WO2024148403A1

WO2024148403A1 - Composite pole for an electrical light pole

Info

Publication number: WO2024148403A1
Application number: PCT/AU2024/050017
Authority: WO
Inventors: Darren John WILLIAMES; Mark James WILLIAMES
Original assignee: Plassets Pty Ltd
Current assignee: Plassets Pty Ltd
Priority date: 2023-01-13
Filing date: 2024-01-12
Publication date: 2024-07-18
Anticipated expiration: 2025-07-13
Also published as: AU2024208543A1

Abstract

A composite pole (10) comprising a metal tubular element (12) having a wall (14) with an outer surface (14a) and inner surface (14b), an inner lining (100) of a polymeric material, and an element (22) that mechanical interlocks the wall (14) and the lining (100), wherein the mechanical interlock element (22) is configured to accommodate shrinkage of the polymeric material during manufacture of the composite pole (10) and shrinkage and expansion of the polymeric material 100 in use of the composite pole (10).

Description

COMPOSITE POLE FOR AN ELECTRICAL LIGHT POLE

FIELD OF THE INVENTION

The present invention relates to an elongate composite pole for an electrical pole for street lighting and to a process for manufacturing the elongate composite pole .

The present invention relates particularly, although by no means exclusively, to the use of recycled polymer materials , such as polymer materials that otherwise would be waste polymers often used as landfill , in the composite pole .

The present invention relates particularly, although by no means exclusively, to an electrical pole for street lighting that includes the composite pole .

The present invention relates particularly, although by no means exclusively, to a process for manufacturing the composite pole from recycled polymer materials , such as polymer materials that otherwise would be waste polymers often used as landfill .

BACKGROUND OF THE INVENTION

The following description of the background of the invention discusses the use of waste polymers (often used as landfill ) as recycled polymer materials for products for the construction industry, noting that the invention is not confined to the use of waste polymers .

The following description of the background of the invention also discusses manufacturing a particular product for the construction industry, specifically an elongate composite pole for an electrical pole for street lighting , using polymer materials , typically waste polymers typically used as landfill , as one of the materials in the composite pole .

Currently, there is an excess of post-industrial and postconsumer waste polymers .

As a consequence , waste polymers are a readily available resource for use as recycled polymer materials , for example , in the manufacture of new consumer products , such as new beverage bottles .

Also , waste polymers are useful as recycled polymer materials in the construction industry, which term is understood herein to include industries that produce and use elongate composite poles for street lighting applications . Recycled polymer materials can provide required construction strength and are also cost efficient .

However , the finished construction industry products made from waste polymers used as recycled polymer materials are not necessarily aesthetically pleasing , particularly when the products are presenting a finished surface .

The optical properties of waste polymers used as recycled polymer materials and the generally variable composition and mechanical properties of recycled polymer materials have typically dictated that construction industry products made from waste polymers used as recycled polymer materials are more suitable for products requiring compression strength .

In addition , there are problems with processing and using polymer materials generally and waste polymers used as recycled polymer materials more specifically in the manufacture of construction industry products such as elongate composite poles for electrical poles for street lighting applications . These problems include , by way of example , accommodating shrinkage of polymer materials as molten polymer materials used in the manufacture of elongate composite products cool to ambient temperature .

There is therefore a need to be able to use polymer materials , such as waste polymers used as recycled polymer materials , for manufacturing products for the construction industry while also providing aesthetic finished products . In the context of the invention , this need extends particularly to the manufacture of elongate composite products which include waste polymers used as recycled polymer materials as a component of the products .

One , although not the only, aim of the present invention is to produce a cost efficient and effective elongate composite pole utilising waste polymers used as recycled polymer materials that are suitable for the construction industry, particularly for electrical poles for street lighting .

SUMMARY OF THE INVENTION

The present invention is based on a realisation that a particular structure for elongate composite poles for electrical poles for street lighting makes it possible to include a polymer material , including but not limited to , a waste polymer used as recycled polymer material , as a component of the poles .

The present invention is also based on a realisation that it is possible to use waste polymers , in particular but not limited to mixed waste polymer materials , as recycled polymer materials in the manufacture of elongate composite poles for electrical poles for street lighting .

The term "mixed waste polymer materials" is understood herein to mean a mixture of different waste polymer materials at the end of a recycling separation process that have not previously been separated into single source polymer material categories . Typically, mixed waste polymer materials have very low, if any economic value and are used as land fill . The mixed waste polymer materials may include any two or more of PET , HDPE , LDPE and other polymer materials in consumer and other industry-derived products that are processed in recycling facilities .

The invention provides a composite pole for an electrical pole for street lighting comprising a metal tubular element having a wall with an outer surface and inner surface , an inner lining of a polymeric material , and an element that mechanical interlocks the wall and the lining , wherein the mechanical interlock element is configured to accommodate shrinkage of the polymeric material during manufacture of the composite pole and shrinkage and expansion of the polymeric material in use of the composite pole . The mechanical interlock element may be located in at least a third of the length of the metal tubular element .

