Systems and methods for carbon fiber pole construction

Abstract

A unique carbon fiber structure that achieves the strength and durability of steel tower alternatives at 90% less weight and lower total installation cost provides an affordable carbon fiber telecommunications tower designed for peak strength-to-weight performance, the carbon fiber structure being a vertically extending tower body of decreasing area with an internal mounting shaft provided therein to house one or more wireless base stations, the tower can be made of multiple cylindrical or conical hollow segments with shaved upper portions, whereby the segments are made of carbon fiber and fiberglass hoop wraps.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This PCT application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 356,567, filed June 29, 2022, which claims the benefit of priority to U.S. Provisional Patent Application No. 18 / 215,915, filed June 29, 2023, both of which are incorporated herein by reference in their entireties.

[0002] FIELD OF THE INVENTION

[0002] The general field of the invention relates to telecommunications towers, and more particularly to carbon fiber towers or composite structures for use in wireless communication systems. [Background technology]

[0003]

[0003] Telecommunications towers are locations where electronic communications equipment and antennas are mounted, enabling surrounding areas to use wireless communication devices such as telephones and radios. The prevalent technology for telecommunications towers is generally steel or concrete structures, whether freestanding or guyed. These tall poles are often galvanized using hot-dip galvanization, in which the steel structure is coated with a layer of zinc. Steel towers are typically manufactured with a design life of 30 to 50 years, but present a significant number of challenges during this time. Developed countries, where internet and mobile phone penetration rates are already high, are transitioning to increasingly data-intensive media devices, such as 4G / LTE and 5G networks. This global expansion requires more towers, higher bandwidth, and access to more remote locations. Steel towers are difficult to transport and install on-site. Heavy steel poses safety hazards.

[0004]

[0004] Coated structures are also susceptible to mechanical and environmental wear, and lattice pylons are no exception, especially in coastal areas. Due to weight and other factors, pylons are subject to surface damage during transportation and installation, and such damage needs to be repaired when the pylon is installed. pylons also face a number of significant obstacles depending on the geographic region. In urban areas, property owners do not accept heavy, unaesthetic pylons. In rural areas, logistics and transportation are major concerns, especially in areas reachable only by boat or on foot. Therefore, there is a need for environmentally friendly composite structures with virtually no negative environmental impact, significantly lower density, and significantly reduced structural weight compared to steel. Summary of the Invention [Means for solving the problem]

[0005] BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Embodiments of the present disclosure are described in detail below with reference to the following drawings. These and other features, aspects, and advantages of the present disclosure will be better understood with reference to the following description, the appended claims, and the accompanying drawings. The drawings described herein are only intended to illustrate selected embodiments, rather than all possible implementations, and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]

[0006] [Figure 1]

[0006] FIG. 1 is a diagram of a production process. [Figure 2]

[0007] FIG. 1 is a diagram of installation options. [Figure 3]

[0008] FIG. 10 is another view of the installation options. [Figure 4]

[0009] FIG. 10 is another view of the installation options. [Figure 5]

[0010] FIG. 10 is another view of the installation options. [Figure 6]

[0011] FIG. 1 is a diagram of a modular mechanism. [Figure 7]

[0012] FIG. 10 is another view of the modular mechanism. [Figure 8]

[0013] FIG. 1 is a diagram of the tower mechanism. [Figure 9]

[0014] 10 is another embodiment of a modular mechanism. [Figure 10]

[0015] FIG. 1 is a diagram of an upright pile. [Figure 11]

[0016] FIG. 10 is another view of the upright stake. DETAILED DESCRIPTION OF THE INVENTION

[0007]

