US 11,939,783 B2
System and method for carbon fiber pole construction
Eddy E. Dominguez, Milpitas, CA (US)
Filed by Eddy E. Dominguez, Milpitas, CA (US)
Filed on Jun. 29, 2023, as Appl. No. 18/215,915.
Claims priority of provisional application 63/356,567, filed on Jun. 29, 2022.
Prior Publication US 2024/0003157 A1, Jan. 4, 2024
Int. Cl. B29C 70/32 (2006.01); B29L 23/00 (2006.01); E02D 27/42 (2006.01); E04H 12/02 (2006.01); B29K 263/00 (2006.01); B29K 307/04 (2006.01); B29L 31/00 (2006.01); E02D 7/06 (2006.01); E21B 7/02 (2006.01)
CPC E04H 12/02 (2013.01) [B29C 70/32 (2013.01); E02D 27/42 (2013.01); B29K 2263/00 (2013.01); B29K 2307/04 (2013.01); B29L 2023/22 (2013.01); B29L 2031/766 (2013.01); E02D 7/06 (2013.01); E02D 2300/0068 (2013.01); E21B 7/027 (2013.01)] 2 Claims
OG exemplary drawing
 
1. A method for making a carbon fiber pole, the carbon fiber pole having a plurality of segments, wherein the plurality of segments are cylindrical or conical in shape wherein the carbon fiber pole has an internal installation shaft provided therein to house one or more radio base stations, the method comprising the following steps in order:
impregnating carbon fiber into resin and hardener to form a composite material;
positioning the composite material into a filament winding process, wherein the filament winding process includes one or more mandrels that rotate and one or more carriage arms that travel horizontally up and down a length of the one or more mandrels which groups rovings of a winding pattern of the carbon fiber and dispenses the carbon fiber to the one or more mandrels at zero to five degrees;
supplementing hoop winding of fiberglass on the one or more mandrels to be positioned on the composite material; and
curing the composite material by placing the one or more mandrels and the composite material in a heating source wherein the one or more mandrels swell inside while the carbon fiber does not stretch as the fiberglass squeezes the resin to consolidate the carbon fiber.
 
2. A method for making a carbon fiber pole, the method comprising:
forming a plurality of segments, wherein the plurality of segments are cylindrical or conical in shape wherein the carbon fiber pole has an internal installation shaft provided therein to house one or more radio base stations;
cutting ends of a segment of the plurality of segments to form a hollow shape; and
shaving an upper portion of the segment;
conducting a filament winding process that includes a mandrel that rotates and one or more carriage arms that travel horizontally up and down a length of the mandrel which groups rovings of a winding pattern of carbon fiber and dispenses the carbon fiber to the mandrel;
positioning the carbon fiber over the mandrel at zero to five degrees;
impregnating the carbon fiber into epoxy resin and harder which later solidifies with the carbon fiber to create a composite material;
supplementing 90 degree hoop winding of fiberglass to surround ends of the mandrel to be positioned on the composite material;
curing the composite material by placing the mandrel and the composite material in an oven wherein the mandrel swells inside while the carbon fiber does not stretch to further consolidate the carbon fiber;
assembling the plurality of segments at a final location;
directly burying the carbon fiber pole in a ground by a foundation base which is bolted to the carbon fiber pole, the foundation base having a pile that is inserted into the ground and connected to the carbon fiber pole; and
driving the foundation base into the ground, wherein the foundation base has two semicircular wings attached to a tip of a steel pipe.