Fiber architecture for a composite pole
View Patent ↗A fiber architecture in the form of an elongate beam having a hollow polygonal cross section with a plurality of substantially flat exterior sides and a corner between each pair of adjacent exterior sides. The cross section is substantially thicker adjacent each corner. The fiber architecture includes a first fabric layer extending around the beam, a layer of circumferential longitudinal rovings extending around the beam adjacent the outside of the first fabric layer, corner longitudinal rovings coterminous and integral with the outside of the circumferential rovings adjacent each corner, and a second fabric layer extending around the beam adjacent the outside of the corner rovings and adjacent the outside of the circumferential rovings not covered by corner rovings. The fabric architecture may be impregnated with resin to form a composite pole that may be used as a utility pole.
1. A fiber architecture comprising an elongate beam having a hollow polygonal cross section with a plurality of substantially flat exterior sides and a corner between each pair of adjacent exterior sides, the beam including a hollow substantially polygonal interior fabric layer, a layer of circumferential longitudinal rovings extending around the beam adjacent the outside of the interior fabric layer, and an exterior fabric layer extending around the beam adjacent the outside of the circumferential rovings, the interior fabric layer further comprising a first fabric sheet and a second fabric sheet that overlap.
2. The fiber architecture of claim 1 wherein the first fabric sheet and the second fabric sheet overlap by at least 24 times a thickness of the fabric.
3. The fiber architecture of claim 1 wherein the exterior fabric layer further comprises a third fabric sheet and a fourth fabric sheet that overlap.
4. The fiber architecture of claim 3 wherein the third fabric sheet and the fourth fabric sheet overlap by at least 24 times a thickness of the fabric.
5. The fiber architecture of claim 3 wherein the overlap between the first and second fabric sheets is displaced by about ninety degrees from the overlap between the third and fourth fabric sheets.
6. The fiber architecture of claim 1 further comprising a surfacing veil adjacent the outside of the exterior fabric layer.
7. The fiber architecture of claim 1 further comprising a second layer of circumferential longitudinal rovings extending around the beam adjacent the inside of the interior fabric layer, and a third fabric layer extending around the beam adjacent the inside of the second layer of circumferential rovings.
8. The fiber architecture of claim 1 wherein the rovings and fabric comprise fiberglass.
9. The utility pole of claim 8 wherein the interior fabric layer further comprises a first fabric sheet and a second fabric sheet that overlap.
10. The utility pole of claim 9 wherein the first fabric sheet and the second fabric sheet overlap by at least 24 times a thickness of the fabric.
11. The utility pole of claim 9 wherein the exterior fabric layer further comprises a third fabric sheet and a fourth fabric sheet that overlap.
12. The utility pole of claim 11 wherein the third fabric sheet and the fourth fabric sheet overlap by at least 24 times a thickness of the fabric.
13. The utility pole of claim 11 wherein the overlap between the first and second fabric sheets is displaced by about ninety degrees from the overlap between the third and fourth fabric sheets.
14. A utility pole comprising:
a fiber architecture in the form of an elongate beam having a hollow polygonal cross section with a plurality of substantially flat sides and a corner between each pair of adjacent sides, the fiber architecture including
an interior fabric layer extending around the beam, the interior fabric layer further comprising a first fabric sheet and a second fabric sheet that overlap,
a layer of circumferential longitudinal rovings extending around the beam adjacent the outside of the interior fabric layer, and
an exterior fabric layer extending around the beam adjacent the outside of the circumferential rovings; and,
resin impregnating the fiber architecture to bind filaments together to produce a composite utility pole.
15. The utility pole of claim 14 wherein the first fabric sheet and the second fabric sheet overlap by at least 24 times a thickness of the fabric.
16. The utility pole of claim 14 wherein the exterior fabric layer further comprises a third fabric sheet and a fourth fabric sheet that overlap.
17. The utility pole of claim 16 wherein the third fabric sheet and the fourth fabric sheet overlap by at least 24 times a thickness of the fabric.
18. The utility pole of claim 16 wherein the overlap between the first and second fabric sheets is displaced by about ninety degrees from the overlap between the third and fourth fabric sheets.
19. The utility pole of claim 14 further comprising a surfacing veil adjacent the outside of the exterior fabric layer.
20. The utility pole of claim 14 further comprising a second layer of circumferential longitudinal rovings extending around the beam adjacent the inside of the interior fabric layer, and a third fabric layer extending around the beam adjacent the inside of the second layer of circumferential rovings.
21. The utility pole of claim 14 wherein the rovings and fabric comprise fiberglass.
22. A fiber architecture for an elongated beam, comprising:
(a) a hollow substantially polygonal interior fabric layer;
(b) a circumferential layer of longitudinal rovings extending around the interior fabric layer, said longitudinal rovings further extending to form circumferential corners corresponding to a polygonal cross-section of the elongated beam; and
(c) an exterior fabric layer extending around the layer of longitudinal rovings.
23. The fiber architecture of claim 22 further comprising a surfacing veil adjacent the outside of the exterior fabric layer.
24. The fiber architecture of claim 22 further comprising a second layer of circumferential longitudinal rovings extending around the beam adjacent the inside of the interior fabric layer, and a third fabric layer extending around the beam adjacent the inside of the second layer of circumferential rovings.
25. The fiber architecture of claim 22 wherein the rovings and fabric comprise fiberglass.
26. The fiber architecture of claim 22 wherein the interior fabric layer further comprises a first fabric sheet and a second fabric sheet that overlap.
27. The fiber architecture of claim 26 wherein the first fabric sheet and the second fabric sheet overlap by at least 24 times a thickness of fabric.
28. The fiber architecture of claim 26 wherein the exterior fabric layer further comprises a third fabric sheet and a fourth fabric sheet that overlap.
29. The fiber architecture of claim 28 wherein the third fabric sheet and the fourth fabric sheet overlap by at least 24 times a thickness of the fabric.
30. The fiber architecture of claim 28 wherein the overlap between the first and second fabric sheets is displaced by about ninety degrees from the overlap between the third and fourth fabric sheets.
31. A fiber architecture for an elongated beam, comprising:
(a) a hollow substantially polygonal interior fabric layer;
(b) a circumferential layer of longitudinal rovings extending around the interior fabric layer, said longitudinal rovings further extending to form circumferential corners corresponding to a polygonal cross-section of the elongated beam;
(c) an exterior fabric layer extending around the layer of longitudinal rovings; and
(d) resin impregnating the fiber architecture to bind filaments together to produce a composite utility pole.
32. The utility pole of claim 31 wherein the fabric architecture further comprises a surfacing veil adjacent the outside of the exterior fabric layer.
33. The utility pole of claim 31 wherein the fabric architecture further comprises a second layer of circumferential longitudinal rovings extending around the beam adjacent the inside of the interior fabric layer, and a third fabric layer extending around the beam adjacent the inside of the second layer of circumferential rovings.
34. The utility pole of claim 31 wherein the rovings and fabric comprise fiberglass.