[0017] The present invention provides a unique carbon fiber structure that achieves the strength and durability of steel tower alternatives at 90% lighter weight and lower total installation costs. A mass production process provides affordable carbon fiber telecommunications towers designed for peak strength-to-weight performance. Composite, non-corrosive, rust-free towers are easily installed and transported to remote locations, and require less maintenance than alternatives. The global ecosystem supports lightweight, small-carbon-footprint, cost-effective towers, and our product is the only solution. The Tapered Monopole series offers a variety of tower options, all designed for unparalleled strength-to-weight characteristics. Carbon fiber structures offer aesthetically pleasing light weight and minimal base width, and they are easy to transport with sections that can be nested within each other to optimize transportation and logistics challenges. Carbon fiber structures are non-corrosive and last many times longer than steel. Carbon fiber structures are environmentally friendly with virtually no negative environmental impact, significantly lower density, and significantly reduced structural weight compared to steel.

[0008] Detailed Description

[0018] Reference is made to particular features (including method steps) of the invention in the summary above, this detailed description, the claims below, and the accompanying drawings. It is to be understood that the disclosure of the invention herein includes all possible combinations of such particular features. For example, when a particular feature is disclosed in the context of a particular aspect or embodiment of the invention or a particular claim, that feature can also be used, to the extent possible, in combination with and / or in the context of other particular aspects and embodiments of the invention, and in the invention as a whole.

[0009]

[0019] As used herein, the term "comprises" and its grammatical equivalents specifically mean that other components, ingredients, and steps are optionally present. For example, an article "comprising" (or "which comprises") components A, B, and C may consist of (i.e., contain only) components A, B, and C, or it may include not only components A, B, and C, but also one or more other components.

[0010]

[0020] When this document refers to a method including two or more specified steps, the specified steps may be performed in any order or simultaneously (unless the context excludes this possibility), and the method may include one or more other steps performed before any of the specified steps, between two of the specified steps, or after all of the specified steps (unless the context excludes this possibility).

[0011]

[0021] The term "at least" before a number is used herein to indicate the beginning of a range beginning with that number (which may be a range with or without an upper limit, depending on the variable being defined). For example, "at least 1" means 1 or more than 1. The term "at most" before a number is used herein to indicate the end of a range ending with that number (which may be a range with 1 or 0 as its lower limit, or a range with no lower limit, depending on the variable being defined). For example, "at most 4" means 4 or less than 4, and "at most 40%" means 40% or less than 40%. When a range is given herein as "from (a first number) to (a second number)" or "from (a first number) to (a second number)," this means a range whose lower limit is the first number and whose upper limit is the second number. For example, 25 to 100 mm means a range whose lower limit is 25 mm and whose upper limit is 100 mm.

[0012]

[0022] Certain terms and derivatives thereof may be used in the following description for convenience of reference, but not for limitation. For example, words such as "upward," "downward," "left," and "right" refer to directions in the drawings to which reference is made, unless otherwise specified. Similarly, words such as "inward" and "outward" refer to directions toward and away from, respectively, the geometric center of a device or area and designated portions thereof. References to the singular tense include the plural, and vice versa, unless otherwise specified.

[0013]

[0023] The present disclosure generally relates to systems and methods for a composite carbon fiber-based tapered monopole series according to one or more exemplary embodiments, which are lightweight, durable, and strong, and offer a variety of tower options, all designed for unparalleled strength-to-weight characteristics. In one or more non-limiting embodiments, fixtures or accessories may also be made from the same or similar materials. Carbon fiber monopoles offer an affordable composite option to traditional steel towers. The unique design offers incredible performance at a fraction of the weight, significantly reducing logistics costs and rented space. Tapered monopoles vary in diameter and height range from 6 meters (20 ft.) to over 42 meters (138 ft.), and can offer extreme structural weight savings compared to steel.

[0014]

[0024] According to one embodiment of the present invention, the antenna tower structure may be a substantially vertically extending tower body of decreasing area with an internal installation shaft therein, the installation shaft being configured to accommodate one or more radio base stations. The tower structure may be made of a number of hollow cylindrical or conical segments.