The mechanical interlock element may comprise a plurality of projections protruding inwardly from the inner surface of the wall .

The projections may be T-shaped .

The projections may be spaced apart in an array of projections .

Each of the projections may be elongate and extend at least a part of the length of the tubular element .

The composite pole may comprise (a) a housing for a control assembly for an electric light unit when the unit is mounted to the pole , with the housing being embedded in the inner lining , and (b) an opening in the wall of the tubular element to provide access to the housing , and (c) a cover that can close the opening and can be opened to provide access to the housing externally of the pole .

The composite pole may comprise (a) a channel defined by a web and a pair of parallel sides extending from the web , wherein the channel is embedded in the inner lining and (b) a pair of spaced-apart transverse partitions connected to the web and to the sides , wherein the housing is defined by the partitions and sections of the web and the sides that separate the partitions .

The channel may include a central section and two outer sections . The housing may be located in the central section of the channel .

The sides of the channel may have out-turned flanges and extending from upper edges of the sides .

The channel and the tubular element may be configured to allow sliding movement of the channel within the tubular element along the length of the tubular element to a predetermined operative position prior to injection of the polymeric material into the tubular element when manufacturing the composite pole .

The out-turned flanges of the tubular element and the T- shaped projections may be configured to define a rail-type system for allowing sliding movement of the channel within the tubular element to the predetermined operative position prior to injection of the polymeric material into the tubular element when manufacturing the composite pole .

The channel may be secured to the tubular element at the predetermined position .

The channel may be securable via mechanical fasteners .

The web and/or the sides of the channel may include apertures that , in the manufacture of the pole allow the at least partially molten extruded/injected polymeric material to flow through the apertures to facilitate forming the inner lining .

There may be a hermetic seal between the channel and the wall .

The control assembly housing that is embedded in the inner lining may anchor the polymeric material and prevent shrinkage and expansion of the polymeric material in that section of the composite pole in use of the composite pole .

The composite pole may comprise an internal pipe embedded in the inner lining and an electrical wire in the pipe extending between the housing and one end of the tubular element and between the housing and another end of the tubular element , with the electrical wire being provided to electrically connect an electrical light unit when mounted to the other end of the pole to an electrical power source .

The inner lining may extend at least 50% the length of the pole from one end of the tubular element .

The inner lining may extend at least 60% the length of the pole from one end of the tubular element .

The inner lining may completely fill the interior of the pole in that section of the length of the pole having the inner lining .

The inner lining may be an annular inner lining .

The polymeric material of the inner lining may include a waste polymer as a recycled polymer material .

The polymeric material may be a fibre-reinforced polymeric material .

The polymeric material may contain a foaming agent .

The polymeric material may comprise a first polymeric material and a second polymeric material having a higher melting point than that the first polymeric material .

The first polymeric material may include a waste polymer as a recycled polymer material .

The second polymeric material may include a waste polymer as a recycled polymer material .

The inner lining may comprise a continuous network of the first polymeric material and a dispersion of fragments of the second polymeric material .

The tubular element may be an extrusion .

The tubular element may be a fabricated element .

The tubular element may be formed from aluminium or an aluminium alloy .

The invention also provides an electrical light pole comprising (a) the above-described composite pole , (b) an electrical light unit mounted to an end section of the pole , and (c) a control assembly for the electric light unit located in the housing of composite pole .

The invention also provides a pole assembly comprising the above-described composite pole and a base section extending axially from an end of the pole , the base section configured to be received in the ground .

The base section may comprise a tubular body .

The base section may comprise an inner tubular section and an outer tubular section that are telescopically arranged .

The inner tubular section may have a rectangular cross section and the outer tubular section as a circular cross section .

The base section may be made from metal . The metal may be any suitable metal such as steel or aluminium.

The base section may be corrosion protected . Non-limiting examples of corrosion protection include surface coatings , galvanisation , and sacrificial anode s / ca thode s .

The invention also provides an electrical light pole comprising (a) the above-described pole assembly, (b) an electrical light unit mounted to an end section of the pole , and (c) a control assembly for the electric light unit located in the housing of composite pole .

The invention also provides an electrical light pole positioned in the ground, the pole comprising (a) the above-described pole assembly and (b) an electrical light unit mounted to an end section of the pole , wherein the pole assembly is positioned in the ground such that a lower end of the composite pole is elevated above a ground level . The electrical light pole may further comprise (c) a control assembly for the electric light unit located in the housing of the composite pole .

The invention also provides a method of installing the above-described pole assembly comprising inserting the base section into the ground such that a lower end of the composite pole is elevated above a ground level .

The lower end of the composite pole may be positioned at a minimum height of 200mm, typically, 250mm, and more typically 300mm above the ground level .

