Note: Descriptions are shown in the official language in which they were submitted.
CA 02407924 2003-11-05
TITLE
BALLAST BOX ATTACHMENT AND
METHOD OF MOUNTING SAID BALLAST BOX
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to a means and methods for elevating
structures, and in particular, to poles anchored in the ground for vertically
elevating any type of member or members to an extended distance.
This invention further relates to installation of lighting fixtures in a
position
elevated above the ground on poles, and in particular, the comprehensive
integrated combination of fixture supports and poles, wiring, and electrical
components to operate the lighting fixtures.
Problems in the Prior Art
A number of structures or things must be suspended from the ground.
Examples are light fixtures, sirens, antennae, wires, and the like. Many times
these structures need to be rigidly supported. Of course, a conventional means
to accomplish this is to utilize an elongated pole.
Commonly known examples of poles of this type are telephone poles,
electrical wire poles, light poles, sign poles, and utility poles. Most of
these types
of poles are anchored in the ground and extend vertically upward to many times
tens of feet in height.
The widespread utilization of these types of poles is indicative of the
preference to utilize elongated structures or
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poles to elevate objects in the air. For whatever reasons,
whether it be economical or practical, the demand for the poles
is very high for a number of different uses.
Poles of this nature can be made of a number of materials
and can be erected and installed in a number of ways. While each
of the commonly used poles achieves the end result of elevating
objects in the air, the different types commonly used have both
their advantages and disadvantages.
Wood poles represent the longest used and still today the
many times preferred type of pole. They are relatively
inexpensive, have a good height to diameter strength ratio, and
can be rather easily adapted for a number of uses.
Problems and disadvantages of wood poles, however, are at
least:
a. Difficult to find straight wood poles, especially for
taller heights;
b. Natural processes decay or at least weaken wood;
c. Wood is fairly heavy;
d. Pole comes in single long length which can be difficult
to transport;
e. Environmental problems associated with using trees
could effect availability;
f. Appearance;
g. Uncertainty of strength;
h. Bottom end is buried in the ground and therefore even
more susceptible to decay and deterioration; and
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An alternative pole that has more recently been utilized is
one made substantially of concrete. For even significantly tall
poles, concrete has great strength in compression and with a
steel cable infra structure offers strength in tension. With
advances in the nature of concrete, such poles offer a relatively
economical and very strong alternative to wood.
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These types of above-mentioned deficiencies have resulted in
the pole of preference being comprised of a steel pole which is
anchored in the ground usually to poured concrete fill. Such a
combination allows the use of high strength yet lightweight
hollow tube steel for the above ground portion, while utilizing
lower cost and high weight concrete as the anchor in the ground.
This also aids in installation~as the concrete bases can be
poured and then the lightweight steel poles mounted thereon.
' These advantages do not come without a price however. The
disadvantages of this type of pole are at least the following:
a. Most expensive;
b. Concrete and rebar (if used) must be custom designed;
c. Heavy, thick base plate must be welded to the
lightweight steel tube;
d. Galvanizing, Which is the preferred protective coating,
is sensitive to the temperature differences between the
thick base and thin tube;
e. Concrete foundations must be accurately constructed on
the site according to the custom design;
f. The poles and the concrete fill, and any other hardware
many times are required to come from different sources
and therefore may not adequately match; and
g. Corrosion problems.
As can be appreciated, the problems with steel and concrete
foundation poles are not insignificant. Because the joint
between the steel and concrete will have to take much of the
stress provided by the long moment arm of the upwardly extending
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pole, and because of wind load and other factors, it is critical
that for each installation the junction between the pole and the
foundation be accurately and correctly prepared. This is an
intricate matter requiring not only the correct design
specifications and construction of the concrete foundation and
the steel pole, but also accurate and faithful adherence to
design and installation specifications by field personnel in
forming the concrete foundation.-
The custom design must include not only the height and
weight requirements associated with each particular pole, but
also must consider the type and strength of concrete used, the
design of the rebar cage in the concrete, and the design and
placement of hardware attaching the steel pole to the concrete.
As is well understood by those with ordinary skill in the
art, a custom design for the concrete foundations requires
significant expenditure of resources. Additionally, the success
of the design is then entirely dependent upon its implementation
in. the field.
Unfortunately, a significant and real problem exists in
contractors carrying out the installations not doing so
accurately. Without a reliable match between the design
parameters of the concrete foundation and the parameters
associated with the steel pole with its actual installation, the
entire pole structure is susceptible to damage or failure.
Accordingly, substantial expense may be incurred over designing
and installing the concrete foundations to allow for field
installation tolerances. Additionally, concrete requires up to
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1
28 days to develop full strength needed for tensile strength and
to anchor the bolts used to secure the pole. The compressive
qualities of concrete develop more quickly.
A second major problem with steel pole and concrete
foundation combinations is that of corrosion. While presently
the corrosion problems are addressed by attempting to galvanize
all metal components, at least the following impediments exist to
that being successful.
The best environment for corrosion is generally within a few
feet above and below the ground line. Frequently, concrete and
steel poles such as described above have the concrete bases or
foundations poured and submerged from close to ground level
downwardly. Therefore, the most corrosion-susceptible area of
the metal, at or near the joint with the concrete, is in that
area where corrosion is the most likely. Moisture in the form of
standing water and condensation is most concentrated in this
area. Additionally, this is also an area where the_concentration
of oxygen is high, which is one of the components of corrosion
and rust.
Secondly, as previously mentioned, the joint between the
steel pole and the concrete foundation often represents the
highest stress area for the combination. It is known in the art
that corrosion increases with stress.
Third, the conventional way of securing the joint is to
utilize long bolts through-a mounting.plate of the steel pole
into the concrete. These bolts also take a majority of the
stress and are therefore very susceptible to corrosion.
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Fourth, galvanizing simply cannot be very reliable for the
following reasons. Stress is detrimental to galvanization. An
annular base plate for the metal pole must be welded to the
tubular elongated portion of the pole. For galvanization to be
reliable, the surface must be extremely clean. Debris or dirt in
general, and in particular flux, which is hard to remove around
welded joints, will not take galvanization. Sometimes direct-
bury steel poles are utilized. Corrosion problems as well as
installation problems similar to described above exist.
Additionally, galvanization is accomplished by heating the
metal. For reliable galvanization, the metal must be heated
uniformly. However, the baseplate must be made of a much thicker
metal than the thin tubular pole on a practical commercial scale.
It is almost difficult during a reasonable production time to
have a thick-in-cross-section metal portion connected to a thin-
in-cross-section metal portion have the same temperature when
exposed to heat.
Additionally, the chemical nature of the steel or metal must
be known to obtain the correct galvanization result. Heat
differences can even crack the weld or otherwise damage the joint
or pole. The plate is generally made of a different metal than
the pole.
In short, the mounting plate and metal pole must be
galvanized inside and out to resist corrosion. For at least the
above reasons, it is very difficult to get such a combination
correctly galvanized. At a minimum, it is very expensive to do
it right. Then, even once galvanized, the high stress in the
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area is damaging to the galvanization. Another risk is to
cracking of the weld because of different thickness of metal.
It can therefore be seen that the conventional types of
poles simply have significant and real problems which are
detrimental or are disadvantageous. There is a real need in the
art for a pole system which does not have these problems.
Additional problems With regard to presently used poles are
also significant-in the art. One very practical and real problem
is involved with the shipping of such poles. For many uses,
poles are needed of lengths of thirty, forty, and even up to over
100 feet. While some applications require many poles of similar
lengths, and therefore may be sent by rail shipment, where long
lengths can probably be accommodated, many applications for such
poles require only a relatively small number. To ship such a
number by rail is expensive, particularly when many of these
applications still require some other type of over-the-highway
transportation to the ultimate location.
Generally trucks have a maximum effective carrying length of
between 40 and 48 feet, at least, for semi-trailers. However,
the effective load carrying length generally is no longer than
around 48 feet. Therefore, it is simply not-possible to ship
poles of much longer length than this via tractor trailer Without
special and expensive permits.
While attempts have been made to produce concrete poles in
segments, this requires significant installation efforts and
joints would create risk and problems. Additionally, it must be
understood that wood and concrete poles, with their heavy weight,
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present shipping problems. Even with shipment in tractor
trailers, there is a weight limit of approximately 45 thousand
pounds, even for the longest semi-trailers. This would limit the
number of such poles that could be transported in one truck as
sofie poles, such as concrete, can each weigh several thousand
pounds, and even around or over.ten-thousand pounds.
Additionally, weight permits are required for increasingly heavy
loads. Thus, the closer you come to the maximum weight per
trailer and truck, the more costs are incurred in obtaining
permits and the like for such heavy loads. This is important
because optimally the goal would be to have one tractor trailer
carry all the poles and parts required for one installation.
Because of limit on truck length and load weight limits, concrete
and even wood poles have certain limitations.
Still further, for steel poles which are installed With
conventional poured concrete foundations, it may be possible to
transport the poles in trucks, but a disadvantage is again the
w requirement that the concrete foundations be created and
installed by a local contractor where, in most cases, quality
control is less reliable. In other words, the entire combination
(pole and foundation) cannot be manufactured and shipped as one
uni~Gary shipment and much reliance on a successful installation
is with the installer at the site.
It is to be understood that another problem with
conventional poles is the difficulty in flexibly and economically
creating a base for the pole which will support the pole and
prevent tilting of the pole by the number of forces which will be
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experienced and caused by the pole. For example, a wood pole has
its relatively small diameter lower end inserted into the ground.
Many times this is insufficient to adequately support the pole
because the ground will give way to the variety of forces
transmitted down the pole to its base. To prevent this,
sometimes a hole larger than the diameter of the wood pole is
bored in the ground and then the space between the pole and the
walls of the hole are filled with concrete or crushed rock or
other backfill. This effectively provides material surrounding
the pole which is not easily displaced. It is one way to attempt
to effectively increase the diameter of the base of the pole in
the ground. To add backfill and to tamp it, or otherwise secure
it, requires time, machinery, and effort. It also requires a
crane to hold the pole vertically while this is being
accomplished, which is also time consuming and expensive.
Steel poles which are attached by bolts to concrete bases in
the ground is a way to allow the base to be customized for the
type of ground or the forces that the pole will exhibit on the
base. However, it is expensive and time consuming to customize a
rebar cage and pour the concrete so that it exhibits not only
compressive strength but tensile.strength. This is needed to
provide enough strength at the junction of the pole to the
concrete by bolts or other fastening means.
If concrete poles are used, similar problems exist with
regard to wood poles: There is therefore a real need in the art
for a method to provide a base or foundation for a pole whose
effective area can be economically designed; to adopt whatever
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sugporting strength is needed for each situation. Sometimes the
base area needs to be large, sometimes it does not need to be so
large. There is also a need to keep the base aligned or leveled
so that when the pole is attached, the pole will also be in a
desired position. It is important to have enough square feet of
surface for the base, but also to do it economically.
There is also a problem in the art as to how to optimally
utilize the light from a plurality of light fixtures elevated on
a~pole. Under conventional systems, there is no integrated
approach to figuring out what types and how many lighting
fixtures are needed for each Light pole or combination of light
poles, to accomplish a certain lighting criteria. One of the
reasons this is not possible is that conventional light pole
systems are not very adjustable once the pole is erected. For
example, once a wood pole is elevated and concrete or backfill is
secured around the base, it cannot be adjusted either vertically,
horizontally, or rotationally. A steel pole which is bolted to a
concrete base has similar problems. Therefore, much of the
adjustment would have to take place by going up to the light
fixtures on top of the pole and trying to adjust them.
In essence, there is-no way to reliably predict prior to
assembly, the exact orientation of the light fixtures, cross arms
or supports, and pole, with respect to one another, and with
respect to the area which is to be lighted. There is therefore a
real need to allow reliability and certainty in these
arrangements prior to actual erection of all these components.
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Still further, there is a need for the ability to allow the
base or foundation of the pole to accurately and reliably predict
the position of the top of the pole and light fixtures attached
to supporting structure at the top of the pole before it is
erected. With such reliable knowledge, the composite lighting
system of a plurality of fixtures each on a plurality of poles
can be predesigned at the factory, shipped in partially assembled
form, and then easily and economically assembled on site. This
would allow the significant advantage of avoiding duplication of
lighting and most efficiently and economically providing lighting
to an area on top of an efficient and economical way of
installing the actual poles and bases, and lighting fixtures.
The above rather detailed discussion of conventional poles
is set forth to attempt to aid in an understanding of the many
factors which are involved in choosing a type of pole,
manufacturing it, installing it, and ultimately maintaining it
for an extended, economical, and effective useful life. There is
- no presently satisfactory system which is adaptable to virtually
every situation, is flexible in that it can be anchored in all
sorts of locations and ground types and all sorts of weather
environments, and is useful for all sorts of heights, wind loads.,
and types of structures to be. elevated. For example, steel poles
which are secured to concrete bases generally require the base to
be fabricated on-site. Rebar cages and concrete must be designed
to meet needs of compressive and tensile strength. This takes
time and materials. There is a need for a less complicated,
quicker system that does not need such reliance on tensile
strength of the concrete.
