therein for the purpose of providing structural reinforcement to said tubular member.  
     
     
         22 . A structural lighting pole comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent, wherein said tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 19.938 inches of deflection when a lateral load of at least 300 pounds is applied at an opposing end section of said tubular member in a transverse direction relative to the axis.    
     
     
         23 . The lighting pole of  claim 22 , wherein the tubular member is configured and adapted such that the twenty-foot section fixed at one end undergoes less than fifteen inches of deflection when the lateral load of at least 300 pounds is applied at the opposing end section.  
     
     
         24 . The lighting pole of  claim 22 , wherein the tubular member is configured and adapted such that the twenty-foot section fixed at one end undergoes less than thirteen inches of deflection when the lateral load of at least 300 pounds is applied at the opposing end section.  
     
     
         25 . The lighting pole of  claim 22 , wherein the tubular member is configured and adapted such that the twenty-foot section fixed at one end undergoes less than twelve inches of deflection when the lateral load of at least 300 pounds is applied at the opposing end section.  
     
     
         26 . The lighting pole of  claim 22 , wherein the tubular member has a wall thickness of less than {fraction (3/4)} inch.  
     
     
         27 . The lighting pole of  claim 22 , wherein the tubular member has a wall thickness of less than {fraction (1/2)} inch.  
     
     
         28 . The lighting pole of  claim 22 , further comprising: 
 means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light.    
     
     
         29 . A structural lighting pole comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent, wherein said tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 36 inches of deflection when a lateral load is applied at an opposing end section of said tubular member in a transverse direction relative to the axis and at a magnitude sufficient to induce failure of the composite.    
     
     
         30 . The lighting pole of  claim 29 , wherein the tubular member undergoes deflection without failure of the composite when the lateral load is at least 500 pounds.  
     
     
         31 . The lighting pole of  claim 29 , wherein the tubular member undergoes deflection without failure of the composite when the lateral load is at least 550 pounds.  
     
     
         32 . The lighting pole of  claim 29 , wherein the tubular member undergoes deflection without failure of the composite when the lateral load is at least 600 pounds.  
     
     
         33 . The lighting pole of  claim 29 , wherein the tubular member undergoes deflection without failure of the composite when the lateral load is at least 650 pounds.  
     
     
         34 . The lighting pole of  claim 29 , wherein the tubular member is configured and adapted such that the twenty-foot section fixed at one end undergoes less than thirty inches of deflection when the lateral load is applied at the opposing end section at a magnitude sufficient to induce failure of the composite.  
     
     
         35 . The lighting pole of  claim 29 , wherein the tubular member is configured and adapted such that the twenty-foot section fixed at one end undergoes less than twenty-eight inches of deflection when the lateral load is applied at the opposing end section at a magnitude sufficient to induce failure of the composite.  
     
     
         36 . The lighting pole of  claim 29 , further comprising: 
 means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light.    
     
     
         37 . A structural, light-weight lighting pole comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent, wherein said tubular member is configured and adapted to support a heavy lighting structure thereon and to bear lateral loads imposed by said lighting structure without failure of the composite, and wherein said tubular member is light weight having an average linear weight distribution of less than five pounds per foot and further having an average outer diameter of at least six inches.    
     
     
         38 . The lighting pole of  claim 37 , wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member is capable of withstanding a lateral load transverse of the axis of at least 300 pounds without failure of the composite.  
     
     
         39 . The lighting pole of  claim 37 , wherein the tubular member has a wall thickness of less than {fraction (3/4)} inch.  
     
     
         40 . The lighting pole of  claim 37 , wherein the tubular member has a wall thickness of less than {fraction (1/2)} inch.  
     
     
         41 . The lighting pole of  claim 37 , further comprising: 
 means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light.    
     