The invention also provides a method of manufacturing the above-described composite pole that includes the steps of :

(a) extruding or fabricating a metal tubular element ;

(b) positioning a housing for a control assembly for an electric light unit within the tubular element at a predetermined location and securing the housing to the tubular element ;

(c) injecting an at least partially molten polymeric material into the tubular element via an end of the tubular element , and

(d) allowing the polymeric material to solidify via heat transfer from the polymeric material to the tubular element .

Step (b) may include forming the housing in a channel and positioning the channel within the tubular element and securing the channel to the tubular element .

Step (b) may include sliding the channel along the tubular element to the predetermined location from one end of the tubular element .

Step (c) may include drawing at least a partial vacuum from another end of the cavity and injecting molten polymer material into the cavity from the one end .

Step (c) may include inserting a nozzle through the cavity from one end of the cavity up to a desired position along the length of the tubular element , for example proximate the other end of the cavity, and progressively withdrawing the nozzle away from the other end while injecting molten polymer material into the cavity .

The applicant has recognised that mixed waste polymers as described herein have different melting points which , in terms of melting and reforming , are not viable using existing industrial equipment .

In order to make it possible to use such mixed waste polymers as the above-described at least partially molten polymeric material , the method may include melting mixed waste polymers at a temperature that is selected to at least partially melt a lower or lowest melting point polymer of the mix and leave other waste polymers in the mix in a solid form and forming an injectable slurry of the mixed waste polymers , whereby at least one molten waste polymer acts as a binder for the other waste polymer (s) in the mix when the mixture solidifies .

Typically, the melting temperature of the mixed waste polymers is in a range of 160-260 ° C , typically 180-250 ° C . BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are described, by way of nonlimiting examples , with reference to the accompanying Figures , of which :

Figure 1 is a side view of a section of the length of an embodiment of a composite pole according to the invention ;

Figure 2 is an enlarged view of the circled section G in Figure 1 ;

Figure 3 is a transverse section along the line V-V of Figure 1 ;

Figure 4 is a transverse section along the line U-U of Figure 2 ;

Figure 5 is a transverse section along the line H-H of Figure 2 ;

Figure 6 is an exploded perspective view of the length of the embodiment of the composite pole shown in Figure 1 showing components of the composite pole before the components are assembled together and before a polymeric material is injected into the assembled components to form an inner lining of the assembled composite pole ;

Figure 7 is an enlarged view of the circled section D in Figure 6 ; Figure 8 is a side view of an embodiment of an electrical light pole for street lighting in accordance with an embodiment of the invention , with the electrical light pole including the composite pole of Figures 1 to 7 , noting that the light fitting is not shown ;

Figure 9 is an enlarged view of an upper section of the electrical light pole shown in Figure 8 ;

Figure 10 is a side view of a pole assembly comprising a composite pole and a base section axially from an end of the composite pole according to another embodiment of the invention , noting that the section breaks denote a variable dimension ;

Figure 11 is a side view of the pole assembly of Figure 10 , the view being rotationally offset from the view shown in Figure 10 by 90 degrees relative to the axis of the pole assembly;

Figure 12 is a side view of the pole assembly shown in Figure 10 , in which the full length of the pole assembly is shown ;

Figure 13 is a longitudinal section along the line N- N in Figure 12 ;

Figure 14 is an enlarged view of circled section A in Figure 12 ;

Figure 15 is an enlarged view of circled section AG in Figure 13 ; Figure 16 is an enlarged view of circled section AN in Figure 13 ;

Figure 17 is an enlarged view of circled section BA in Figure 13 ;

Figure 18 is a side view of another embodiment of an electrical light pole for street lighting in accordance with an embodiment of the invention , with the electrical light pole including the pole assembly shown in Figures 10-17 , noting that the light fitting is not shown ;

Figure 19 is another side view of the electrical light pole of Figure 18 , the view being rotationally offset from the view shown in Figure 18 by 90 degrees relative to the axis of the electrical light pole ;

Figure 20 is a side view of yet another embodiment of an electrical light pole for street lighting in accordance with an embodiment of the invention , with the light pole including a pole assembly comprising a composite pole , as previously described, and a base section comprising an inner tubular section and an outer tubular section that are telescopically arranged, noting that the light fitting is not shown and the section breaks denote a variable dimension ;

Figure 21 is a transverse section along the line BF in Figure 20 ;

Figure 22 is a transverse section along the line BE in Figure 20 ; Figure 23 is a perspective view of the base section of Figure 20 in isolation ; the internal components being shown in phantom at an overlapping region of the inner tubular section and the outer tubular section ;

Figure 24 is an enlarged view of the overlapping region in circled section AQ in Figure 23 ;

Figure 25 is an exploded perspective view of the base section shown in Figure 23 ;

Figure 26 is a side view of the base section shown in Figure 23 ;

Figure 27 is an enlarged view of the circled section BH in Figure 26 ;

Figure 28 is a longitudinal section along the line AX -AX in Figure 26 ;

Figure 29 is an enlarged view of the circled section AY in Figure 28 ;

Figure 30 is a side view of the base section shown in Figure 23 but with different annotations ;