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Still further, for purposes of economy, there is a real need
for a pole system which can be easily shipped, whether only a few
or quite a few; is easy in terms of labor and resources to
install; and which can be maintained over a long life span.
Finally, there is a real need for an efficient pole system
which allows easy installation and shipment of the entire system
together, along with the structure or structures to be elevated
and any attendant hardware, such as wiring and the like.
It is therefore a principle object of the present invention
to provide a means and method for rigidly elevating a structure
which improves over or solves the deficiencies and problems in
the art.
Another object of the present invention is to provide a
means and method as above described which is generally universal
in its application for elevating different structures to
different heights for different situations, and with respect to
different installations of the base in the ground.
A still further object of the present invention is to
provide a means and method as above described which is economical
in terms of the manufacture, materials, transportation,
installation, labor, and life span. -----
Another object of the present invention is to provide a
means and method as above described which is easy to assemble,
install, and maintain.
A still further object of the present invention is to
provide a means and method as above described which is durable
and strong, both in its individual components and compositely.
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Another object of the present invention is to provide a
means and method as above des,cribed.which permits pre-
installa-tion design and concurrent shipment of all or most
components for each installation.
A further object of the present invention is to provide a
means and method as above described which improves corrosion
resistance.
Another object of the present invention is to provide a
means and method as above described which is an improvement with
respect to the problems caused by stress.
Another object of the present invention is to provide a
means and method as above described which allows for economical
and efficient provision o.f a supporting base in the ground for a
pole, where the base can be easily predesigned and installed for
a variety of ground types and pole strength and heights.
A still further object of the present invention is to
provide a means and method as above described which facilitates
the.provisian of a composite photometric output from a plurality
of light fixtures for each pole, by allowing the fixtures to be
quickly and easily aligned to a predetermined position and
orientation, and allowing the fixtures to be reliably erected to
a position of known and reliable relationship to the target area
for the lighting.
As is well known in the art, the conventional way to install
elevated lighting fixtures is to transport a pole to the site it
will be erected in the ground. Secondly, before erection, some
sort of supporting structure such as cross arms.are secured to a
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position near the top of the pole by brackets or otherwise.
Third, the lighting fixtures are mounted onto the cross bars by
brackets or other means. Fourth, wiring is installed from the
light fixtures to electrical components such as ballasts, fuses,
and the like. The ballasts and other components also have to be
attached to the fixtures, crossbars or pole by brackets or other
means. The complete assembly is then erected by a crane and held
in position until the portion of the pole in the ground is
adequately supported.
The installation process therefore requires a plurality of
steps.' Some of the steps require different types of expertise.
One party might supply and ship the pole. Workers for another
contractor may install cross arms and fixtures. Electricians are
usually needed for wiring the fixtures to the required components
and connection to electrical power.
As can be appreciated, expensive bracket structures are many
times needed to construct the cross bars to the top of the pole
and to attach light fixtures and wiring at the top of the pole.
Sometimes attachment of ballasts (generally at the top of the
pole), requires special equipment and efforts.
Additionally, the amount of time need~d_for the construction
of the complete unit is substantial. Each stage of the
installation process many times requires various personnel,
different completion times, and many times different equipment
and supplies. Still further, once the basic components are
. installed on the pole, the pole must be raised and inserted into
the ground or on a base. It must then be held there by a crane
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until secure, which further prolongs the time and expense of the
installation. Once secured, it can not be reoriented or
adjusted.
There have been various attempts to address certain of these
problems. However, none has comprehensively addressed these
concerns and developed an integrated way to produce savings in
time, money, and effort.
The inventors Gordin and Drost disclose a pole structure
which addresses a portion of the installation of this type of
lighting. The base can be accurately secured in the ground with
significant savings of time and cost. The pole can be quickly
and relatively easily erected on the base with a reduced risk of
corrosion problems: If desired, the cross bars can be attached
to the pole before erection onto the base. That invention
addresses certain problems in the art, such as quicker and easier
pole construction. It removes the necessity of installing cross
bars and lights once the pole is erected, or at least allows
adjustment of the pole once directed onto the base, instead of
having to hold the pole while the concrete is setting up or
rearranging the cross arms or lights once installed on the cross
arms.
The present invention comprehensively addresses all problems
involved in lighting installation in the following way. A
breakdown of the various concerns for ultimate installation of
this type of lighting can be visualized in the following matrix:
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CA 02407924 2002-11-19
A B C
Lights Pole Elec.
1. Design 1A 1B 1C
2. Manufacturing 2A 2B 2C
3. Supply 3A 3B 3C
4. Installation 4A 9B 4C
5. Operation 5A 5B SC
6. Maintenance 6A 68 ~ 6C
Numbers 1-6 list various stages involved with a lighting
system from origination to ongoing operation.' Letters A-C list
the primary structural components of a complete lighting
installation.
The boxes lA-6C of the above matrix are intended to
exemplify the many different areas of concern when dealing with
lighting applications of the type addressed by the present
invention. No single, integrated, approach to all these areas
exists in the art. As previously stated, this is extremely
significant from the standpoint of the costs in time and money
involved with present day methods. Some examples are given
below.
With regard to matrix position 1A, resources directed to
design of lights tend to be limited to the efficiencies and
economies in manufacturing, operation and maintenance of the
lights, along with design of how they will functionally operate
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for certain applications. There is a lack of concern with regard
to how the lights will be shipped (matrix box 3Aj or how they
will be installed (matrix box 4Aj. '
While some design efforts of lights might also be directed
towards the electronics associated with the lights (matrix box
ZC), there is a noticeable absence of prediction and coordination
With the characteristics of poles (matrix boxes 1H-6B) and the
total electrical setup with each light and pole (matrix boxes 2C-
6 C~ ) .
By further example, designs of poles are centered on how to
make the pole either easy to manufacture (box 2H), or cheap to
manufacture and install (boxes 2B, 4Bj. Minimal concerns are
given towards integration with lights or electrical components
(boxes lA-6A, 1C-6C). A major concern is getting the pole in the
ground and securing it there. Thereafter, it can require
considerable effort to adjust the lights to a desired
orientation, since the pole is nonadjustable.
The primary point of showing the eighteen different matrix
positions is to emphasize the complexity of coordinating and
integrating all of these factors into an economical yet valuable
coordinated lighting installation.
--. Not only is there an absence of coordinated integration of
these factors in the art, additionally there is room for
improvement in individual components or methods in the matrix, or
sub-components thereof. For example, the design of one light
pole may be economical, but it may be less durable than other
types, or even less aesthetically pleasing. The structure for
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fixing the lights to the top of the pole might be easy to
manufacture, but extremely difficult and unreliable as far as
securement to the pole, accuracy in supporting the lights, or
even in the efficiency and economy of the amount of material
used.
By still further example, prior art methods of aiming lights
once installed in the top of the pole require significant labor.
Little consideration is given to the design and manufacturing of
the pole structure to reduce the amount of time needed for
mounting and aiming the fixtures.
Hy still further example, because of the separate steps
involved in installing a lighting installation, preparation of
the electrical components and wiring is usually left until last.
It requires electricians and labor to customize the length of the
wires, and to install ballast boxes and other components by
brackets or other methods to erect a pole and light fixtures.
There is an absence of consideration of design and manufacturing
to be able to prewire and prepackage all the components necessary
for a certain light pole and fixtures at the factory. Still
further, there is a noticeable lack in the prior art of being
able to design and.c~ontemplate the supply or shipping of
component parts for several poles, lighting fixtures, and
electrical components, to a site by economical and available
transportation systems. There is also a lack of contemplation of
positioning the components (such as ballast boxes) at a
convenient location for future maintenance.
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:.._
It can therefore be seen that a real need exists in the art
for an integrated approach to lighting installations, and that
particular components or methods in the prior art also could be
improved.
These areas of need for improvement start with the design of
lights, pole, and electrical components, and extend all the way
to maintenance of the same. An integrated approach looking at
all factors of the matrix discussed above is both needed and
would be extremely advantageous from an economic point of view,
as well as with regard to flexibility and uniformity of lighting
installations.
The need of an integrated approach to design (row one of the
matrix) would be to design the best lighting fixtures, poles, and
electrical components for the application, allow flexibility so
that they could be used in different ways and combinations, and
provide esthetically pleasing structures; all to provide good
function and result for the application. Manufacturing (in row
two of the matrix) looks.to efficiency and use of materials and
expensive labor, along with high reliability, flexibility, and
functionality.
Supply.(in row three of the matrix) refers to the ability to
package and ship all of the components from the factory with high
flexibility to minimize the number of different parts that need
to be manufactured and the ability to satisfy a variety of
different applications.
Installation (in row four of the matrix) demands improved
speed with minimization of labor and expensive equipment, but
with reliability and accuracy.
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. . ,.
Operation (in row five of the matrix) demands simplicity,
durability, and reliability, as well as functional advantages.
Finally, maintenance (in row six of the matrix) looks to
ease and simplicity of servicing, repair, and replacement of
parts.
Some of the prior art addresses individual particulars of
the matrix, but none looks at the total integrated picture, or
even substantial sections of the matrix.
' It is therefore a primary object of the present invention to
provide a means and method for integrated lighting fixture
supports and components which solves or improves upon the
problems and deficiencies in the art.
A further object of the present invention is to provide a
means and method as above described which uses an integrated
comprehensive approach to all the stages of lighting including
design, manufacturing, supply, installation, operation, and
maintenance of lighting fixtures, poles, and electrical
components to operate the lights.
Another object of the present invention is to provide a
means and method as above described which reduces the amount and
cost of labor involved in all stages.
Another object of the present invention is to provide a
means and method as above described which reduces the cost of all
stages.
Another object of the present invention is to provide a
means and method as above described which reduces the time
involved in all stages.
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A still further object of the present invention is to
provide a means and method as above described which reduces the
possibility of errors in all stages.
Another object of the present invention is to provide a
means and method as above described which allows more accurate,
reliable, and durable installation.
Another object of the present invention is to provide a
means and method as above described which is more efficient and
economical in all stages.
A still further object of the present invention is to
provide a means and method as above described which is very
flexible and adaptable to a variety of different applications.
Another object of the present invention is to provide a
means and method as above described which can be utilized on new
lighting installations, or in replacement installations.
A still further object of the present invention is to
provide a means and method as above described which can be
utilized for a variety of different heights of poles, number of
lights, and electrical component and power situations.
Another object of the present invention is to provide a
means and method as above described which can be substantially
predesigned, packaged, and shipped at the factory.
Another object of the present invention is to provide a
means and method as above described which can be preassembled to
some extent at the factory in a variety of different
configurations yet still meet dimension and weight requirements
for standardized shipping of components to installation sites.
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Another object of the pres~nt invention is to provide a
means and method as above described which allows the use of an
insertable pole top unit on top of a tapered light pole, when the
vertical member of the pole top which connects to the tapered
pole is modified to have a tapered lower end, where the taper is
created from a straight type by flaring the bottom end, as
opposed to manufacturing a tapered section.
These and other objects, features, and advantages of the
present invention will become more apparent with reference to the
accompanying specification and claims.
SUMMARY OF THE INVENTION
The present invention relates to means and methods for an
improved pole system for rigidly elevating an object or structure
in the air with a base anchored in the ground. The invention
specifically solves or improves over many of the deficiencies in
the prior art by utilizing a special concrete base which is
anchored in the ground but to which a lightweight, strong steel
pole section or sections can be easily yet reliably secured.
The base includes an upper portion which extends above the
ground. The pole has a mating interior bore at its lower end
which slip fits over the upper section of the base, but does not
get nearer than a few feet from the ground. The upper portion of
the base and the interior bore of the pole can either both be
tapered in a manner that the pole can be slip fitted a
predetermined distance onto the tapered part of the base and
secured there, or if the parts are not tapered, have a stop
member control how far the pole fits over the base.
- 24 -
CA 02407924 2002-11-19
... __
Optionally, the pole can be comprised of a plurality of
steel sections, each added to the top of the preceding section in
turn beginning with the steel section attached to the base in a
similar manner by slip fitting each section to the other.
The invention also allows for a base or foundation which can
be enlarged economically and efficiently, as needed, to
accommodate different types of ground or soil conditions and for
different sizes, strengths, and heights of poles. A pretested,
prestressed concrete base is positioned and plumbed Within a bore
in the ground. The bore in the ground is sized according to how
much support will be needed. The system relies only on the
compressive strength of the concrete, as well as its rigidity
when set up to effectively enlarge the size of the base in the
ground.
Additionally, the invention allows for a reliable accurate,
pre-known positioning of the light fixtures on top of the pole,
even though they can be suspended sometimes over 100 feet in the
air. The base can be plumbed and set. The pole and pole top,
having known, predesigned and reliably consistent relationships,
will also end up in pre-defined, pre-known position once the pole
is erected on the base. This allows for integration with a three
dimensional coordinate system-centered on the target area to be
lighted. It also allows for a factory pre-design of the number
of fixtures, their aiming and orientation, to economize on the
number of fixtures needed, and to create a composite efficient
beam from each pole that in turn can be integrated with a number
of poles for the best possible and most economical lighting.