     
         42 . A street light comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent and having a substantially constant exterior taper;    means for supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    lighting means attached to the upper section of the tubular member for projecting light;    wherein the tubular member has a wall thickness of less than {fraction (3/4)} inch, said tubular member being configured and adapted to support a lighting structure thereon without failure of the composite material, such that a twenty-foot section of said tubular member is capable of withstanding a lateral load transverse of the axis of at least 300 pounds without failure of said composite material;    wherein the tubular member is configured and adapted to bear flexure stress imposed by a lighting member when said lighting member is attached to said tubular member and extends outward from said tubular member in a sideways direction;    wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 19.938 inches of deflection when a lateral load of at least 300 pounds is applied at an opposing end section of said tubular member in a transverse direction relative to the axis;    wherein the tubular member is configured and adapted such that a twenty-foot section of said tubular member fixed at one end undergoes less than 36 inches of deflection when a lateral load is applied at an opposing end section of said tubular member in a transverse direction relative to the axis and at a magnitude sufficient to induce failure of the composite;    wherein the tubular member is light weight having an average linear weight distribution of less than five pounds per foot and further having an average outer diameter of at least six inches;    wherein the tubular member is characterized by a substantial absence of core material disposed therein for the purpose of providing structural reinforcement to said tubular member;    wherein the tubular member is constructed of multiple, filament-wound layers, including an inner, circumferential hoop-wound layer, and at least one internal, helical-wound layer, and an external, circumferential hoop-wound layer;    wherein the inner, circumferential hoop-wound layer comprises windings that form an angle within a range of 80-100 degrees with respect to the central axis of the tubular member;    wherein the at least one internal, helical-wound layer comprises windings that form an angle within a range of 10-20 degrees with respect to the central axis of the tubular member.    
     
     
         43 . A structural lighting pole comprising: 
 a one-piece, unitary, elongate, tubular member defining a central axis, said tubular member being constructed from a filament-wound composite of fiber-reinforced bonding agent and having a wall thickness of less than {fraction (3/4)} inch, wherein said tubular member is configured and adapted to support a lighting structure thereon without failure of the composite material, and wherein said tubular member is constructed of multiple, filament-wound layers, including an inner, circumferential hoop-wound layer, and at least one internal, helical-wound layer, and an external, circumferential hoop-wound layer.    
     
     
         44 . The lighting pole of  claim 43 , wherein the inner, circumferential hoop-wound layer comprises windings that form an angle within a range of 80-100 degrees with respect to the central axis of the tubular member.  
     
     
         45 . The lighting pole of  claim 44 , wherein the angle formed by the windings of the inner, circumferential hoop-wound layer is within a range of 85-90 degrees.  
     
     
         46 . The lighting pole of  claim 43 , wherein the at least one internal, helical-wound layer comprises windings that form an angle within a range of 10-20 degrees with respect to the central axis of the tubular member.  
     
     
         47 . The lighting pole of  claim 46 , wherein the angle formed by the windings of the at least one internal, helical-wound layer is approximately 15 degrees.  
     
     
         48 . A method of constructing a structural lighting pole, said method comprising the steps of: 
 (a) winding a multiple-tow bundle of fibers about a mandrel and maintaining said fibers under tension within a range of 30-100 pounds, to thereby form an inner, circumferential hoop-wound layer defining a central axis, such that said layer is formed of windings that form an angle within a range of 80-100 degrees with respect to said central axis;    (b) winding a multiple-tow bundle of fibers about the inner, circumferential layer and maintaining said fibers under tension within a range of 30-100 pounds to thereby form at least one internal, helical-wound layer, such that said internal, helical-wound layer is formed of windings that form an angle within a range of 10-20 degrees with respect to the central axis;    (c) winding a multiple-tow bundle of fibers about the at least one internal, helical-wound layer to thereby form an external, circumferential hoop-wound layer, such that said external, circumferential hoop-wound layer is formed of windings that form an angle within a range of 80-100 degrees with respect to the central axis;    (d) undertaking steps (a)-(c) above in a manner sufficient to form a filament-wound composite tubular member of fiber-reinforced bonding agent having a wall thickness of less than {fraction (3/4)} inch, wherein said tubular member is configured and adapted to support a lighting structure thereon without failure of the composite material;    (e) supporting the tubular member in a stationary, upwardly-extending orientation such that said tubular member terminates in an upper section; and    (f) attaching lighting means to the upper section of the tubular member for projecting light.    
     
     
         49 . The method of  claim 48 , wherein a twenty-foot section of the tubular member is capable of withstanding a lateral load transverse of the central axis of at least 300 pounds without failure of the composite material.  
     
     
         50 . The method of  claim 48 , wherein step (b) further comprises making the internal, helical-wound layer thicker by either maintaining the fibers closer together during winding or by making more than one internal, helical-wound layer.