Figure 31 is an enlarged view of the circled section AT in Figure 30 ;

Figure 32 is transverse section along the line AU-AU in Figure 30 ;

Figure 33 is a side view a composite pole according to another embodiment of the invention , the composite pole is similar to the composite pole shown in Figures 1 -9 in that it comprises an opening with a door that can be opened and closed to provide access to a control assembly, and additionally shows a locking system comprising a locking assembly locking the door ; noting that the section breaks denote a variable dimension ;

Figure 34 is a transverse sectional view along the line AO-AO in Figure 33 ;

Figure 35 is an enlarged view of the circled section AP in Figure 34 ;

Figure 36 is a front perspective view of the door shown in Figure 33 in isolation ;

Figure 37 is rear perspective view of the door shown in Figure 36 ;

Figure 38 is a side view of the door shown in Figure 36 ;

Figure 39 is a front view of the door shown in Figure 36 ;

Figure 40 is a longitudinal section along the line I- I in Figure 39 ;

Figure 41 is a transverse section along the line J- J in Figure 39 ;

Figure 42 is an exploded perspective view of the locking assembly shown in Figure 33 ;

Figure 43 is a top view of the locking assembly shown in Figure 42 ;

Figure 44 is an end view of the locking assembly shown in Figure 42 ;

Figure 45 is another end view of the locking assembly shown in Figure 42 ;

Figure 46 is a side view of another embodiment of an electrical light pole for street lighting in accordance with an embodiment of the invention ; the electric light pole is of a similar arrangement to that shown in Figure 18 but differs in that the base section comprises a flanged end configured to be bolted to the ground; noting that the light fitting is not shown and the section breaks denote a variable dimension ;

Figure 47 is another side view of the electrical light pole of Figure 46 , the view being rotationally offset from the view shown in Figure 18 by 90 degrees relative to the axis of the electrical light pole ;

Figure 48 is a perspective view of the electrical light pole of Figure 46 ;

Figure 49 is an enlarged view of the circled section AD in Figure 48 ;

Figure 50 is a bottom perspective view of an embodiment of the base section with a flanged end shown in isolation ;

Figure 51 is a top perspective view of the base section shown in Figure 50 ;

Figure 52 is a top view of the base section shown in Figure 50 ;

Figure 53 is a side view of the base section shown in Figure 50 ;

Figure 54 is another side view of the base section of Figure 53 , the view being rotationally offset from the view shown in Figure 53 by 90 degrees relative to the axis of the base section ;

Figure 55 is a transverse section along the line AP- AP in Figure 54 ;

Figure 56 is a differently annotated version of the side view of the base section shown in Figure 55 , the cross-hatching illustrating a region of the base section that is surface treated;

Figure 57 is a side view of another embodiment of an electrical light pole for street lighting in accordance with an embodiment of the invention ; the electric light pole is of a similar arrangement to that shown in Figure 20 but differs in that the base section comprises a flanged end configured to be bolted to the ground; noting that the light fitting is not shown and the section breaks denote a variable dimension ; Figure 58 is a perspective view of an adaptor plate configured for use with the base section shown in Figures 46 to 57 ;

Figure 59 is a top view of the adaptor plate shown in Figure 58 ; and

Figure 60 is a side view of the adaptor plate shown in Figure 58 .

DESCRIPTION OF EMBODIMENTS

Figures 1-7 show an embodiment of a composite pole 10 in accordance with the invention .

The composite pole 10 is suitable for use , for example , as a part of an embodiment of an electrical light pole 30 (see Figures 8 and 9) for street lighting in accordance with the invention . The composite pole may be any suitable length and other dimensions for this purpose .

The composite pole 10 comprises :

(a) a metal tubular element 12 , in this embodiment made from aluminium or an aluminium alloy) , having a wall 14 with an outer surface 14a and inner surface 14b (see Figure 3) , an upper end 11 and a lower end

13 (see Figure 1 ) ;

(b) an inner lining 100 of a polymeric material ; and

(c) an element 22 that mechanical interlocks the wall

14 and the lining 100 , wherein the mechanical interlock element 22 is configured to accommodate shrinkage of the polymeric material during manufacture of the composite pole and shrinkage and expansion of the polymeric material in use of the composite pole 10 , for example during the service life of an electrical light pole 30 that includes the composite pole 10 .

During the manufacture of the composite pole 10 , in accordance with an embodiment of a manufacturing method described further below, the polymeric material is injected as an at least partially molten slurry and solidifies via heat transfer from the polymeric material to the wall 14 to form the lining 100 .

The tubular element 12 is manufactured by extrusion , but it may be manufactured by other fabrication methods such as by injection moulding .

The tubular element 12 is made from aluminium or an aluminium alloy . The grade of the aluminium of the tubular element 12 shown in the Figures is aluminium 6106 T6. The invention is not confined to manufacturing the tubular element 12 from aluminium or an aluminium alloy . The tubular element 12 may be made from any suitable metallic or non-metallic material . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of a material for the tubular element 12 in any given situation .