- 25 -
CA 02407924 2002-11-19
_ .
The invention also allows for the pole top member to be made
economically, even though it requires, in some embodiments, a
flared lower end to be mated with the flared upper end of the
light pole. A straight pipe can be used for the vertical member
for the pole top and have its bottom end flared for mating slip
fitting on top of the tapered pole. This reduces significantly
the cost of the pole top member as opposed to utilizing a tapered
center section.
' The system therefore provides a strong, almost unitary pole
structure which can be adapted to virtually any situation or
location. The strength of the base~can be designed to
accommodate various pole heights and various ground conditions by
altering the makeup of the concrete of the base and any
reinforcing structure, as to the w~.dth of the base, and the
length of the base and other factors. The pre-manufactured base
can literally be expanded to meet specific strength and support
needs by the single step of widening the hole in the ground and
pouring concrete around the base as it is held plumb. This
effectively~expands the area of the base. Also, predefined
simple methods of field modifications can be made. In all
instances, any metal portions of the pole are kept out of the
high corrosion zone near the ground level. Yet, the above ground
portion of the system is almost fully comprised of the light
weight, yet strong steel: In turn, the base is made of the
relatively heavy, stable concrete which cannot corrode.
The invention also relates to the ability of the system to
be easily adapted, assembled, and installed. The invention
- 26 -
CA 02407924 2002-11-19
advantageously overcomes the problems associated with
installation such as reducing labor costs, material costs, and
design costs. It also provides ways to insure installation is
reliable such as providing for ways to plumb the base and/or pole
segments to insure that the base, and consequently the pole, are
plumb after installation.
Still further, the invention overcomes the severe problem in
the art of not being able to easily custom design the system of
pole structures for each installation and then easily ship,
install and maintain those poles.
Additional features and advantages of the invention includes
a means and method for an integrated approach to a total lighting
installation. Normally, the design, manufacture, and
installation of lighting fixtures for lighting installations is
quite independent and separate from those same stages with
respect to how the lights are elevated and supported, and how the
lights are electrically connected to electrical components and an
electrical power source. The present invention allows a
comprehensive and integrated approach to the'design, manufacture,
shipment, installation, operation; and maintenance of lighting
fixtures, supports and poles, and electrical wiring and
components.
A number of different structural features of the invention
can be utilized to further this integrated and comprehensive
approach. The tapered, slip-fit pole and base described
previously can be utilized. A unitary slip-fitable top portion
of the pole, with pre-defined relationships between cross arms
- 27 -
CA 02407924 2002-11-19
and the vertical axis of the pole can also be utilized. The
manufacturing process can allow the structure to be easily
adapted to prewiring and preassembly of light fixtures to the
pole top at the factory.
Mounting brackets for ballast boxes to the poles can
facilitate quick and easy mounting of the boxes to the pole.
Additionally, the ballast boxes themselves are configured at the
factory to be almost completely-preassembled and prewired. The
ballast boxes are actually electrical component enclosures to
allow the pre-assembly, prewiring and integration of a number of
electrical components beyond just ballasts. with respect to this
invention, the term "ballast box" will be used interchangeably
with "electrical component enclosure". Substantial savings in
time and installation costs are achieved by minimizing the amount
of work that needs to take place to install and erect the entire
lighting installation on site.
The components are manufactured in a manner that they can be
easily shipped by convenient, efficient, and economical
transportation vehicles. Still further, the components of the
entire installation are designed to be able to be selected to
meet a variety of desired configurations for different .
applications. Different pole heights and strengths, different
numbers of fixtures, and different wiring and electrical
requireirients can be easily met without much on-site
customization.
Still further, means can be used to increase the durability
and reliability of the lighting installation. For example,
- 28 -
CA 02407924 2002-11-19
abrasion and trauma resistant members can be utilized with the
wiring extending through the pole to minimize damage or breakage.
Strain relief devices can also be utilized to eliminate the risk
of damage to the wiring. Specific structure for attachment and
communication between components such as ballast boxes and poles
is utilized to increase reliability of operation and reduce the
risk of water damage or deterioration of the components over
time.
The concrete base can be prefabricated. All it requires is
some backfill of suitable strength to hold the base against the
forces it will experience. Components, such as ballast boxes,
can be located at convenient locations for access, once the
installation is complete. The pole, generally steel, is upon
ground, but near enough the ground to utilize its advantageous
properties.
Whether utilized collectively or individually, these
enhancements and features represent real savings in time and cost
with respect to the installation of lighting structures.
BRIEF DESCRIPTION QF THE DRAWINGS
Figure 1 is a front partial sectional view of a prior art
wooden pole set into the ground.
Figure 2 is a similar front elevational view of a prior art
substantially concrete pole set into the ground.
Figure 3 is a similar front elevational view of a steel pole
with a poured concrete foundation in the ground as known in the
prior art.
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CA 02407924 2002-11-19
' Figure 4 is a perspective view of the foundation and lower
portion of the steel and concrete pole combination of prior art
Figure 3.
Figure 5 is a sectional view taken along line 5-5 of Figure
4.
Figure 6 is a front elevational view with a partial
sectional view around the base of one embodiment of the
invention.
- Figure 7 is a similar view to Figure 6 showing an
alternative embodiment of the present invention.
Figure 8 is a view similar to Figure 6 showing one method of
installation of the metal pole section to the concrete base
according to the present invention.
Figure 9 is an enlarged front elevational view of one
embodiment of the concrete base for the present invention.
Figure 10 is a partial still further enlarged view of an
upper tapered section of the concrete base and the lower tapered
portion of the steel pole section according to one embodiment of
the~present invention illustrating how these two elements are
slip fitted together and ultimately locked together.
Figure 11 is a front elevational view of a tapered concrete
base and tapered lower part of the pole section according to the
present invention, showing the use of.a coating to assist in
installation of the system.
Figure 12 is a front elevational view of a base member
according to the present invention positioned in an excavated
hole for anchoring in the ground, further showing a leveling or
- 30 -
CA 02407924 2002-11-19
plumb means used to insure the base is plumb or vertical during
installation.
Figure 13 is a front elevational view similar to Figure 12
showing an alternative combination for leveling or plumbing the
base member.
Figure 14 is a sectional view taken along line 14-14 of
Figure 13, but including an additional cross bar through the base
member and two additional leveling jacks from that illustrated in
Figure 13.
Figure 15 is a perspective view of a leveling jack depicted
in Figures 13 and 14.
Figure 16 is a perspective view of an alternative embodiment
for a leveling jack.
Figure 17 is a sectional elevational view of a base member
according to the present invention illustrating a means for
lifting and positioning the base member within an excavated hole
in a generally plumb position.
Figure 18 is a partial perspective view of the base member
according to the present invention showing means for a forklift
to lift and position a base means in an excavated hole in a
basically plumb position.
Figure 19 is a partial perspective view of a still further
embodiment for leveling and plumbing a base member in an
excavated hole.
Figure 20 is sectional view taken along line 20-20 of Figure
19.
- 31 -
CA 02407924 2002-11-19
__.;,. .:
,... ,~ ~ .
Figure 21 is a still further alternative embodiment for a
leveling or plumb means for the present invention.
Figures 22 and 23 are side views depicting a method for pre-
assembling and installing a pole system according to the present
invention.
Figures 24A, 248, 24C, and 24D are cross sectional view of
alternative pole structures that can be utilized according to the
present invention.
Figure 25 is a depiction of an alternative embodiment of the
present invention where the base member and the pole section do
not have matching tapered portions, but slip fit together until
abutting a stop member.
Figure 26 is a perspective depiction of a complete embodi-
ment of a lighting installation according to the invention.
Figure 27 is an enlarged side sectional view of the top part
of the embodiment shown in Figure 26.
Figure 28 is a top sectional view taken along line 28-28 of
Figure 27.
Figure 29 is a partial view of the top part of Figure 27
illustrating the removable top cap of the embodiment.
Figure 30 is an enlarged perspective and partial exploded
view of the upper portion of the embodiment of Figure 26.
Figure 31 is an enlarged front elevational view and partial
sectional view taken generally along line 31-31 of Figure 26.
Figure 32 is an enlarged isolated view of electrical cabling
and associated components according to the invention.
- 32 -
CA 02407924 2002-11-19
.a ..,.
Figure 33 is a sectional view taken along~line 33-33 of
Figure 32.
Figure 34 is an isolated, enlarged, exploded perspective
view of attachment brackets for a ballast box to a pole according
to the invention.
Figure 35 is a front view of a segment of a pole
illustrating the attachment of a ballast box to the pole.
Figure 36 is an enlarged view taken along line 36-36 of
Figure 35.
Figure 37 is similar to Figure 35 but showing an additional
step in the installation of a ballast box according to the
present invention.
Figure 38 is an enlarged isolated view taken along line 38-
38 of Figure 37.
Figure 39 is similar to Figures 35 and 37 except showing the
completion of installation of a ballast box according to the
present invention.
Figure 40 is an enlarged isolated view taken along line 40-
40 of Figure 39.
Figure 41 is an enlarged front elevational view of a ballast
box and its contents according to the present invention.
Figure 42 is a sectional view taken along line 42-42 of
Figure 41.
Figure 43 is an isolated exploded view of a hub or conduit,
and method of attachment of the conduit, of a pole to a ballast
box according to the present invention.
- 33 -
CA 02407924 2002-11-19
_. . . .:: .
Figure 44 is an enlarged sectional view taken along line 44-
44 of Figure 43.
Figure 45 is a sectional depiction of a prior art method of
attaching a conduit between a ballast box and the interior of a
pole. The view is similar to that of Figure 44 for comparison.
Figure 46 is a graphical depiction of a variety of different
lighting fixture configurations that can be utilized with the
pole top member according to the present invention.
Figure 47 is a perspective view of capacitors and a
capacitor mounting bracket assembly according to the present
invention.
Figure 48 is a sectional view taken along line 48-48 of
Figure 47.
D$TAIT.ED DESCRIPTION OF THE PREFERRED EM$ODIMENT
The detailed description of the preferred embodiments of the
present invention will now be set forth. It is to be understood
that this detailed description is intended to aid in an
understanding of the invention by discussing specific forms the
invention can take.. It does not, nor is it .intended to, __,
specifically limit the invention in its broad form.
This detailed description will be made with specific
reference to the drawings comprised of Figures 1 through 25.
Reference numerals are used to indicate specific parts or
locations in the drawings. The same reference numerals will be
used for the same parts or locations throughout the drawings
unless otherwise indicated.
- 34 -
CA 02407924 2002-11-19
_._._ ..
..
The broad invention has generally been described in the
Summary of the Invention. It is to be understood that in the
following description of specific preferred embodiments, the
structure elevated by the poles will be light fixtures or arrays
of light fixtures, such as are commonly used for lighting
sporting fields such as softball fields, tennis courts, and the
like. An example of one type of such arrays and fixtures can be
found at commonly owned U.S. Patent No. 4,190,881 by Drost and
Gordin issued 2/26/80. As will be further understood, the
present invention and all its preferred embodiments achieves at
least all of the stated objectives of the invention. It provides
a pole system which can be predesigned for specific applications.
As will be understood further, the preferred embodiments of the
invention will show how the system of the invention can be
predesigned for a particular application and location.
Furthermore, the invention is basically universal in that it can
accommodate almost all combinations of height, weight, location,
ground condition, shipping requirements, and installation
problems. It can also maintain the critically important
alignment both vertically and rotationally.
The invention accomplishes all of its objectives _-,.
economically and by providing a strong, reliable, long lasting
pole and base.
To emphasize the advantages of the invention, the
description will first again briefly review some of the problems
and deficiencies of commonly utilized prior art poles. The
advantages of the present invention will then be briefly
- 35 -
CA 02407924 2002-11-19
':'': : . ' . . .. . .. .
. ..._
discussed with particular reference to use as light poles, and
then the specifies of the invention as applied to light poles
will be set forth.
Figure 1 shows a wooden light pole 10 having an upper
section 12 and a lower section 14. An array cf light fixtures 18
includes three cross arms 20, each carrying a plurality of light
units 22 and is attached to upper section 12 of pole 10 by means
known in the art (not shown).
Pole 10 is installed in ground or soil 24 in an excavation
hole 26. As is commonly done in the art, the space around pole
in hole 26 is filled with a filler material to attempt to
better anchor pole 10 in the soil 24. Examples of material 28
are soil, tamped rock, or poured concrete, such as is known in
the art. Concrete has the advantage that it does not depend as
heavily upon the skill of the contractor for a reliable
foundation. Tamping rock properly in a deep hole is difficult
and time-consuming.
The problems with wood poles have been previously
discussed. Briefly, they are fairly heavy, are susceptible to
rot and decay, and it is difficult to find tall and straight
poles.. Twisting and warping can also cause problems,_s.uch as
misalignment of the structure held by the pole, for example,
light fixtures. Perhaps more significantly, the installation of
the lower section 14 into ground 24 requires an exact and well
executed process to make sure the pole is vertical or plumb, and
that it will stay that way. Transportation of long poles is also
a problem.