[0015]

[0025] The segments may be hollow with an inner diameter and an aperture passing through the segment. The segments may have a bottom portion. Sidewall portions extend outwardly and upwardly from an upper edge of the bottom portion, whereby the sidewall portions terminate in the top portion, whereby the circumference of the top portion may be equal to or less than the bottom portion. In some embodiments, the sidewall portions may be flat or at any different angle depending on the needs of erecting the tower.

[0016]

[0026] The segments can be created by a filament winding process involving a rotating series of stationary steel mandrels carrying arms that move horizontally up and down the length of the mandrels, as shown in FIG. 1. Filament winding creates hollow structures of surprising strength. The moving arms contain winding eyes, which gather rovings of carbon fiber in a specific winding pattern and distribute them onto the mandrel. As the mandrel turns, the rovings wrap around it to form a composite layer that covers the upper side of the mandrel's surface. The precise orientation of the carbon fibers when positioned over the mandrel can be at multiple angles, such as 0 to 40 degrees, but in one or more preferred embodiments, can be 0 to 5 degrees. Before encountering the mandrel, the carbon fibers may be impregnated with a specially designed epoxy resin and hardener, which later hardens with the carbon fibers to create the final composite material. In some embodiments, the carbon fibers may be pre-impregnated with epoxy resin.

[0017]

[0027] After the carbon fiber is positioned on the steel mandrel, the winding loop can supplement the 90-degree hoop wrap of glass fiber to surround the end of the mandrel. Different amounts can be used depending on the situation. The glass fiber is placed in a furnace, which squeezes out the resin, reinforcing the carbon fiber. This process, using a 90-degree hoop wrap of glass fiber, creates the necessary reinforcement to achieve the optimal material properties needed to meet or exceed regulatory requirements for telecommunications structures. By weaving a continuous roving of carbon fiber, then weaving the glass fibers and embedding them in a resin matrix, the filament winding process produces an optimal product: the perfect telecommunications tower. The glass fiber on the exterior of the segment provides an electrical effect and prevents corrosion when in contact with metal.

[0018]

[0028] After executing the desired pattern, the entire assembly of mandrel and carbon fiber and fiberglass composite material is placed in an oven to cure. During this process, the steel mandrel expands inward while the carbon fiber does not stretch to further strengthen the carbon fiber. Once the composite resin has sufficiently cured, the mandrel can be withdrawn, leaving a composite segment, and both ends can be trimmed to leave a hollow shape.

[0019]

[0029] After this process is complete, the top portion may be thickened, and the radially inward extending or skived area may be ground down or otherwise reduced. The diameter of the skived area may be less than the diameter of the segment aperture, allowing the inner diameter of the second segment to be positioned over the top of the first segment. During use, modular segments are stacked to create poles of different heights. The conical skived area allows segments to be nested within one another during shipping, dramatically improving shipping costs and the need for large transport vessels. Multiple segments can be assembled on-site using slip joint methods or other similar methods, allowing installation by hand or machine. *The diameter of a segment greater than 1.5 is the skived segment area. In some embodiments, a 9mm wall thickness may be skived down to a 7.86mm wall thickness for a perfect fit and a tighter joint without obstructions.

[0020]

[0030] During installation, the carbon fiber tower may be installed in a manner different from that shown in Figures 2-5. The carbon fiber tower may be buried directly in the ground without a foundation, or it may have a foundation base with special piles inserted into the ground and connected to the carbon fiber tower. The conventional method of drilling a shaft with a screw may be ideal in hard soil layers without groundwater. This may be accomplished using a twin-axial earth auger method with a casing. During operation, the user may dig a 2-meter x 2-meter x 5-meter hole and assemble the liner plate from the bottom. For a 40-meter carbon fiber tower, the diameter may be 1.5 meters. For a 40-meter carbon fiber tower, the hole may be 5.2 meters deep, and the area around the liner plate may be refilled. The carbon fiber tower may then be erected, and the gap may be filled with concrete. When driving dedicated foundation piles that are bolted to the carbon fiber tower, a height of 10 meters may be used for ordinary soil, and 20 meters may be used for liquefied soil.