The tubular element 12 has a textured outer surface 14a .

As can best be seen in Figure 2 , the tubular element 12 has a plurality of ribs (shown as lengthwise extending lines) on its outer surface 14a which are spaced around its circumference and extend along its length .

The tubular element 12 has a length of 6000mm, an internal diameter of 120mm and a wall thickness of 2 .5mm. It is noted that other embodiments of the invention may have different lengths , diameters , and wall thicknesses .

As can be seen in Figures 1 , 6 , and 8 the tubular element 12 has a first opening 16 in the wall 14 which provides access into its interior . The first opening 16 is positioned so that , in use of an electrical light pole 30 (see figures 8 and 9) that includes the composite pole 10 , the first opening 16 is below ground with the center of the opening being 975mm from the bottom of the tubular element 12 or 525mm below the plane of the ground . In use , the first opening 16 is used to insert cables for connecting to and transmitting power to the electrical light pole 30 . The first opening 16 is 150mm in length .

As can be seen in Figure 6 , composite pole 10 also comprises tubes 40 that extend axially within the composite pole 10 . The tubes 40 allow passage of electrical cables through the composite pole 10 . At an upper end of the composite pole 10 is an end cap 32 . The end cap 32 provides an attachment point for a light fixture 60 (see Figures 8 and 9) .

As can be seen in Figures 1 , 2 , and 5-8 , the tubular element 12 has a second opening 18 in the wall 14 which provides access into its interior . The second opening 18 is positioned so that , in use of the electrical light pole 30 , the second opening 18 is above the ground with the center of the opening being 860mm above the plane of the ground . In use , the second opening 18 is used to provide access to a control assembly (not shown) for the electrical light pole 30 . The second opening 18 is 255mm long , has an internal width of 81mm and has an external width of 95mm. The second opening 18 has a door 20 (see Figure 4 ) that can be opened and closed to provide access to the control assembly . It is noted that other embodiments of the invention may have different dimensions to those mentioned in this paragraph .

As can be seen in Figures 2 , 3 and 4 , the mechanical interlock element 22 is in the form of a plurality of T- shaped projections 22 protruding inwardly from the inner surface 14b of the tubular element 12 . The T-shaped projections 22 are provided as a mechanical interlock between the lining 100 and the tubular element 12 . The T- shaped projections increase surface area of the inner surface 14b and therefore maximise the area of contact between the inner surface 14b and the lining 100 at an interface therebetween . The area of contact between the inner surface 14b and the lining 100 is proportional to the degree of adhesion between the components . The T- shaped projections are evenly spaced around the inner circumference of the tubular element 12 and extend along its length . It is noted that the invention is not confined to this arrangement of T-shaped projections 22 . The interlock element 22 may be any suitable shape that increases surface area of the inner surface 14b , thereby enhancing adhesion between the inner surface 14b and the lining 100 . Adjacent T-shaped projections 22 are 25mm apart . From a top view of the interior of the tubular element 12 , the height of the vertical section of each T- shaped projection is 6mm and has a thickness of 2 .5mm. The thickness of the horizontal section is 2 .5mm. It is noted that other embodiments of the invention may have different dimensions to those mentioned in this paragraph .

The tubular element 12 may come in various shapes .

The Figures show that the tubular element 12 is of a constant diameter throughout its length .

In another embodiment , the tubular element 12 has a tapering diameter throughout its length such that it has a triangular shaped profile .

In another , although not the only other , embodiment , the tubular element 12 has an upper section which is at an angle to a lower section . The upper and/or lower section of the tubular element 12 may have constant and/or tapering diameters .

The lining 100 is formed from a slurry of a solid material , such as a solid polymeric material , and a molten polymeric material . It is noted that the invention is not confined to forming the lining 100 from such a slurry . By way of example , the lining 100 may be formed from a molten polymeric material . The molten polymeric material may be a single composition or a mix of multiple polymers . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of how to form the lining 100 in any given situation . In one embodiment of manufacturing the composite pole 10 shown in the Figures , the slurry comprises at least 70% , typically 80-90% , molten polymeric material by weight . The invention is not confined to this amount of molten polymeric material .

The molten polymeric material may be polyethylene , high density polyethylene (HDPE ) , low density polyethylene (LDPE ) and polypropylene (PP) . Suitably, the polymeric material is sourced from post-consumer waste plastic material such as soft plastic material i . e . , shopping plastic bags and plastic food packaging . It could also be a mixture of any of the above materials , including contaminants such as labels and glues associated with plastic packing . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of the polymeric material in any given situation .

The solid material of the slurry is suitably, for example , wood fragments , hay, metal fragments and/or fragments of a polymeric material (s) (such as waste polymer (s) ) having a higher melting point (s) than the plastics used to make the molten liquid . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of the solid material in any given situation .

The slurry may also have other additives such as fibre reinforcing materials and/or foaming agents .