- 36 -
CA 02407924 2002-11-19
As can be well appreciated by those of ordinary skill in the
art, sometimes poles are simply inserted into hole 2fi, which is
then backfilled with the removed soil. Soil simply does not have
the density or properties to reliably hold the pole in aligned
position either from axial, twisting (rotational), or lateral
movement over time. By adding material 28, the effective area of
the portion of pole 10 in ground 24 is increased, and the
properties of the material are such as to improve stability.
This process still relies significantly on the type of
installation job done by the installers. It can be seen that the
wood is exposed at ground level to..moisture as is previously
described.
It is also to be understood that if crushed rock is used as
material 28 when installing any type 'of pole, it is crucial that
it be tamped accurately or the pole will lean. This requires the
rental or use of pneumatic tamper machine and knowledge of how to
accurately perform the tamping. This is a time-consuming task.
Figure 2 similarly shows concrete light pole 30 having a
lower end 32 anchored in ground 24 surrounded by material 28 like
the embodiment of Figure 1. Additionally, in this prior art
embodiment, a steel top section 34 is fitted over---top end 3G of
pole 30 and array 18 of lights is in turn connected to top
section 34.
The problems with concrete poles have been previously
discussed. Although corrosion around ground level is not a
problem because of the use of concrete, the extreme weight of
such a mass many times causes pole 30 to sink into the soil or
- 37 -
CA 02407924 2002-11-19
..
otherwise tilt or laterally move. Similar problems in
installation for concrete poles exist as with pole 10 of Figure
1. Transportation of long poles because~of length and weight is
also a problem.
Therefore, Figure 3 depicts the prior art light pole of
preference, namely steel light pole 40 which is connected to
bolts 46 (see figure 5), which are secured in material 28, which
is generally concrete. Array 18 of lights is secured by means
known within the art to the top of steel light pole 40, whereas
the bottom of pole 40 has an annular flange 44 surrounding
tubular pole 40 which is welded to pole 40 and secured by bolts
to material 28. Material 28 is poured concrete with a rebar
design that must be installed on-site and is used to fill
excavated hole 26. It can be seen, however, that flange 44 is
within the high corrosion area near the ground.
Additionally, such as is known in the art, the joint created
at flange 44 bears a high amount of stress for the entire
combination. It therefore presents an unreliability factor in
the sense of concentrating a significant amount of stress in one
location. This is particularly true when referring to the
potential corrosion problems created by.the joint. It must be
additionally understood that many times moisture accumulates
within the interior of these hollow poles and corroded material
and moisture can fall through the pole to the area around flange
44. This adds to the possible corrosion. Corrosion is virtually
as big a problem inside-out as it is from the outside-in for
these types of poles.
- 38 -
CA 02407924 2002-11-19
__ . __.. : _ .,. - _. . .
Even though the pole of Figure 3 is the most expensive, for
reasons previously described, it is also the most preferred
because it is lightweight, strong, aesthetically pleasing, and
its installation is relatively easy when compared to a preferred
ground concrete fill (figure 3) or properly tamped rock backfill,
and when compared to installations such as is shown in Figures 1
and 2 which require a large crane to handle the higher weight of
the wood or particularly the concrete poles. Additionally, if
material 28 is cement, for optimum results, the crane must
continue to hold the poles until the concrete is basically set.
This requires time and money to rent the crane for that period,
and hire the labor for that period; as opposed to pole 40 of
Figure 3 where the concrete fill 28 can be set (requires up to 28
days to set up) and then the pole 40 afterwards installed. It is
to be understood that the setup time for concrete is generally in
terms of hours. Concrete truck cannot H~ait hours at a time.
Therefore, it requires generally a truck trip per pole which can
be very expensive. Also, unless multiple cranes.are available,
only one pole can be installed over a period of hours.
Figures 4 and 5 show in more detail the specifics of pole
and poured foundation 28 and 42 of Figure 3. In Figure 4, it can
be seen that.flange 44 is attached to fill material 28 by the use
of long bolts 46 which extend deep into the material 28 and are
set there when the concrete is formed. Additionally, lines 48
represent generally the rebar or reinforcing bars that need to be
designed into material 28 for each specific application. Because
bolts 46 extend deep into material 28, a significant amount of
- 39 -
CA 02407924 2002-11-19
- ., . .
stress of the whole system must be borne by material 28 so that
bolts 46 will not pull out. Thus, the special and specific
designing of each foundation 28 for each application (pole
height, weight, wind load, etc.) must be accurately predicted and
implemented into the foundation 28 for it to be successful.
Figure 5 depicts bolts 46 and also shows how flange 44
receives a portion of the bottom of the pole 40 in circular
aperture 50 that is completely through flange 44. Many times an
angled or beveled edge 52 is machined into flange 44 at the upper
junction between material 28 and pole 40 to allow for weld 54.
Figure 5 shows how thicknesses of flange 44 and pole 40 vary, how
it would be crucial for weld 54 to be done accurately, and how
the various problems with corrosion and galvanization can occur .
as previously described. It is to be understood that.many times,
to get a strong enough junction weld 54 must be a "triple weld"
which refers to multiple layers of welds around pole 40 in the
groove formed by beveled edge 52. The expense for this is
substantial as well as the reliance on the effectiveness of the
welds. It complicates the galvanization because of significant
heat and residue flux. It is to be understood that welds could
also be placed inside aperture_50 at the bottom of pole 40.
Figure 5 also shows that conventionally, nuts 53 are first
threaded onto bolts 46. Base plate 44 is then inserted onto the
bolts and rests on nuts 53. Nuts 55 then secured plate 44 to
bolts 46. Grout 56 is used to attempt to seal between plate 44
and foundation 28. The stress on the joint can therefore be
seen. Also, sometimes conduit or wiring 59 must be run through
- 40 -
CA 02407924 2002-11-19
grout 56 into pole 40. As can be appreciated, water (represented
by line 58) can accumulate or stand exactly around this joint,
both outside and inside the pole, whether from rain,
condensation, or other causes. The grout, manner junctions
between parts, and openings presents a risky corrosion
environment right at or near ground level.
Therefore, the preferred embodiments of the present
invention illustrate how many of these problems in the prior art
are overcome. The following will be a brief description of the
elements for preferred embodiments of the present invention.
Discussion of how the system of the invention allows for easy
design, manufacturing, installation, and maintenance will follow
that.
Figure 6 shows one preferred embodiment of the invention. A
pre-cast, prestressed concrete base 60 has a lower section 62
which can be anchored in ground 24. It is generally preferred to
anchor base 60 in material 28 which is poured concrete. An upper
section 64 (see Figure 8) of base 60 is tapered inwardly and
upwardly. It is to be understood that the tapered upper section
64 is above ground level of ground 2.4 and preferably generally
two or so feet above-ground 24. It should also be understood
- that upper section 64 does not need to be tapered as will be
later discussed.
The invention allows a pole to be comprised of either one
steel section, or several relatively short, lightweight, and
convenient-to-assemble sections. With respect to a pole holding
an array of lights for an athletic field, this_allows:
- 41 -
CA 02407924 2002-11-19
1. Ease of separately establishing a pre-manufactured
concrete base rigidly fixed in the earth;
2. Advantage of a lightweight but~strong top section
preassembled with a pre-aimed array of fixtures
which must accurately point to the field; and
3. Easy attachment of the pole to the base with
universal orientation of lights to the field.
In the embodiment of Figure 6, a pole section 66 is slip
(fitted onto tapered upper section 64 (see figure 8) of base 60.
Pole section 66 itself is tapered along its entire length from
its lower end 68 to its upper end 70 to which is attached light
array 18. It is to be understood that the inside diameter of
lower end 68 of pole section 66 equal to or is just.slightly
larger than upper section 64 of base 60 when it is slip fitted
down onto upper section 64. However, because of the relative
tapers, the farther pole section 66 is brought down upon upper
section 64 of base 60, the tighter the two components become
locked. Therefore, by utilizing sufficient force, the base fi0
and pole section 66 can virtually become locked together without
additional hardware.
This means._that the outside diameter of lower section 62 of
base 60 is greater than the inside diameter of part of pole
section 66. It is again to be understood that the invention also
contemplates use with bases and pole sections which are not
tapered.
In figure 6, pole section 66 could be about 40 feet in
length with a bottom inside diameter of around 9 1/2 inches, and
- 42 -
CA 02407924 2002-11-19
can utilize a 0.07 inch per foot taper uniform around the pole's
circumference (as measured along a side of the pole section 66).
Base 60 has a similar 0.07 inch per foot 'tapered top section 64
approximately 6 feet long with an overall length of close to 15
feet. The outside diameter of lower section 62 of base 60 is
also around 9 1/2 inches.
Figure 7 shows an alternative embodiment for the invention.
Instead of dust one pole section 66, a lower pole section 72 is
slip fitted onto base 74 and an upper pole section 76 having the
same taper from top to bottom as section 72 is slip fitted onto
the top of lower pole section 72. It can be locked into position
in the same manner as previously described. It can therefore be
seen that a plurality of pole sections can be added to base 60 to
achieve required height for a structure. It is to be understood
that the width and length of base 60 or 74 is designed for
overall height, weight, and load carrying ability for each pole
structure. Generally, the width and height of base 74 would be
greater than that for base 60 under fairly similar conditions
because of the added height.
In figure 7, base 74 is around 20 feet long with a lower
section--diameter of_around 13 1/2 inches. Pole section 72 is 40
feet long, has a lower diameter of around 13 1/2 inches and is
slip fitted about 6 feet down on base 74 but not lower than about
2 feet above the ground. Twelve feet of base 74 extends below
ground therefore. Pole section 76 is around 30 feet long, has a
lower end diameter configured to allow it to slip fit approxi-
mately 2 feet over the top of pole section 74. Appropriate gauge
- 43 -
CA 02407924 2002-11-19
_. ;_ .. .. _- . . ; . _
steel is selected for height and load, and the strength of base
74 is computed for these parameters. Generally, most poles must
be made to withstand 80 mph wind with l.3 gust factor which
includes consideration of fixtures attached at the top.
Figure 8 depicts one method by which pole section 66 of
Figure 6 could be slip fitted onto base 60. A crane or
extendable arm 78 grasping pole section 66 could maneuver it over
base 60 and then slide or slip fit it down into position. It is
to be understood that in the preferred embodiment, pole 66 is
first gently slip fit onto base 60. Because generally light
array 18 has been mounted, some rotational positioning of pole
section 66 may be necessary, so that array 18 is facing in the
correct direction. As one of the major advantages of the present
invention, even after this preliminary installation, the pole
section 66 can virtually be adjusted 360' around base 60.
Figure 9 shows in enlarged form a preferred embodiment of a
base 80 according to the present invention. As can be seen,
lower section 82 can be generally cylindrical in nature. Upper
section 84 is basically frusto-conical and has a not very
pronounced taper. Base 80 is hollowed out by bore 86 extending
--~--through it. Base 80 could be solid, however. It is particularly
pointed out that at the top of upper section f4, a bevel 88 is
introduced so that any moisture will run off bevel 88 down bore
86 away from the pole which will be slip fitted upon base 80.
Additionally, openings 90 communicate with bore 86 to provide
access for cables, wiring, and the like into the interior of base
80 and through the upper open end of base 80 into the interior of
- 44 -
CA 02407924 2002-11-19
any pole section. Figure 10 is a still further enlarged partial
view of base 80 and shows a pole section 92 at least partially
slip fitted onto upper section 84 of base 80. In order to pull
pole section 92 further down tapered upper section 84 of base 80,
and to more securely lock the pole and base together, one way to
accomplish the same is to utilize ratcheting turnbuckles 94 to
exert force to pull pole section 92 downwardly. A bar 96 can be
inserted through a bore transversely through base 80. A nut 98
can be welded to one or more sides of pole section 92 and a bolt
100 can be threaded into nut 98. Ends 102 and 104 of turnbuckle
94 can be secured to bar 96 and bolt 100 respectively. By
operation of handle 106, the turnbuckle 94 can cause downward
movement of ends 102 and 104 to provide the pulling force and
thus lock section 92 onto base 80.
It is to be understood that multiple ratcheting turnbuckles
94 (and nuts 98 and bars 104j could be utilized around the
perimeter, or one could be connected at various positions. For
example, this procedure could be used on opposite sides of pole
section 92. It is to be further understood that the somewhat
resilient nature of steel of pole 92 in the preferred embodiment
allows some slight spreading which contributes to the resilient
forces and frictional engagement of pole 92 to base 80.
Therefore, no other hardware is needed for a secure junction.
Figure 11, however, shows an alternative method for locking
pole section 92 to base 84. Instead of requiring the use of
force to pull the two elements together, a substance 108 could be
coated over either the upper section 84 of base-80 or the
- 45 -
CA 02407924 2002-11-19
interior of the bottom inside of pole section 92, or both.