[0021]

[0031] Initially, carbon fiber towers may be transported in nested bundles composed of multiple segments. Depending on the tower size, these bundles are approximately 19 ft. [5.8 m] or 37 ft. [11.3 m] in length. Nested carbon fiber towers may be lowered using a forklift or boom truck. Due to their lightweight nature, individual carbon fiber tower segments may be lowered by hand. It should be noted that if a nested tower set includes long outer modules (i.e., 5 / 6, 6 / 7, or 8) and short inner modules (i.e., 1, 2, 3, or 4), the center of gravity of the nested set will be closer to the base. Before lowering the towers, ensure that all towers are secured with blocks and that the lower row of towers remains tightly strapped until all towers are properly secured, without unraveling or cutting any straps or ties. Nested bundles of carbon fiber may be secured with shipping bolts.

[0022]

[0032] To unseat a nest, the module shipping bolts located at the large ends of the nested module sets are removed. These bolts hold all of the modules together from a single point. The nested module sets should be lifted (wooden dunnage is recommended for this purpose) to allow for bolt removal, and the shipping bolts should be at the bottom of the nested modules to minimize module movement after the shipping bolts are removed and avoid potential injury. After the shipping bolts are removed, the segments are unseat-assembled and lined up for assembly, starting with the innermost (smallest) segment first. For smaller segments, this can usually be accomplished by hand by a crew of two to four people. For larger modules, handling with a boom truck is recommended to move the modules faster and more safely. When unseat-assembling segments, it is important that the base of the segment be elevated during its removal from the nested set to minimize scratches along the length of the segment.

[0023]

[0033] Once the segments are unnested and arranged for assembly, it is recommended that the modules be "blocked" into place to keep them clear of debris from the ground and slip joints, as shown in Figures 6-8. Two blocks per segment are recommended. Pipe cradles and assembly shelves may also be used instead of wood blocks to raise the modules to a comfortable working level. Therefore, any debris from the slip joint area should be wiped clean, especially within the thick end of the smaller (upper) segment to be assembled, where the tip of the larger (lower) segment will be inserted. Therefore, the locations of the segments and brackets may be marked, or the user may identify pre-existing marks.

[0024]

[0034] Assembly shelves can be the most efficient way to assemble carbon fiber towers, allowing for complete tower assembly in just 10 to 15 minutes. These shelves elevate the tower to a comfortable working height and facilitate quick and easy installation of brackets and accessories by using rollers. Starting with the largest tower section to be assembled (making sure to position the thick end of the base module, if desired), the smaller base segment slides down over the tip of the larger segment, using the alignment marks as a guide. Segments with elongated tips may have four quadrant axes, with base alignment marks on the axes. The alignment marks typically appear as text with data including the segment's weight and serial number. If the original alignment line printing has faded, the alignment mark will appear as a single solid line. In this type of assembly, the base module should first be positioned and vertical. Then, depending on preference and site conditions, subsequent tower segments can be lifted into place as a single pre-formed unit or assembled individually. Alignment holes in the top and bottom sections of the pole can also be used to notice missing alignment line prints. Once the tower is assembled vertically, the modules still need to be "pulled together" using two 3-ton come-alongs, safety leashes or chains and jacking lugs.

[0025]

[0035] Next, the user attaches and secures the tower segment lift level kit to the top of tower section 8. The user attaches (4x) 20' guy cables to the tower section lift level kit at four specific locations. The user then lifts tower section 8 from the tower section lift level kit with a crane and attaches it to the tower base. The user then attaches the other ends of the (4x) guy wires from the tower section lift level kit to the hooks of the come-along tool at four locations. The user then attaches the other hooks of the come-along to the base plate at the four guy wire lift locations.