The applicant has found that the larger the volume of waste polymers and the more varied the waste polymers used to form the slurry, the higher the melt flow of the slurry .

The melt flow of the slurry is an important factor in this embodiment of manufacturing the composite pole 10 because a high melt flow enables the slurry to fill the tubular element 12 to the required level or amount and does not solidify too early before the filling process is completed . A typical melt flow of the slurry is MFL 15 .

An advantage of the invention is that it makes it possible to use waste polymers (and other waste materials) which would otherwise go to landfill , thereby contributing to soil pollution and air pollution (through burning of the landfill ) .

As can best be seen in Figures 6 and 7 , the composite pole 10 also comprises (a) a channel 50 defined by a web 50a (Figure 7 ) and a pair of opposing parallel sides 50b, 50c (Figure 7 ) extending from the web 50a . The channel 50 has two spaced apart partition walls 50d, 50e (Figure 7 ) along its length with each partition wall 50d, 50e , being connected to the opposing parallel sides 50b , 50c , and the web 50a of the channel .

The partition walls 50d, 50e divide the length of the channel 50 into 3 sections , namely a middle section and two outer sections .

The middle section defines a housing for the above- mentioned control assembly (not shown) for the electrical light pole 30 . Each partition wall 50d, 50e , has a centrally located aperture 50f for receiving ends of tubes 40 for housing electrical cables for a light fixture 60 of the electrical light pole 30 that is only partially shown in Figures 8 and 9. The tubes 40 are shown in Figures 3-7 .

The parallel sides 50b , 50c and the web 50a of the outer sections of the channel 50 have a plurality of apertures 50g for allowing the polymeric material 100 to flow through when forming the inner lining 100 .

The parallel sides 50b , 50c of the channel have out- turned flanges 50h .

Suitably, the channel 50 is made from aluminium and has a length of 1000mm, a height of 87 .5mm, an external width of 287mm and an internal width of 81mm. It is noted that other embodiments of the invention may be made from a different metal or metal alloy and have different lengths , diameters and wall thicknesses .

As noted above , one use of the composite pole 10 is as the "pole" part of the electrical light pole 30 shown in Figures 8 and 9. As shown in the Figures , the electrical light pole 30 also includes the light fixture 60 , which in the embodiment shown in the Figures , is a T-shaped unit with an upright section extending from the upper end of the composite pole 10 and a cross-member that has a longer section that is configured to support a light fitting (not shown) . It is noted that the light fixture 60 may be any suitable fixture and the invention is not confined to the fixture shown in the Figures . In use , the electrical light pole 30 can be positioned in and retained in the ground in any suitable way . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of how to position and retain the electrical light pole 30 in the ground in any given situation .

Figures 10-17 show a pole assembly 101 according to another embodiment of the invention comprising :

(a) a composite pole 10 having the features described above in relation to the embodiment shown in Figures 1-9 , and

(b) a base section 80 coupled to the lower end 13 of the composite pole 10 .

The composite pole 10 and the base section 80 are separate components in this embodiment that can be coupled together , as shown in the Figures .

When the pole assembly 101 is used as the "pole" part of the electrical light pole , the base section 80 is received in the ground and configured such that the lower end 13 of composite pole 10 is elevated from ground level GL .

This arrangement provides an advantage for servicing and replacing the composite pole 10 , as this work can be done entirely above ground .

The base section 80 comprises a steel tubular body 81 having a first end 82 (see Figure 12 ) and a second end 83 and a central passage 84 (see Figure 13) with extends axially between the first and second ends 82 , 83. As best illustrated in Figures 10 and 11 , the tubular body

81 comprises a wall with plurality of drainage holes 85 therethrough . The drainage holes 85 allow ingress/egress of water into/out of the central passage 84 . The drainage holes 85 have a stadium shaped profile . The drainage holes 85 are evenly offset by 90 degree intervals around the tubular body 81 .

Also shown in Figure 12 , the tubular body 81 comprises a pair of access openings 86 that are diametrically positioned at a first level that is approximately 517mm beneath the ground level GL when the base section 80 is installed in the ground . Each of the access openings 86 allows for cables to be inserted or removed from the central passage 84 . Each access opening 86 has a rectangular shaped profile .

The pole assembly 101 has a length of 6 , 302mm. The base section 80 has a length of 1 , 700mm. In use , the first end

82 of the base section 80 is inserted 1 , 400mm into the ground such that the second end 83 projects 300mm above ground level GL .

The center point of each drainage hole 85 is located 1 , 514mm from the first end 82 . When installed in the ground, the center point of the drainage holes 85 is located 114mm above ground level GL .

The access openings 86 have a length of 157mm and a width of 50mm. The center point of each access opening 86 is located approximately halfway between the first end 82 and second end 83 . The dimensions mentioned in the three preceding paragraphs are examples only of suitable dimensions for a particular application and the invention is not confined to these dimensions . A person skilled in the art would know or could readily determine the factors to consider to make an appropriate selection of dimensions in any given situation .