Substance 108 can be an adhesive which would first allow the
initial slip fitting of pole section 92 to base 80 to provide
abutment and then lock the two elements in place. The large
surface area between the pole section and base when slip-fitted
together allows for perhaps not quite as good adhesive to be used
to accomplish its purpose compared with a joint of smaller
abutting surface areas. It is to be understood that such a -
configuration reduces or eliminates significant gaps, pockets, or
chambers at the joint. Additionally, the use of the substance
108 could completely fill any air gaps or spaces whatsoever and
virtually eliminate places for water~or air to work st corrosion.
The ability of the semisolid or initially liquid substance to be
directed to fill up all spaces allows this advantage.
It is to be further understood that substance 108 could have
other advantageous properties. For example, it could have
lubricating properties to facilitate easier slip fitting and 360°
rotation of pole section 92. It could also have sealant
properties to further resist moisture and corrosion. As an
alternative, substance 108 could have any one of the above
mentioned properties and be advantageously utilized with the
invention. It is preferred, however, that it have at least
adhesive properties. In the preferred embodiment, an epoxy
substance, such as is known in the art, could be used which would
bond to both steel and concrete. Alternatively, silastic
(silicone), or urethane could be utilized. In general, substance
108 is applied in between a 5 to 30 mil thick coating, and
generally more along the lines of a 10 mil thick coating.
- 46 -
CA 02407924 2002-11-19
This eliminates the need for jacking the two elements
together, such as was explained with respect to Figure 10, which
in many applications requires up to 2000 lbs. of pressure on each
side and up to 6 to 8 inches of further movement between the
elements to get a secure locking fit.
It is also to be understood that to further prevent
corrosion possibilities, gaskets or sealants could be used to
completely seal or fill up any spaces Whatsoever in base 80 or
between the pole and base.
It can therefore be seen that the present invention utilizes
a tapered end of the base and the tapered pole sections to allow
easy and economical creation of a pale structure. To aid in an .
understanding of how the invention in a complicated and arduous
manner provides such an advantageous combination, a short
discussion of many of the factors involved in designing this
combination will be set forth.
With regard to pole section 92, the following types (by no
means an exhaustive list) of elements have to be considered:
1. Amount of taper.
2. Shape and diameter of pole.
3. Number of sections.
4. Number of connections.
5. Weight to strength ratio.
6. Wind load.
7. Type of steel/gauge of steel/wall thickness.
8. Stress through pole.
9. Corrosion resistance.
- 47 -
CA 02407924 2002-11-19
_ .
10. Galvanization inside and out.
11. Rotational alignment ability.
12. Transportability (length, diameter, weight).
13. Electrical or other interior connections or pieces.
14. Length of slip fit.
15. Crane or other lifting means size and availability.
16. Cost of materials.
17. Industry standards.
18. Type of structure to be suspended.
19. Installation location variables.
It is to be understood that a similar plurality of factors
must also be analyzed for the base 80 (further including
properties unique to concrete and its use as a support base in
the ground) and the composite combination of base 80 and pole 92,
as can be appreciated by those skilled in the art.
In the preferred embodiment, the taper of pole section 92 is
a 0.14 inch reduction in diameter for every foot upwardly (or in
other words, a small angular degree of fraction of degree inward
taper). A possible range of tapers would be from .12 through .16
plus or minus .020 inch taper per foot of length. This is the
equivalent of the previously mentioned 0.07 inch per foot taper.
The taper allows the stress experienced by the pole section
to be distributed over 100% of the pole, and not necessarily
concentrated in any certain areas.
While the shape of the preferred embodiment of the pole is
circular in cross section, other shapes are possible where poles
need not be rotated for precision alignment of fixtures after the
- 48 -
CA 02407924 2002-11-19
-. , .... .
?base is set (see figures 24A-24D). Ease BO has a similar or
exactly identical taper to pole 92. In the preferred embodiment,
the base is hollow to reduce weight and allow wiring, etc. to be
brought in from the ground into the pole, and is made even
lighter by utilizing prestressed concrete (more strength per
pound . Wound wire is used instead of rebar. The wound wire has
a tensile strength of between 250 and 275 thousand psi (pounds
per square inch). The concrete base 80 is then centrifugally
cast to provide a high density outside layer which is extremely
strong and is more resistant to moisture penetration.
The need for the tapered joint between base 80 and pole 92
to be precise is essential. The base 90 is therefore cast in a
steel die and spun for 20 minutes. It is then cured in steam for
one day: Afterwards, it sits for a substantial period until it
reaches its full strength.
By using this high strength concrete, the weight is reduced
but the strength is retained.
It is to be understood.that base 80 can be made longer for
different soil conditions and can be made longer and wider for
different heights and stress conditions fox poles. Generally in
the preferred embodiment,~__upper section 84 of base 80 is
somewhere around 7 to 8 feet in length. Because of the long
overlap for the slip fit joint (generally the 7 to 8-feet for 7
to 8 feet upper section 84), this comprises a relatively low
stress joint because it involves substantial surface area contact
and overlap length between members. There are no welds, bolts,
or any other hardware in this joint area (Which can weaken the
- 49 -
CA 02407924 2002-11-19
~ ,,"~ - - _... - . ;"'~
point or present focused stress points). Additionally, it is
above the primary corrosion zone by remaining tv~o or more feet
above the ground. Additionally, the thickness of pole section 92
is the same throughout its length and therefore it is easier to
reliably galvanize the steel.
It is therefore crucial to understand that when designing
and manufacturing the components for the invention, a variety of
different design considerations are taken into effect. However,
the advantage of the present invention is that they can be
analyzed and contemplated during design and then pre-manufactured
to allow an entire unit (pole sections) and base) to be shipped
together (along with fixtures and arrays}. Quality control over
all of the elements can be more easily accomplished.
The problems with shipping with prior art devices have been
previously discussed. As can be seen in these preferred
embodiments, the lower weight of the prestressed concrete base
80, the lower weight of the hollow pole section 90 and any
additional sections, as well as the ability to section the pole
(if needed) allows for better flexibility and more economical
shipping.
The additional advantages of the invention can be seen with
respect to installation on site.
It is to be understood that one way to assemble and install
a pole system according to the present invention would be to
preassemble base 80 and any pole sections 92 horizontally on the
ground or otherwise, and then utilize a crane or similar device
to pull the combination upright and insert it into the excavated
- 50 -
CA 02407924 2002-11-19
H ::~. . ' .. . .
hole. Then dirt, rock, or concrete could be poured around base
60 to set the combination in place. Such a process is
schematically depicted at Figures 22 and 23. It is to be
understood that various disadvantages of this method have been
previously discussed. One advantage of the present invention,
however, is that a majority of the weight of the combination is
in base 80. Therefore, the crane or other device would be able
to grip the assembly at a lower point (i.e., towards the center
of gravity of the assembly). From a practical viewpoint, this
allows use of a smaller crane or other machine which
significantly reduces cost if the crane were rented or otherwise
leased.
Secondly, flexibility of the invention can be seen in that
the base 80 could first be anchored in the ground and made plumb,
and then the pole sections can be slip fitted into place in any
manner desired. This would be done, preferably, by setting the
base 80 in concrete to avoid the unreliable backfill of rock or
dirt. Generally, the pole sections would be preassembled and
then the entire structure would be slip fitted to base 80. This
produces a reliable, rigid installation and alignment.
A number of advantageous methods have been developed to
facilitate this type of installation. First, as shown in Figure
12, base 80 can be, by means known Within the art, set within
excavated hole 26 so that it rests on the bottom of the hole. A
level means 110 comprised of an elongated linear level 112 (in
this case four feet long) with a transversely extending foot 114
can be utilized in the position shown in Figure 12 to level or
- 51 -
CA 02407924 2002-11-19
~ ..,~
plumb base 80. Foot 114 would be of a transverse length
(approximately 1/4" for a 4 foot long level and a .14 inch taper
per diameter for every foot) so that knowing the taper of upper
section 84 of base 80, when placed against the taper in the
position shown in Figure 12, level 112 will read that base 80 is
vertical along its longitudinal axis only when level 112 is
vertical. In other words, the tangent of the angle 116 formed
between level 112 and tapered side of upper section 84 would
equal the length of foot 114 divided by the length of level 112.
Level means 110 can be moved around the perimeter of upper
section 84 to insure it is plumb in all directions. This
leveling process could take place as concrete or other fill is
put into hole 26 and such sets up. Then the verticality of any
pole sections 92 slip fitted onto base 80 is assured. It is also
to be understood that level 112 could be used with other
installation methods.
Figure 13 shows an alternative method to level or plumb base
80 (especially when base 80 is not, or cannot be set on the
bottom_of hole 26). It is to be understood that a slurry is
preferred to be used to keep base 80 plumb during pouring of the
concrete. A bar 120 inserted through a lateral bore 122 which is
generally perpendicular to the longitudinal axis through base 80
could be utilized to sit into V-brackets 124 of screw jacks 126
on opposite sides of base 80. In a pendulum like manner, base 80
could swing around bar 120 (the bottom of the base would not
touch the bottom of excavated hole 26) to find its plumb position
in that plane (a vertical plane through the longitudinal axis of
- 52 -
CA 02407924 2002-11-19
.. ' I ~ ,
base 80 and extending generally perpendicular to a vertical plane
through bar 120). This allows for setting base 80 in holes
deeper than base 80 or holes with a soft bottom which would not
support base 80. Screw jacks 126 could then be adjusted and
utilized with a conventional level on bar 120 or with respect to
base 80 to insure that base 80 is level in the plane through the
axis of bar 120 parallel to the page at Figure 13.
Alternatively, one side of bar 120 could be blocked to a certain
height and then one jack 126 could be used to level the other
side. Additionally, a rebar cage could be added to base 80 and
extend to the bottom of hole 26, or more concrete could be added
to fill up hole 26 under base 80.
Figure 15 shows screw jack 126 in more detail. V-brackets
124 are rotatably mounted to screw rod 128. A nut 130 is rigidly
secured to bracket 124 and screw rod 128 which is threadably
mounted in nut 132 rigidly secured to base 134. By turning nut
132, screw rod 128 rotates and moves up and.down in base 134.
Figure 16 shows an alternative jack means that could be used
in the embodiment of Figure 13. Bar 120 could have an aperture
136 extending therethrough. Instead of V-brackets 124, screw rod
128 could simply extend through aperture 136. This time, by
turning nut 130, bar 120 would be raised or lowered:
Figure 14 shows an alternative embodiment to Figure 13. To
prevent base 80 from moving in any direction in excavated hole
26, an additional bar 13$ could be inserted through an
appropriate transverse bore 140 (close to but spaced from bore
122) through base 80 but in a perpendicular direction to bar 120.
- 53 -
CA 02407924 2002-11-19
_. , ..'' ..,; '.
As shown in Figure 14, additional screw jacks 126 would hold bar
138. All screw jacks 126 could be adjusted to level or plumb
base 80. 8y utilizing the two bars, however, base 80 would. be
locked into position. Therefore, when pouring concrete or other
material into hole 26, could not be easily moved out of alignment
base 80.
The Figures 17 and 18 show two further methods for
installing base 80 into hole 26 in a plumb manner. In Figure 17,
an aperture 142 from the exterior of base 80 into bore 86 would
allow a strap 144 connected to a crane or other machine to be
inserted and threaded out aperture 142. A locking pin 146 could
be slipped through loop 148 in the end of strap 144 to hold strap
144 in the position shown in Figure 17. By virtue of suspending
base 80 in the manner shown in Figure 17, it would basically find
its plumb position when lowered into hole 26.
In Figure 18, a bar 150 is inserted transversely through
base 80. This would allow a forklift 152 to raise base 80 and
again it would act somewhat like a pendulum, at least in one
plane to find its basically plumb position. The forklift can be
maneuvered to keep base 80 plumb during backfill with concrete.
Once the concrete is poured to top of hole 26, the forklift can
be removed as concrete will support the weight of base 80 and
keep it level.
Figures 19-21 show two additional, more intricate methods
for plumbing base 80 in hole 26. In Figure 19, a long bar 154 is
inserted through an oversized bore 156.so that there is some play
if base 80 were tilted in a vertical plane through bar 154. A'
- 54 -
CA 02407924 2002-11-19
short bar 158 is inserted in a bore 160 perpendicular to bore 156
but partially intersecting bore 156. As can be seen in Figure
20, bar 158 would rest upon bar 154. Essentially, the abutment
point 162 between bars 158 and 154 would be a small intersection
of two rounded surfaces. Thus, base 80 would be able to tilt by
the forces of gravity in virtually any direction. Abutment point
162 acts somewhat like a knife-edge balance point and allows base
80 to automatically plumb itself to the extent it is free to tilt
in the setup. Screw jacks 126 can be utilized to roughly plumb
base 80. A fluid slurry mix of concrete can be poured to allow
base 80 to remain plumb.
Figure 21 shows a modification of this self plumbing setup.
To avoid having two transverse bores through base 80, Figure 21
utilizes a large bore 164 in which a sleeve 168 is positioned. A
rounded raised member extends from the interior center of the
sleeve 168. Bar 154 and jacks 126 can then be configured as
shown so that bar 154 extends through sleeve 168. the abutment
point I?2 between member 170 and bar 154 again acts as a knife-
edge balance point to allow base 80 to plumb itself.
