Carbon fiber tubular pole and method of manufacture
View Patent ↗A carbon fiber tubular pole and method of construction thereof. The pole includes a left in place lightweight mandrel, preferably formed of tubular polyvinylchloride or cardboard, which substantially reduces cost of manufacture. Moreover, an outer tubular glass fiber sleeve over a tubular carbon fiber sleeve resin saturated through and through maintains the aesthetic appearance of the black carbon fiber while substantially strengthening the end product. A second outer layer of a mixture of resin and colloidal silica over the cured resin layer adds shine and increases smoothness.
1. A method of making a carbon fiber tubular pole comprising:
providing an elongated tubular mandrel defining a hollow interior;
inserting a removable support rod into the hollow interior of the elongated tubular mandrel;
sliding and stretching a carbon fiber sleeve over the elongated tubular mandrel;
sliding and stretching a glass fiber sleeve over the carbon fiber sleeve;
rotating the removable support rod for rotating the elongated tubular mandrel while applying a sufficient quantity of a curable resin to saturate through the sleeves to contact with the mandrel;
smoothing and further stretching the uncured resin saturated sleeves; and
allowing the uncured resin to cure and monolithically permanently secure the tubular mandrel and the sleeves together; and
removing the removable support rod from the hollow interior of the elongated tubular mandrel.
2. A method of making a curved carbon fiber tubular connector as set forth in claim 1 , wherein the step of providing an elongated tubular mandrel includes providing an elongated tubular mandrel having a hollow interior dimension for receiving a second tubular member within the hollow interior dimension of the elongated tubular mandrel.
3. A method of making a curved carbon fiber tubular connector as set forth in claim 1 , wherein the step of providing an elongated tubular mandrel includes providing an elongated tubular mandrel having a dimension for insertion into a hollow interior dimension of a second tubular member.
4. A method of making a carbon fiber tubular pole comprising:
providing an elongated tubular mandrel formed from a hollow tubular polymeric material;
inserting a removable support rod into the hollow tubular polymeric material;
sliding and stretching a carbon fiber sleeve over the hollow tubular polymeric material;
sliding and stretching a glass fiber sleeve over the carbon fiber sleeve;
rotating the removable support rod for rotating the elongated tubular mandrel while applying a sufficient quantity of a curable resin to saturate through the sleeves to contact with the tubular polymeric material;
smoothing and further stretching the uncured resin saturated sleeves;
allowing the uncured resin to cure and monolithically permanently secure the carbon fiber sleeve and the glass fiber sleeve and the hollow tubular polymeric material together; and
removing the removable support rod from the hollow tubular polymeric material.
5. A method of making a curved carbon fiber tubular connector, comprising:
providing a curved tubular polymeric material defining a hollow interior;
inserting a removable support rod into the hollow interior of the curved tubular polymeric material;
sliding and stretching a carbon fiber sleeve over the curved tubular polymeric material;
sliding and stretching a glass fiber sleeve over the carbon fiber sleeve;
rotating the removable support rod for rotating the curved tubular polymeric material while applying a sufficient quantity of a curable resin to saturate through the sleeves to contact with the curved tubular polymeric material;
smoothing and further stretching the uncured resin saturated sleeves;
allowing the uncured resin to cure and monolithically permanently secure the curved tubular polymeric material and the sleeves together; and
removing the removable support rod from the curved tubular polymeric material.
6. A method of making a curved carbon fiber tubular connector as set forth in claim 5 , wherein the step of providing a curved tubular polymeric material defining a hollow interior includes heating a straight polymeric material for bending the polymeric material to form the curved tubular polymeric material.
7. A method of making a curved carbon fiber tubular connector as set forth in claim 6 , including the step of applying a mixture of colloidal silica and resin over the cured resin.
8. A method of making a curved carbon fiber tubular connector as set forth in claim 6 , wherein the step of providing a curved tubular polymeric material includes providing a curved tubular polymeric material having a hollow interior dimension for receiving a second tubular member within the hollow interior dimension of the curved tubular polymeric material.
9. A method of making a curved carbon fiber tubular connector as set forth in claim 6 , wherein the step of providing a curved tubular polymeric material includes providing a curved tubular polymeric material having a dimension for insertion into a hollow interior dimension of a second tubular member.