Figure 14 shows a tag 52 that is distanced by 70mm from an upper end of the second opening 18 in the direction of installation .

Figure 15 shows an interface 90 between the composite pole 10 and the base section 80 . The interface 90 comprises a male element , plug 92 , on the base section 80 that is received in a female element , socket 94 at a lower end of the composite pole 10 . The plug 92 and socket 94 are open ended such that the tubes 40 of the composite pole 10 can communicate with the central passage 84 of the base section 80 . The plug 92 and socket 94 comprise transverse holes 96 that are alignable such that a fastener , M20 bolt 98 , can be received therethrough to secure the plug 92 to the socket 94 . The base section 80 can be earthed via the installed M20 bolts . The holes 96 have a secondary function of providing a port through which the central passage 84 of the base section 80 and the tubes 40 can be filled with settable material , such as grout , if required .

Figure 16 shows the end cap 32 which includes a fill stop plate 34 . The fill stop plate 34 prevents flowable material , such as grout , from exiting the top of the composite pole 10 when being filled . Figure 17 shows a cable access pipe 36 which extends from an end of the end cap 32 . The cable access pipe 36 communicates with the tubes 40 and central passage 84 of the base section 80 such that electrical cables can extend through from one end of the pole assembly 101 to the other .

Figures 18 and 19 show an electrical light pole 102 for street lighting . The electrical light pole 102 includes the pole assembly 101 shown in Figures 10-17 .

Figures 20 to 32 show an electrical light pole 102a for street lighting in accordance with another embodiment of the invention . The light pole 102a includes a pole assembly 101a comprising a composite pole 10 , as previously described, and a base section 80a of a different arrangement to that shown in Figures 10-19.

The base section 80a differs from the base section 80 in that it comprises an inner tubular section 110 and an outer tubular section 120 that are telescopically arranged . Both inner and outer tubular sections 110 , 120 are made from steel .

The length LI of the base section 80a is 2 , 640mm. The base section 80a is installed at a depth such that an upper end of the base section 80a projects 1 , 250mm above ground level GL .

The inner tubular section 110 has a square profile having a wall that is 6mm thick .

As shown in Figure 25 , the inner tubular section has an upper end 112 and a lower end 114 .

The outer tubular section 120 has a circular profile having a wall that is 6mm thick .

As shown in Figure 25 , the outer tubular section has an upper end 122 and a lower end 124 .

In an overlapping region 132 shown in Figures 23 and 24 , the inner tubular section 110 and the outer tubular section overlap by approximately 200mm.

A spacer 130 is disposed between the inner tubular section 110 and the outer tubular section 120 and welded thereto to secure the sections together . The spacer 130 is disc shaped and is dimensioned such that it can be received within the outer tubular section 120 . The spacer 130 has a square shaped opening 132 that is dimensioned to receive the inner tubular section 110 .

As shown in Figures 23-29 , the telescopic base section 80a comprises a pair of spacers , upper and lower spacers 130a , 130b , that are axially spaced apart along the length of the inner and outer tubular sections 110 , 120 in the overlapping region 132 . The spacers 130a , 130b are axially spaced by approximately 180mm.

As shown in Figure 25 , the wall of the outer tubular section 120 has a cable access opening 134 that can be closed via a removable door 136. The cable access opening 134 allows electrical cables to be inserted and/or removed from inside the telescopic base section 80a . As shown in Figures 25 and 26 , the wall of the outer tubular section 120 comprises a weld opening 138 . The weld opening 138 enables the lower spacer 130b to be welded (plug welded) to an internal surface of the outer tubular member 130 from outside of the outer tubular member 130 when the telescopic base section 80a is assembled .

As shown in Figure 25 , the wall of the inner tubular section 110 comprises a rectangular opening 115 which provides access into its interior .

As shown in Figure 25 , the telescopic base section 80 comprises rails 116 , 117 that form a mounting bracket 113 within the opening 115 .

A pair of longitudinal rails 116 are secured to the inner tubular member either side of the rectangular opening 115 .

A pair of spaced apart transverse rails 117 are secured to the inner longitudinal rails 116 such that they extend across the opening 115 . Each of the transverse rails 117 has openings configured to receive a fastening means such that electrical components can be secured within the opening 115 .

As shown in Figure 25 , a top alignment plate 118 is secured to the upper end 112 of the inner tubular section 110 . The top alignment plate 118 is configured to allow for adjustment of the inner tubular section 110 relative to the composite pole 10 .

As shown in Figures 24 , 25 and 31 , the telescopic base section 80a also comprises an L-shaped bracket 140 . The L-shaped bracket 140 is configured to connect to the inner and outer tubular members 110 , 120 . The L-shaped bracket 140 comprises first and second arms 142a , 142b that are arranged perpendicular to each other . The first arm 142a is welded to an external surface of the wall of the outer tubular member 130 . The second arm 142b is welded to an external surface of wall of the inner tubular member 110 . The first arm 142a comprises a hole 144 for receiving an M16 bolt . The hole 144 is configured to align with a corresponding hole on the composite pole and receive an M16 bolt to secure the composite pole to the telescopic base section 80a .