After installation by any of the above methods, the
invention in its assembled form presents a pole having accurate
and reliable anchoring in the ground, has sufficient strength in
both the base and the pole sections, and is resistant to
corrosion in the base and in the pole sections. It provides the
preferred steel upwardly extending pole without the disadvantages
of conventional steel poles. The invention therefore provides a
long lasting durable pole, which impacts on the cost of such
poles over their life spans.
- 55 -
CA 02407924 2002-11-19
It will therefore be appreciated that the present invention
can take many forms and embodiments. The true essence and spirit
of this invention are defined in the appended claims, and it is
not intended that the embodiment of the invention presented
herein should limit the scope thereof.
A primary example of an alternative embodiment according to
the invention can be seen at figure 25. Embodiment 180 consists
of a base 182 and pole section 188 similar to those previously
described. However, base 182 has a straight (not tapered) top
section 184. A stop member 186 extends laterally from base 182.
Pole section 188 is also a straight-sided (not tapered) tube
pole. It can be slip fitted onto top portion 184 of base 182
until it abuts stop 186. Epoxy 190 can be coated on both the
exterior of base 182 and interior of pole 188 to assist in
bonding the two. Sealant can also be used. It can be seen that
pole 188 is again held above ground. This embodiment is
particularly useful for square or mufti-sided poles, that do not
require or are not desired to be tapered.
It is also to be understood that the pole sections are
preferred to.be made of steel but other materials are possible,
for example, eluminum.
As can be seen by referring to the prior art design in
figure S, the presently claimed invention completely eliminates
all the problems associated with potential corrosion, stress, and
even vandalism of the nuts, bolts, joint, and overall structure
of that prior art embodiment, even though in the prior art design
of figure 5, concrete is utilized in the ground, the metal is
- 56 -
CA 02407924 2002-11-19
i
attempted to be galvanized, and grout or other sealant is
attempted to be placed around the base/pole joint.
In order to achieve a better understanding of other aspects
of the invention, a detailed description of a preferred
embodiment depicted in Figures 26-46 will now be set forth.
Reference numerals are utilized in the drawings to indicate parts
and locations in these drawings. The same reference numbers will
be used in all these drawings for the same parts and locations
unless otherwise indicated.
This detailed description will first discuss an example of a
total integrated lighting installation according to the
invention. Thereafter, specific features will be discussed.
Finally, the operation, methods and processes involved with this
structure and features will be described, along with examples of
possible enhancements, alternatives, or additions.
Referring particularly to Figure 26, a lighting installation
210, according to the present invention, is depicted. A rigid
base 212 is secured in a vertically plumb gosition in hole 214 in
ground 216. In this preferred embodiment, base 212 is made of a
prefabricated, prestressed concrete that can be shipped on-site
and installed in~hole 214 according to methods similar to those
described previously. One method is to insert base 2I2 in hole
214, and hold it plumb. Liquid fill (preferably concrete) is
then filled around base 212 in hole 214 and allowed to at least
partially set. Base 212 is kept plumb while the concrete sets up
thereby insuring a vertically plumb base.
- 57 -
CA 02407924 2002-11-19
l
Base 212 has a tapered upper end 220 upon which can be alip-
fit onto pole 222. It is to be understood that in this
embodiment, pole 222 is made up of sections 222a, 222b, and 222c,
each being tapered along its. length and each being slip fitable
upon the other, as has been previously described. Because of the
accurate positioning of base 212, sections of pole 222 also can
reliably be installed in a plumb orientation. It is to be
further understood that there are various ways to erect the pole
sections onto one another; one way is to assemble pole sections
222a through 222c on the ground, and then lift them by crane to
slip fit over upper end 220 of base 212. Also note that once
positioned on base 212, pole 222 can be rotated for accurate
rotational orientation of the pole, before it is secured in
place. This is a highly advantageous feature of this invention.
In the embodiment of Figure 26, an advantageous feature is
the utilization of pole top 224. A center piece 226 has a
tapered bottom end 228 which is slip fitable over the upper most
tapered end 230 of pole section 222c. Extensions 232 extend
perpendicularly from the axis of center piece 226 and at the
outer ends are mounted cross arms 234 and 236, which are
perpendicular to the outwardly extending axis of extensions 232
as well as the axis of center piece 226.
This unitary pole top 224 allows attachment to pole 222
easily and quickly, whether on the ground, or once pole 222 is
erected. All components of pole top 224 are pre-manufactured.
No separate installation of extensions 232 or cross arms 234 or
236 is required. This framework is all calibrated during
- 58 -
CA 02407924 2002-11-19
r . ..~
manufacturing so that the exact relationship geometrically
between those parts is known. Therefore, when pole top 224 is
attached to pole 222, a three dimensional axis is in place and
pre-deffined because all parts are orthogonal. As will be
discussed in more detail later, lighting fixtures 238 (as shown
in Figure 26) have adjustable joints 240,-and can also be pre-
installed on pole top 224 either prior to shipment, or on-site on
the ground. The joints 240 can be adjusted to predetermined
aiming angles because of the known, fixed orientation of cross
arms 234 and 236 to center piece 226.
Figure 26 also shows how ballast boxes 242, 244, and 246 can
be mounted on lowest pole section 222c, some distance off the
ground, but in an easily serviceable location.
As can be appreciated, lighting installation 210 can be
erected very quickly with a minimum amount of labor and
machinery. Its components can be manufactured efficiently and
economically, allowing great flexibility in the design of the
actual installation for various uses. The various components of
installation 210 allow it to be shipped economically and
efficiently, with a minimum amount of custom installation on
site. It is particularly pointed out how the entire installation
can be pre-planned, and partially assembled at the factory. It
then can be installed with a minimum risk of mistakes for
reliable operation. Finally, it is configured to allow for easy
maintenance.
These features encompass all of the lighting fixtures, pole
and structural supports, and electrical components, as will be
set forth in more detail below.
- 59 -
CA 02407924 2002-11-19
_. ' j
Figure 27 depicts in enlarged cross-sectional detail pole
top 224. It also illustrates internal wiring components that
comprise an additional advantageous feature of the invention. As
can be seen, center piece 226, extensions 232, and cross arms 234
and 236 are generally hollow. The prefabrication of those three
components at the factory includes openings between the various
elements so that wiring can be communicated throughout those
components. This allows for significant amount of prewiring of
the light fixtures 238 at the factory.
Figure 27 further shows how extensions 232 space cross arms,
234 and 236 away from center piece 226. This allows joints 240
and fixtures 238 to be positioned anywhere along cross arms 234
or 236, including directly in front of center piece 226. This
subtle feature allows great flexibility in placement of lighting
fixtures 238 which can advantageously impact a variety of
factors, including the number of fixtures per cross arm, a -
reduction in cross arm 3ength, and even the aesthetic appearance
of the lighting array. For example, in Figure 26, cross arm 234
is shown with five lighting fixtures 238. One fixture is
directly in front of middle section or center piece 226. Cross
arm 236 is shown With six lighting fixtures. Conventionally, the
lighting fixture could not be easily installed directly in front
of a pole. The present inventior. allows this and therefore five
fixtures could be placed on a cross arm of shorter length than
conventional, which gives more aesthetic uniformity to the
fixtures, and can even reduce the amount of material needed, and
hence, the material costs for the bar. Tha ability to place
- 60 -
CA 02407924 2002-11-19
':; _::~:~-t
fixtures directly in front of the pole also makes it easier to
reach and maintain those fixtures, as well as others, which will
be closer to the pole.
Figure 27 shows the tapered bottom end 228 of pole top 224
and how it slip fits in mating fashion over the upper most
tapered end 230 of pole section 222c. As previously described,
the tapers are closely conformed to allow a secure and rigid fit.
Adhesives or other coatings can be used between the members, such
as lubricants or sealants. Again it is to be understood that
once pole top 224 is somewhat slip fitted onto tapered end 230,
it can still be rotationally oriented.
Figure 27 also illustrates the easy pre-configured wiring in
pole top 224. Wires 248 are communicated to each lighting
fixture 238 to supply electrical power to the lamps (not shown)
in those fixtures. Each of the wires 248 terminates in a
connector 250 which can be plugged into a mating connector 252
which is the terminal for a bundle of cables 254 that extend down
the interior of pole top 224 and pole 222. Connection of cables
254 to wires 248 merely entails plugging connectors 250 and 252
together.
Figure 27 additionally shows how the cabling arrangement can
be secured inside of pole top 224. A U-shaped hook 256 having
both free ends secured to the interior of center piece 226 of
pole top 224 provides an anchor for hanging cables 254. In the
preferred embodiment, cable grip 260 (preferably a "KELLUM GRIP",
available from FLEXCOR) surrounds cables 254 and has a loop 262
extending therefrom. A snap ring 264 can then be connected
- 61 -
CA 02407924 2002-11-19
.._.. .
between U-shaped hook 256 and loop 262 to securely and reliably
suspend the top of cables 254 in the position shown. In
comparison, normally a J-shaped hook is used on the interior of
the pole which can result in loop 262 or any other connection
means to be dislodged from the hook. In other words, the
components of the invention provide completely enclosed
connecting members which provide a positive secure attachment.
It is important that a reliable securement and support of
cables 254 be accomplished to eliminate any cable strain on wires
248, connectors 250 or 252, or cables 254. Additionally, this
assists in the longevity of the wiring as well as the positioning
of the wiring for minimum abrasion or trauma with the inside of
the pole.
As can be further appreciated, this reliable suspension of
cables 254 allows for the wiring and cabling to be precut and
configured with connectors so that the cabling is neither too
long or too short and the easy connection can be made. Moreover,
a ground connection lug 261 can be positioned inside pole top 224
to allow easy access to a ground terminal. Also note that both
bundles of cables 248 and 254 can be secured to the U-shaped hook
256 for strain relief, if desired.
Figure 28, a top sectional view taken along line 28-28 of
Figure 27, shows in further detail this arrangement. In this
Figure, apertures 266 in the bottom of cross arm 234 can be seen
allowing access of wires 248 to light fixtures 238.
Additionally, bolt holes 268 surround each aperture 266 in cross
arm 234 to allow the quick and easy installation of light
-- 62 -
CA 02407924 2002-11-19
_.:.'"' . : ,
fixtures 238 to cross arm 234. It can also be seen that cross
arm 234 has ears 270 at opposite ends. These ears have apertures
which allow the connection of a platform or cage to the cross
arms for maintenance purposes, if needed, or for securement
during crating and shipping.
Figure 28 also shows how the U-shaped hook 256 and cable
grip 260 can be generally centered inside of pole 222.
Figure 29 is an isolated sectional detail of the upper
portion of pole top 224 illustrating the ease of connection of
wires 248 to cable bundle 254. A removable cap 272 on the top of
pole top 224 allows easy access to connectors 250 and 252 so that
cable bundle 254 can be supported from hook 256 and connectors
250 and 252 can be plugged together. Cap 272 is then
repositioned by means well within the skill of those with
ordinary skill in the art (for examples screws, set screws, or
the like), and the electrical connection is completed.
Figure 30 shows in isolation, and in partially exploded
fashion, pole top 224. This Figure further emphasizes the fact
that normally the spacing of aperture 266 will be equal. There
is usually a minimum distance determined by the width of the
reflectors 274 (see Figure 28).~ This ties in with the discussion
regarding-how many fixtures can be supported by each cross arm.
Furthermore, the exact shape of extensions 232 can be seen.
A radius cut 276 at one end of the extension mates with the arc
or curvature of the center piece 226 of pole top 224 at that
location.
- 63 -
CA 02407924 2002-11-19
°y_.., - .
Figure 30 furthermore shows ears 2?8 on the exterior of the
lower tapered bottom end 228 of pole top 224, in comparison with
ears 280 on the upper most tapered end 230 of pole section 222c.
These ears can be utilized to connect jack means (not shown)
between each pair of ear 278 and ear 280 on opposite sides to
jack top 224 onto pole section 222c for the secure fit. Again
this can be done on the ground, or when elevated, but consists of
a easy yet reliable connection between those pieces. It is noted
that ears 280 are positioned far enough down the pole section
222c to allow upper most tapered end 230 to be inserted within
bottom end 228 of pole top 224 a substantial distance for a
preliminary fit. The jacking between the two sections
accomplishes the final rigid fit between the pieces. Once fitted
into final position, a set screw 259 could be used to further
insure against movement or rotation.
Figure 31 depicts several things. First, it depicts ears
282 and 284 on pole sections 222b and 222a respectively. These
ears are used in the same manner as ears 278 and 280, to jack the
two tapered pole sections together. Ears 286 can also exist at
the bottom of pole section 222a for a similar purpose. A
connection means on base 212 would have to be established arid
then jacks attached between ears 286 and that connection means.
Figure 31 also shows in more detail base 212. It is
important to understand that a hollow channel 288 exists in base
212. One or more perpendicular openings (in Figure 31 openings
290, 292, and 294) communicate with channel 288. Opening 290 is
above ground lever openings 292 and 294 are below. Any of the
- 64 -
CA 02407924 2002-11-19
_.
openings allows cabling from the electrical power source to enter
the base 212 and then extend upwardly through channel 288 into
the hollow interior of pole 222. Any openings 290, 292, and 294
not used can be sealed up.
