Composite Pole Structure Using Recycled Thermoplastic Outer Layer
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Solution Overview
Problem
Existing composite poles for structural applications, such as holding commodities like wires and streetlamps, face challenges in utilizing substantial amounts of thermoplastic waste materials due to their limited recyclability and mechanical properties, while traditional materials like wood and concrete have environmental and performance limitations.
Innovation Solution
A composite pole design comprising a tubular structure with an inner layer of continuous glass fibre reinforced thermoplastic matrix and an outer layer of thermoplastic waste material, combined with a specific fibre orientation and production process to enhance mechanical properties and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoplastic waste material is used in composite poles, then recyclability and environmental sustainability are improved, but mechanical properties and structural strength deteriorate
Solution Approach 1:
The patent applies composite materials by combining thermoplastic waste material with natural fibre reinforcement (such as hemp, flax, or jute) to create a hybrid composite that maintains mechanical strength while utilizing recyclable waste materials. The natural fibres provide structural reinforcement to compensate for the lower mechanical properties of the thermoplastic waste matrix.
Solution Approach 2:
The patent changes the physical and chemical parameters of the thermoplastic waste material through processing methods such as melting, extrusion, and formulation with additives or natural fibre blends. This transforms the waste material into a usable composite matrix with improved mechanical properties suitable for pole construction.
2Strength
If continuous glass fibres are used for reinforcement, then mechanical strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by using continuous glass fibres only in specific critical regions of the pole where maximum mechanical strength is required, such as the base section or areas subject to high stress. Other sections may use shorter fibres or alternative reinforcements, reducing overall manufacturing complexity while maintaining necessary strength.
Solution Approach 2:
The patent segments the reinforcement strategy by dividing the pole into different sections with varying fibre types and orientations. This allows optimization of material usage - continuous glass fibres in high-stress zones and alternative reinforcements elsewhere - thereby reducing overall manufacturing complexity and cost.
3Length of moving object
If pole height is increased to meet structural requirements, then structural performance is improved, but susceptibility to groundline decay and mechanical failure increases
Solution Approach 1:
The patent employs a protective outer shell or coating system that acts as a barrier against groundline decay and environmental degradation. This flexible protective layer extends the service life of tall poles by preventing moisture and biological agents from reaching the structural core, thereby maintaining reliability despite increased height.
Solution Approach 2:
The patent uses composite materials with inherent resistance to groundline decay, such as thermoplastic-based composites that do not rot like wood. This allows the construction of taller poles that maintain structural integrity and resistance to biological degradation over extended service periods.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite pole effectively utilizes substantial amounts of thermoplastic waste, providing enhanced mechanical properties and recyclability, while meeting structural requirements for durability and environmental sustainability.
Implementation Method 1
Thermoplastic polymers have the potential of being recycled since they can be melted by heating
Implementation Method 2
re-shaped in the liquid form and cooled to solidify, generally by crystallisation
Data Source
Figure 1~2c
Figure 3a~3f
Figure 4a~4i
AI summary
The invention relates to a composite pole (1) for structural applications defining a tubular structure comprising a bore (4) and extending along a Z-axis, wherein • a length of the composite pole, L = 3 to 20 m, • an aspect ratio of the length (L) to the bottom hydraulic diameter (D3b), L / D3b = 30 to 40 and • a ratio of the top hydraulic diameter (D3t) to the bottom hydraulic diameter (D3b), D3t / D3b = 0.5 to 1.0, preferably, 0.7 to 0.9), Characterized in that, the composite pole is formed by a wall comprising an inner tubular layer (2) and an outer tubular layer (3), wherein • the inner tubular layer (2) defines the bore (4) and is made of a thermoplastic polymer matrix (2m) reinforced by continuous glass fibres and • the outer tubular layer (3) is applied directly over the inner tubular layer (2), and is made of thermoplastic polymer waste material (3m) preferably admixed with chopped glass fibres.