[0026]

[0036] It is recommended that a 3-ton come-along be used to ensure the slip joints are properly packed. The user then checks the specifications for the expected height, overlap, and required guy wire tension. The user can then begin to lift the handles of the come-along, one at a time, using a cable tension meter to measure that the proper tension is being applied to the cable to ensure the tower sections are vertical. The user also uses a distance meter at each lift point from the base of the tower, aimed directly at the target plate on the lift level kit. Once the tower sections are at the same level, correct height, and correct overlap, the user removes the tower section lift level kit. The user then attaches the lift level kit to the cable from the crane and disconnects the (4x) come-alongs from the (4x) guy wires for removal.

[0027]

[0037] The user then attaches a level lift kit to the next tower section and attaches an additional 20 ft (4x) guy wires with shackles to extend the length of the lifting guy wires. The user then uses a crane to lift the tower section and attach it to the lower tower section. The user then aligns the straight guideline markers on both the top and bottom tower sections. The user then attaches the other end of the (4x) guy wires from the tower section to the hooks on the come-along tool.

[0028]

[0038] Next, the user attaches and secures the tower segment leveling plate to the top of the tower section. The user attaches (4x) 20' guy cables to the tower section leveling plate at four specific locations. The user then uses a crane to lift the tower section 8 from the tower section leveling plate and attach it to the tower base. The user then attaches the other ends of the (4x) guy wires from the tower section leveling plate to the base plate at four locations. The user then inserts four lifting lugs, two per tower section, into the pre-drilled lifting lug holes in the tower section. The pre-drilled lifting lug holes are positioned 180 degrees to each segment. The user then ensures that the lugs are fully inserted, flush with the tower wall, and oriented in the direction of the come-along to prevent damage to the tower wall or the lifting lugs. The user then wraps the lifting lug safety cord or chain around the tower section at each of the lifting lug locations.

[0029]

[0039] 9. Once the tower sections are at the same level, at the correct height, and with the correct overlap, the user installs the locks to hold the tower sections securely in place and removes the tower section leveling plates. The user then installs and secures the tower section leveling plates to the top of the tower sections. The user then installs (4x) 20' guy cables to the leveling plates at four specific locations. The user then installs (4x) 20' guy cables to the leveling plates at four specific locations. The steps may then be repeated until the tower is fully erected.

[0030]

[0040] The level of the tower section can be confirmed by using a Disto distance meter. There are four measurement points that need to be measured while hoisting the four guy wires. The user may then continue hoisting the come-along jack until the distance meter readings are equal at all four hoisting points, indicating that the tower sections are vertical and at the same level. The top cap can be placed on the top segment of the assembled tower and secured to the tower with four self-tapping 5 / 16" [8 mm] hex head screws, using the pilot holes in the top cap.

[0031]

[0041] In one or more non-limiting embodiments, as shown in Figures 9, 10, and 11, the foundation is a single pile foundation supported by a bearing layer with an N-value of 2 at ground level -10.0 m for applications in normal areas. The pile construction method is a winged, rotary-penetrating steel pipe pile (AMZ Method Co., Ltd. Edge). The pile tip soil: N-value 2 is assumed to be the bearing capacity in the push-in direction of the steel pipe pile method AMZ Method: Ministry of Land, Infrastructure, Transport and Tourism certified method TACP-0623 (sand / gravel) / TACP-0624 (clay). Extraction direction: Minister of Land, Infrastructure, Transport and Tourism certified method GBRC Performance Certification No. 20-14. The results of a boring survey conducted by soil investigation confirm that the N-value of the bearing layer at the pile tip is 2 or greater. If the N-value is 2 or less, the pile length will extend to the layer with an N-value of 2 or greater.