Figure 31 also shows an opening 296 in the side wall of
bottom section 222a of pole 222. This allows communication of
the electrical wires within pole 222 to such things as ballast
boxes 242, 244, and 246. In the preferred embodiment these
ballast boxes are positioned several feet above ground level, but
near enough to ground that they can be easily accessed and
serviced. For ease of manufacturing and installation, only one
opening 296 is ordinarily required in pole 222. Electrical
communication between ballast boxes 242, 244 and 246, can be
between adjacent ends of those boxes.
Figure 32 shows in enlarged detail cable grip 260 previously
described. It also shows the enhanced features of a particular
bundling of cables 254 as well as an abrasion reducing means 298.
Cable grip 260 basically consists of a somewhat flexible wire
mesh cage 300 that can be expanded to slip over cabling. Strands
from the cage form loop 262 to which can be attached snap ring
264 according to the preferred embodiment. Once snap ring 264 is---
connected.to U-shaped hook 256 (see Fig. 27) on the interior of
the pole, the weight of cables 254 within wire cage 300 elongates
and narrows cage 300 causing it to grip cables 254 and be secure
at that location along cables 254.
Although this type of wire grip is well known in the art, it
is proved to have certain deficiencies when applied to the
- 65 -
CA 02407924 2002-11-19
y
present use. For example, many times a large number of wires
need to be communicated from the lighting fixtures down the pole
means. The wire cage 300 has to have a secure grip and hold such
a group of wires in place. Those wires in the center, based
simply on gravitational weight, tend to slide or slip and move
downwardly, as opposed to the wires around the circumference
which directly are in contact with the wire cage 300. This can
cause significant problems. This is particularly true when
applied to installations where the wiring is tens of feet tall.
Moreover, the wire cage 300 can dig into the insulation
surrounding cables 254 over time, helped by the gravitational
weight of the cables. As was previously mentioned, in the prior
art loop 262 generally is simply placed over a J-shaped hook
which presents the risk of the loop coming undone or being
dislodged.
In the present invention, several steps are taken to
eliminate these problems or deficiencies. First of all, the
cluster of cables 254 are twisted to provide a helix along their
entire length, as shown in Figure 32. This eliminates or greatly
reduces the risk that interior wires will slide downwardly with
respect to other wires of the cluster. Secondly, an abrasion
resistant sheath 302 (such as rubber) encapsulates the twisted
cables 254 along its entire length. Finally, a line 304 is
wrapped around the sheath 302. The wire cage 300 of the cable
grip 260 is then inserted over the line 304 and sheath 302. This
eliminates or reduces the risk of digging into the insulation of
cables 254 themselves. Sheath 302 is also an anti-slip cover to
allow better gripping by cage 300.
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CA 02407924 2002-11-19
. -
Figure 32, in conjunction with Figure 33 depicts abrasion
reducing means 298. To prevent trauma to cables 254 by swinging
against the inside of pole 222 along its length, which can abrade
or otherwise cause damage to the cabling, abrasion reducing means
298 are positioned at spaced apart locations along cables 254
(generally every 15 feet. The device 298 basically includes a
body 306 having an interior channel 308. Body 306 could be of a
number of different shapes (for example, football shaped, round,
etc.) and is preferably hollow (for example 1/8 inch hollow
rubber body). Body 306 has a slit 310 which allows it to be
opened sufficiently to be inserted so that channel 308 surrounds
cables 254. It is preferred that body 306 be somewhat resilient
and shock absorbing. Also, the lateral diameter of body 306
should extend substantially away from cables 254 in all
directions. Body 306 can include clamps 312 and 314 at opposite
ends of slit 310 one-half way around its circumference. These
clamps would either be connected to body 306 or clamp a portion
of body 306 to cables 254 when tightened down. Clamps 312 and
314 can be separated or opened to be inserted over cables 254,
such as is known in the art, and include closure members 316 and
318 to securely clamp them in place.
Therefore, abrasion reducing means 298 reduces the risk of
damage to the cables along sometimes tens or even hundreds of
feet lengths of pole 222. They can be spaced apart as desired
and will absorb any shock of the cable traveling towards the
interior sidewall of pole 222, or prevent cable 254 from abutting
the interior of pole 222. Normally, one will be positioned two
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CA 02407924 2002-11-19
.:.
feet below the top of pole top 224, and spaced apart thereafter
as desired. Figure 33 shows a top view along line 33-33 of
Figure 32. In this embodiment, body 306 substantially fills the
space between cables 2~4 and the interior of pole 222.
Figure 34 is an enlarged isolated perspective view of the
brackets used for the quick mounting of ballast boxes 242, 244,
and 246. Receiving and locating bracket 320 is attached to pole
222 by means known within the art. One example would be welding.
Alternatively, it could be bolted. Bracket 322, on the other
hand, is secured to the back of each ballast box by bolts,
welding, or other means known within the art.
Bracket 322 includes a base portion 324 which is attached to
the ballast box, and two opposite arms 326 and 328 which extend
outwardly away from the base, and then laterally parallel to the
back of the ballast box. At the outermost end of arms 326 and
328 is a pin or bolt 330 extending between and secured in that
position by means known within the art. Basically, bracket 322
extends the laterally positioned pin 330 to a spaced apart
position from the back of the ballast box and above the top of
the ballast box. This allows persons to manually move the
ballast box to a position adjacent bracket 320 on-the pole, and
to be able to visually see placement of pin 330 to guide i.t into
the bracket 320.
Bracket 320 consists of two parallel arms 332 and 334. At
the lower end of arms 332 and 334 are extensions 336 and 338
which extend at first outwardly and then upwardly. A bar 340
then connects these outer ends of extensions 336 and 338.
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CA 02407924 2002-11-19
_.; .
The side profile of each arm 332 and 334~is identical. An
edge surface 342 exists which forms a rail or bearing surface for
pin 330 of bracket 322 to be guided and slide along, when pin 330
is brought into abutment with bracket 320. Edge surface 342 has
,a first portion 344, a second curved portion 346, and a third
flat or straight portion 348 that are above from bar 340. A
fourth portion 350, lower or recessed from the first through
third portions, terminates in a curved cradle portion which then
extends backwardly and parallely in a fifth portion 354. It
should be understood that the width between arms 332 and 334 is
Less than the width between arms 326 and 328 so that pin 330 can
rest on both rails or edges 342 of arms 332 and 334,
respectively.
Figures 35-40 show the sequence of operations to install a
ballast box upon a pole utilizing brackets 320 and 322. Figure
35 shows in solid lines the initial lifting and presentation of
ballast box 242 and bracket 322 to bracket 320 on pole 222. The
dashed lines illustrate that the next step would be to lower
ballast box 242 vertically downwardly so that pin 330 passes
above bar 340 and comes to a resting gosition on the third
portions 348 of edge surfaces 342 of arms -332 and 334.
Figure 36 (by arrow 356) illustrates the movement to that
position. Thereafter, as illustrated by arrow 356, ballast box
242 is moved laterally backwards so that pin 330 slides and drops
down on the fourth portion 350 of edge surfaces 342 back and then
until it hits curved cradle portions 352 to lock pin 330 in
place.
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CA 02407924 2002-11-19
-,
Figure 37 shows in solid lines ballast box 24Z in this
position. As can be further seen in Figure 38, when pin 330 is
in this position, ballast box 242 is pivoted upwardly, but is
basically located because pin 330 is held in the cradle portions
of bracket 322.
As has been previously described, ballast box 242 includes
an aperture 361 towards its end opposite from bracket 322 which
ultimately will mate to conduit 358 which is secured to pole 222.
Because it is difficult to accurately perform this step, brackets
320 and 3242 make this much easier by again locating ballast box
342 in the pivoted position shown in Figures 37 and 38. All that
needs to be done, as shown in Figures 37 and 38, is to pivot
ballast box 242 downwardly (see arrow) towards pole 222.
Location of conduit 358 into the aperture and ballast box 242 is
therefore virtually automatic.
Figures 39 and 40 therefore show the ballast box 242 located
with pin 330 of bracket 322 in bracket 320, and pivoted
downwardly onto conduit 358. The insertion of conduit 358 into
the embossed aperture 361 in ballast box 242 would prevent
movement of ballast box along the axis of pole 222. The cradling
of pin 330 in bracket 320 preventswlift oft between brackets 320
and 322. Additionally, by securing means, conduit 358 is secured
to ballast box 242 to prevent lift off of that end of ballast box
242. As can be appreciated, once pole 222 is brought to
vertical, the gravitational weight of the ballast box will
eliminate the risk of pin 330 sliding upwardly and outwardly from
bracket 320.
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CA 02407924 2002-11-19
It can therefore be seen that this special structure allows
the ballast boxes to be quickly and easily installed onto pole
222 with a minimum of difficulty. These types of ballast boxes
can weigh several hundred pounds. Previously the connection of
conduit 358 to an opening in the back of ballast box 242 had to
be by estimation because the connection could not easily be
directly viewed. This was very difficult. The present invention
eliminates these problems.
Figures 41 and 42 depict contents of the interior of ballast
box 242 according to the invention. A housing 360, of basically
rectangular shape has an open front side which is bounded by a
formed edge 362 (see Figure 42). A door 364 is attached to
housing 360 by a standard hinge 366 along one side. Door 364
also has a formed edge 368 around its perimeter and includes a
gasket or insulation strip 370 to seal and insulate the area
between edges 362 and 368 when the door is closed upon housing
360. This assists in keeping out moisture and the elements from
the interior of ballast box 242. Lockable clasps 363 can be
positioned on housing 360 to sealingly lock door 364 to housing
360.
Figures 41-and 42 also illustrate the stackability of
additional ballast box 244 on top of ballast box 242. Basically,
this is accomplished by opening an aperture 372 in the top of
housing 350, and securing a conduit 374 in place in that
aperture. An embossed or recessed opening 376 exists in ballast
box 244 in its bottom wall.
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CA 02407924 2002-11-19
As can be easily understood by referring back to the
discussion of how each ballast box is attachable to pole 222,
upper ballast box 244 can be located in its attachment bracket
and then slid longitudinally downward so that opening 376 in the
bottom of ballast box 244 seats upon conduit 374 of ballast box
242. Again, the gravitational weight of box 244 will hold it
basically in position once the pole is put to vertical. If
desired, however, connection means can be utilized between the
top of conduit 374 and ballast box 244 to further secure it in
position.
As is understood, additional ballast boxes can then be
stacked successively above ballast box 244 utilizing the brackets
and openings and conduits previously discussed. Totally enclosed
communication of wiring between boxes can then be accomplished
through these components. It also still requires only one
opening in pole 222 to communicate with any and all ballast
boxes.
By still referring to Figures 41 and 42, the general
arrangement of electrical components inside ballast box 242 is
seen. In the upper portion of housing 360, bellasts 378 are
positioned on the brackets 380. Lower inside housing 360 are
capacitors 382 attached to the interior of housing 360 by
brackets 384.
A dividing wall 386 exists underneath the capacitor and
capacitor brackets to divide the interior of housing 360 into
upper and lower compartments. A fuse block 388 can exist in the
lower compartment under dividing wall 386. Additionally, opening
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CA 02407924 2002-11-19
361 in communication with conduit 358 enters into this lower
portion of housing 360 underneath dividing wall 386.
Still further, a vertical wall 392 (see Figure 42) is
positioned in the middle of the lower portion of housing 360.
Thermo-magnetic circuit breakers 394 can be attached to the front
of this vertical wall, as can what are called landing lugs.
These components are available from a variety of vendors and are
standard components. The advantage of placement of these
components in this particular structure is as follows.
Dividing wall 386 which extends substantially across housing
360 provides a thermal barrier between the upper and lower
chambers of housing 360. Additionally, placement of circuit
breakers 394 inside ballast 242 provides easily accessible power
disconnect means (on/off switch 395) right at ballast box 242.
In some conventional setups, the power disconnect must be
accomplished at a remote location from the pole, which is
inconvenient.
Still further, each of the electrical components has easy to
mount standardized brackets which allows easy assembly of the
ballast box at the factory. It also provides for flexibility as
far as the number of components used (for example the number of
ballast boxes is related to the number of light fixtures for the
pole). Still further, it involves ease of maintenance.
Finally, this arrangement again enables substantial pre-
wiring of the components at the factory, to eliminate that need
on-site.
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CA 02407924 2002-11-19
1
,,
The only substantial connections that need to. be made would
be between the wiring or cabling coming from the connection to
the electrical power source to circuit breakers 394 and landing
lugs 396. These components have to be able to handle the types
of cables ordinarily used for this electricity and must be able
to handle high voltage, high current cabling.
Still further, the connections for these components are such
that they are set up for virtually any conceivably needed
arrangement. For example, sometimes three phase electrical power
is needed, sometimes single phase. The landing lugs and circuit
breaker connections are such that all it requires is for the
installer to know which type~of electricity is being used, and
insert the leads into the premarked locations. This eliminates
the risk of improper installation while allowing the flexibility
to use either type of electrical power.
Figures 43-45 refer to the specific means utilized to secure
the conduit 358 communicating with the interior of pole 222 with
ballast box 242. As can be seen in Figure 43, the embossed
portion 420 around aperture 361 in the back of ballast box 242
includes tabs 398 which extend from basically opposite sides into
-Opening 361 and have holes 400 at their outer ends.
Threaded receivers 402 are positioned in the interior outer
end of conduit 358 in alignment with tabs 398. As shown in
Figure 43, screws 404 are insertable through springs 406, washers
408, and holes 400 in tabs 398, and then can be tightened into
receivers 402 in conduit 358 when conduit 358 is brought in to
embossed opening 361. As can be additionally seen, an 0-ring
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CA 02407924 2002-11-19
~ ,
410, basically conforming to the end of conduit 358 and fitting
within embossed opening 361, will form a seal to deter moisture
or water from entering that joint. Springs 406 perform a biasing
force to hold screws 206 in place.
Figure 44 shows in cross section the arrangement when all
components are fastened together. In particular, it is noted
that springs 406 are captured in washers 408 in enlarged portions
407 of bores 409. The invention therefore provides a non-
threaded junction which is sealed.
For purposes of comparison of the improvement of this
combination, Figure 45 shows one prior art method of attaching
the conduit 412 between a pole and a ballast box 414. The
exterior of conduit 412 is partially threaded. The entire
conduit 412 can be inserted through an opening 416 in ballast box
414. Threaded nuts 418 and 419 are then moved towards one
another on opposite sides of the wall of ballast box 414 around
opening 416 to hold these components in place.
A prime deficiency and problem with this arrangement is the
requirement of the threads on the exterior of conduit 412. To
attempt to weather proof these components, which are generally
metal, the metal must be galvanized. The galvanization usually
enters the threads making the connection extremely difficult.. It
is hard to accurately turn the nuts 418 and 419 on the threaded
conduit 412 to reliable and secure connection. Sometimes the
threads must be retapped. The combination of Figures 43 and 44
eliminates these problems and provides the weather-tight seal.
CA 02407924 2002-11-19
Figure 46 schematically depicts examples of the tremendous
flexibility of design of the present invention. In particular,
it shows how pole top 224 can be predesigned and manufactured to
support a variety of numbers of lighting fixtures 238 in a
variety of configurations. Moreover, it shows how the dimensions
of any of those arrangements can be constricted to fit within
limitations for shipping these entire assemblies preassembled.
By way of example, the arrangements carrying 2 through 8 fixtures
are no more than five feet wide from top to bottom. The
arrangement carrying 19 fixtures is no more than eight feet from
top to bottom. The arrangement carrying 15 fixtures is no more
than five feet from side to side. The numbers on each of these
configurations corresponds with the number of fixtures that are
attached to them. Any of these combinations can be shipped in
standard semi-trailers.
Figures 47 and 48 depict an advantageous bracketing
structure for mounting capacitors 382 to the interior of ballast
box 242. As can be,seen in Figure 47, a receiving bracket 422
having L-shaped legs 424 and 426 is attached on its back surface
428 to the interior side wall of ballast box 242.
A U-shaped channel piece 430 has a pin 432 extending
transversely across the interior of the channel as shown.
Capacitors 382 are attached to the opposite side of channel piece
430. Once secured in position, pin 432, as shown by arrows 434,
is moved and dropped into slpts 436 between legs 424 and 426, and
back surface 428. The weight of channel piece 430 and attached
capacitors 382 holds channel piece 430 in receiving bracket 422.
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CA 02407924 2002-11-19
._ . .
Figure 48 shows in more detail how capacitors 382 are
connected to channel piece 430. J-shaped pieces 438 are
positioned so that their hook ends 440 grasp lip 442 on each
capacitor 382. A bolt 444 extends through an aperture in hook
end 440 and extends along the side of capacitors 382 to a
threaded aperture 446 in channel piece 430. Also,~C-shaped
members 448 grasp around lips 442 of adjacent capacitors 382,
shown in Figure 48, and bolts 950 extend through apertures in
members 448 back to threaded apertures 446 and U-shaped channel
piece 430. This arrangement holds capacitors 382 against U-
shaped piece 430 in an economical but secure manner. The entire
assembly of capacitors 382 and channel piece 430 can be easily
removed for replacement or servicing. ,
Note also that slots 436 are narrower in diameter from top
to bottom, as shown in Figure 48. Therefore, pin 432 actually
cams down into frictional fit within slots 362 and adds security
to that fit. However, it is not difficult to remove the entire
assembly.
This arrangement therefore provides an easily assemblable
and economical way to mount capacitors within the ballast box.
It can therefore be seen that the individual structural
components of the preferred embodiment of the invention allowed
wide and advantageous flexibility with regard to design,
manufacturing, supply, insulation, operation, and maintenance of
the invention. This must be kept in mind when considering the
practical operation of the invention. By "operation", it is
intended to mean all of the above mentioned steps and processes
_ 77 _
CA 02407924 2002-11-19
involved with the invention beginning with the design of the
components for the particular installation, and ending with its
maintenance.
In operation, information as to the particular location and
application for each lighting installation is obtained. Such
things as pole height, number of lighting fixtures, direction of
aiming of fixtures, and the like are gathered. This type of
information then can be analyzed to determine such things as the
number and types of ballast boxes, the length of cabling, and the
number of cross bars needed or desired.
It should further be understood that this analysis is not
merely limited to each single lighting installation comprising a
pole and a number of fixtures. It is many times also analyzed
with a view towards the position and combination with other
lighting installations at the same site. Thus, this further
illustrates how the comprehensive and integrated approach can
result in better or more efficient composite lighting of a
location, which all ties in with the improved functionality and
economy of the present invention.
At this early design stage, it can therefore be seen that
the light fixtures and their function,,the pole and its
functions, and'the electronics and its functions are taken into
consideration. The present invention allows this sort of
integrated planning by the manufacturer or vendor of the
installations. It should not go unnoticed that the flexibility
of the invention also allows the customer to request certain
configurations, whether for aesthetic purposes, or otherwise,.
which may be accommodated by these designs,
_ 78 _
CA 02407924 2002-11-19
' 4,
Manufacturing of the components can also be analyzed and
integrated into each customized installation in the sense that
the components are so flexibly and easily assembled that custom
manufacturing is greatly reduced. Also, it is emphasized that
the particular types of components of the invention reduce, the
associated hardware and parts needed to assemble the final
installation. For example, no bracket mounting hardware is
needed for the cross arms. No significant hardware is needed for
securing the different pole sections together. Openings in bolt
holes for mounting such things as light fixtures are
premanufactured. Cabling channels are preplanned and
premanufactured. Again, this applies to both the light fixtures
and their mounting means, the pole and cross bars and base, and
various other electrical components.
Still further, the invention allows the production of such
things as precise lengths of cabling, provision of abrasion
resistant means, electrical connectors, and prewiring of a
substantial amount of the same at the factory. It is again
emphasized that in custom installations as presently conducted,
the cabling has to be laid and then cut, then.electricians need
to make the connections. Any attempts at precutting the cabling
risks the cabling being too long or too short.
With regard to supply and shipping of the integrated
components for an installation, as previously described, the
flexibility of the invention allows substantial preassembly at
the factory and then shipping by economical conventional means to
location. For example, as previously discussed in detail, a pole
_ 79 _
CA 02407924 2002-11-19
top member 224 with fixed cross arms 234 and 236 can have the
desired number of fixtures attached at the factory and prewired
so that all that is required is to install the pole top on top of
the pole and plug in the prewired cabling to the remaining
cabling for the installation. The fixtures can be aimed
according to predesigned directions, as has been previously
explained in patents of the present inventors. Specifically,
although these installations utilize substantially large light
fixtures for lighting wide scale areas such as athletic fields,
the preassembled pole top array with fixtures can~normally be
shipped in a semi-trailer, which has significant limitations with
respect to width or height, when dealing with this large of an
object. The pole can be shipped in sections as can other
components, including concrete premanufactured bases. Therefore,
a number of installations can be partially preassembled at the
factory, placed on one semi-trailer, and shipped directly on
site. There is no requirement of switching freight carriers, as
is sometimes a problem with one piece long poles which do not fit
on semi-trailers.
The invention also allows virtually the entire installation
to be at least partially preassembled at the factory in the- sense
that even the .electrical components, some of which are obtained
from other manufacturers, can be installed at the factory. The
installation can be virtually pre-progranuned and prepackaged at
the factory. Much of the matrix discussed previously can now be
completed at the factory. This eliminates quite a bit of the
dependence on the contractors on-site. An example of this would
- 80 -
CA 02407924 2002-11-19
be the contents of the ballast boxes which can be shipped and
easily installed without the need of substantial assembly on
site.
With regard to installation of lights, pole, and
electronics, as has been previously discussed, the present
invention greatly reduces time, labor, and effort required.
Essentially, once the bases 212 are sufficiently set in the
ground, it is a matter of unloading the components, adjusting the
lighting fixtures 238 into the preselected aiming angles from the
fixed cross arms 234 and 236, installing the desired number of
pole sections and pole top together, installing~ballast boxes as
needed, and connecting up the electrical connections. The pole
is then raised and slip fitted onto the base. Any adjustments as
far as rotational direction can be made, and finally the
electrical connections to the electrical power source are made
completing the installation. This should be directly compared to
the problems discussed with regard to erecting poles such as are
known in the prior art, then assembling the cross bars and
fixtures, and finally preparing the electrical components and
wiring.
It can be appreciated that the advantages of the invention.
also apply to the use and operation of each installation. The
pole structure has improved resistance to corrosion add space, it
can be made from materials such as steel which is desirable. The
fixed cross arms on the top pole provide a ready made
unchangeable reference coordinate system for the aiming of the
light fixtures. The abrasion reducing means and abrasion
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CA 02407924 2002-11-19
_ . _, _
resistant sheaths, cable grip, and prewiring increase the
reliability and durability of the wiring. The optional
connections of the ballast boxes also furthers this goal.
Overall, although the installation is quick and economical,
it has high reliability and durability.
Maintenance likewise is improved in that the ballast boxes
are easily accessible, and yet are secure and shielded from water
and the elements. The reliability of the wiring and the
mechanical structure reduces the chances of required maintenance.
Features such as built in ears or tabs allow the attachment of
maintenance equipment and these considerations can be analyzed
from the very beginning design of the installation.
It can therefore be seen that the base according to one
embodiment of the invention, comprised of the prestressed,
precast concrete, can be plumbed in a bore in the ground, and
then concrete can be poured around the base to effectively
increase its size. Since the concrete only needs to have
compressive strengths, it can set up quickly. The whole process
then ensures the base is plumb and secure for any type of hole it
needs to support.
This ties in with the ability then to be ensured that the
top of the pole will also be directly vertically above the base.
As previously described, this-allows.the design of the system to
be prepacked and shipped to the installation site. The entire
unit can.then be installed. It is virtually then reassembled on
cite as a composite, integrated, unitary installation according
to the predesign parameters.
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CA 02407924 2002-11-19
. ::.:. : ._ _
The most efficient utilization of the lighting fixtures can
therefore be preplanned at the factory and integrated with other
lighting fixtures and poles for the particular location. All of
the fixtures can then be reliably predesigned to provide an
efficient composite photometric bEam. The lighting fixtures, no
matter how many, can basically be designed as a part of the pole
structure. They can be quickly installed so that the entire
array of fixtures on each pole can then be quickly aimed to
create the smooth, efficient, composite beam. The field or area
to be lighted can be predefined to have an orthogonal coordinate
system. The poles and light fixtures can therefore accurately be
predicted as to where they will exist in that coordinate system
to make this composite beam in lighting possible.
Still further, it is disability to reliably predict the
position of the fixtures prior to installation, that allows other
needed components for the lighting installation such as ballast,
capacitors, wiring, etc., to be predesigned and at least
partially preassembled and sized at the factory. This in turn
allows for a quick economical and easy installation on site which
is of very important economic value.
It can furthermore be seen that. the present invention allows
the utilization of a straight pipe for center piece 226 of pole
top 224, as seen in Fig. 30. By methods known in the art, the
bottom end 228 can be tapered by flaring it so that it can be
integrated with the tapered upper end 230 of pole 222. It is to
be understood that pole top center piece 226 would cost almost
ten times as much if it had to be prefabricated in a tapered
fashion .
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CA 02407924 2002-11-19
It will therefore be appreciated that the present invention
can take many forms and embodiments. The present preferred
embodiment is in no way intended to limit the scope thereof which
is defined solely by the claims set forth below.
For example, various of the components can be utilized
separately from the other components with advantageous results.
The quick attach ballast boxes, the pole structure, the pole, top
member, the abrasion resistant devices, and preconfigured wiring
are examples of just a few.
The ballast boxes can be mounted at any location around the
perimeter of the pole. Sometimes they are preferred to be in
back of the pole.
Additionally, these various advantageous features can be
used in any combination with one another that is reasonable and
desired.
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