[0032]

[0042] The piles used in this construction method (AMZ piles) have two semicircular wings attached to the tip of a steel pipe (101.6-457.2), and are fitted with an assembly plate and a drilling blade. The pile tip consists of a steel pipe (steel pipe at the tip), blade, assembly plate, I, and drilling blade. The tip is welded to the shaft steel pipe. There are two integrated types, in which the blade is directly attached. JIS G 3106 welded structural rolled steel (SM490A)-2017 is used for the I blade. If the thickness is 25 mm or more, the blade is chamfered. JIS G 3101 general structural rolled steel (SS400)-2017 is used for the assembly plate and drilling blade (auxiliary drilling blade). JIS G 3444 general structural carbon steel pipe (STK400, STK490)-2016 is used for the pile shaft steel pipe. JIS G 3444 general structural carbon steel pipe (STK400, STK490) 2016 is used for the tip steel pipe.

[0033]

[0043] The embodiments have been selected and described in order to best explain the principles and practical applications of the invention and to enable those skilled in the art to understand the invention in relation to various embodiments, along with various modifications suited to the particular uses contemplated. The invention according to one or more embodiments set forth in this description may be embodied in modified and alternative forms within the spirit and scope of the appended claims. Therefore, the description is to be considered illustrative rather than limiting of the invention.

Claims

1. 1. A method for a carbon fiber pole, comprising forming a plurality of segments during a filament winding process, the plurality of segments being cylindrical or conical in shape, the carbon fiber pole having an internal mounting shaft therein for housing one or more wireless base stations.

2. 10. The method of claim 1, wherein the filament winding process includes a rotating series of mandrels carrying one or more arms that move horizontally up and down the length of the mandrels to gather a roving of carbon fiber in a winding pattern and distribute the carbon fibers onto the mandrels.

3. The method of claim 2 further comprising positioning the carbon fiber over the mandrel at between zero and five degrees.

4. 4. The method of claim 3, further comprising impregnating the carbon fibers with an epoxy resin and a hardener, which subsequently harden with the carbon fibers to create a composite material.

5. 5. The method of claim 4, further comprising adding a 90 degree hoop wrap of fiberglass to surround both ends of the mandrel to be positioned over the composite material.

6. 6. The method of claim 5, further comprising curing the composite material by placing the mandrel and the composite material in an oven, wherein the mandrel expands inwardly while the carbon fibers do not stretch to further strengthen the carbon fibers.

7. The method of claim 6 further comprising withdrawing the mandrel.

8. The method of claim 7 further comprising cutting both ends of the composite material to form one of the plurality of hollow segments.

9. The method of claim 8 further comprising skiving off an upper portion of the segment.

10. 10. The method of claim 9, wherein the diameter of the higher segment is 1.5* the area of the shaved segment at the upper portion of the segment.

11. 10. The method of claim 9, wherein said skiving down said upper portion comprises skiving down a wall thickness of 9 mm to a 7.86 mm segment.

12. The method of claim 9 further comprising assembling the plurality of segments at a final location.

13. 13. The method of claim 12, further comprising burying the carbon fiber pole directly in the ground without a foundation.

14. Furthermore, drilling shafts with screws into hard groundwater-free formations by the twin-axial earth auger method with casing; Excavating a square area and assembling a liner plate at the bottom; and Refilling said square area 14. The method of claim 13, comprising:

15. 13. The method of claim 12, further comprising burying the carbon fiber poles directly in the ground using a foundation base having piles inserted into the surface and connected to the carbon fiber towers.

16. The method of claim 12, further comprising: hammering a foundation base that is bolted to the carbon fiber tower, wherein the two semicircular wings of the foundation base are attached to the ends of steel pipes.

17. A carbon fiber pole made of multiple segments that are cylindrical or conical in shape and have an internally mounted shaft.

18. 18. The carbon fiber pole of claim 17, wherein the components attached to the carbon fiber pole are made of carbon fiber.

19. 20. The carbon fiber pole of claim 18, wherein the plurality of segments are made of carbon fiber and fiberglass hoop wraps on the ends of the plurality of segments.

20. 20. The carbon fiber pole of claim 19, wherein the plurality of segments have skived sections, the diameter of an upper segment being 1.5 times the area of the skived section of the upper portion of a lower segment.

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