Figures 33 to 45 show a composite pole 10 similar to that described with reference to Figures 1 , 2 , and 5-8 . The composite pole 10 comprises a tubular element 12 that defines a wall 14 and having a second opening 18 in the wall 14 which provides access into its interior and a door 20 that can be opened and closed to provide access through the second opening 18 .

Figure 33 shows a locking system 150 for locking the door 20 to the composite pole 20 . Features of the locking system 150 will be described with reference to Figures 36- 45 .

Figure 33 shows that the door 20 has a wall W defining an upper end UE and a lower end LE .

Figures 34 and 35 show that the wall W is curved with the same radius as the radius of wall 14 of the tubular element 12 . The wall W of the door 20 has edges E that align with exposed edges EE of the wall 14 around the second opening 18 . When the door 20 is closed the edges E , EE mate to provide a seal which minimizes ingress/egress of water therethrough .

As shown in Figures 37 to 40 , the door 20 comprises a female locking element 152 that forms part of the locking system 150 . The female locking element 152 is located at an upper end UE of the wall W and comprises a boss B (see Figures 37 and 38) which projects from an underside of the wall W and an opening O extends through the wall W and the boss B . The opening O is configured to receive a male locking element , locking assembly 154 , which will be described later with reference to Figures 42 to 45 . The locking assembly 154 forms part of the locking system 150 .

Figure 40 shows that the boss B comprises a projection P that radially extends into the opening O to divide the opening O into the following sections : a first outer section FOS ; a second outer section SOS ; and an inner section IS of reduced diameter when compared with the first and second outer sections FOS , SOS .

As shown in Figures 39 to 41 , the door 20 comprises a lever portion L . The lever portion L comprises a plate PL that is secured (i . e . , welded) to an underside of the lower end LE of the wall W . The plate PL projects from the lower end LE of the wall W and is configured to be received in an opening (not shown) in the composite pole 10 such that the door 20 can be pivoted towards the composite pole to secure the door 20 to the composite pole 10 via the locking system 150 . As shown in Figures 42-45 , the locking assembly 154 comprises a locking bolt 155 and a resilient circlip 159. The locking bolt 155 is configured to be threadably received in a socket (not shown) in the composite pole 10 . The circlip 159 is configured to prevent the locking bolt 155 from being unintentionally removed from the door 20 , i . e . , dropping out of the door .

The locking bolt 155 is divided into three portions : a locking head 156 ; a transition region 157 ; and a male threaded spigot 158 .

As shown in Figures 43 and 44 , the locking head 156 comprises a triangular profile engagement portion 156a and a first shoulder 160 - the purpose of which will be described in the next paragraph . The locking head 156 is configured to be rotatably driven by a wrench , wherein that triangular profile engagement portion 156a is receivable within a corresponding triangular profile socket in the wrench . The male threaded spigot 158 comprises a second shoulder 162 - the purpose of which will be described in the next paragraph .

The locking assembly 154 is configured to be inserted into the opening O in direction D (see Figure 40) with the circlip 159 around the transition region 157 . The circlip 159 is elastically deformable and is dimensioned such that it is compressed when the locking assembly 154 is inserted through the inner section IS and expands when it exits the inner section IS and enters the second outer section SOS . The first shoulder 160 prevents further insertion of the locking assembly 154 into the opening O when it abuts an outer facing surface of the projection P . The expanded circlip 159 , now located between an inner facing surface of the projection P and the second shoulder 162 , prevents removal of the locking bolt 155 in a direction opposite to direction D .

Figures 46 to 49 shows an electrical light pole 102 , similar to that shown in Figure 18 , but differs in that the base section 80-1 has a flanged end 82-1 configured to be bolted to the ground . The flanged end 82-1 comprises four circumferentially spaced elongate circular profile holes H that are configured to receive fasteners , such as a rag bolt , to secure the base section 80b to a concrete footing .

Figures 50-55 show an embodiment of the base section 80-1 . The base section 80-1 has a length of 1 , 550mm, an outside diameter of 165mm, a wall thickness of 5mm and a flange diameter of 275mm. The center points of each of the holes H are arranged at a pitch circle diameter of 233mm.

Figure 56 shows a region of the base section 80-1 that has a surface treated region STR and an unsurfaced treated region USTR. The surface treated region STR is etched and coated with titanium oxide paint to a minimum thickness of 400micrometers . The unsurfaced treated region USTR is left uncoated such that the base section 80-1 can be earthed .

Figure 57 shows an electrical light pole 102a , similar to that shown in Figure 20 , but differs in that the outer tubular section 120 has a flanged end 122 . The flanged end 122 of Figure 50 functions in a similar manner to that described with reference to Figures 46 to 49. Figure 58 to 60 show an adaptor plate AP for use with the base sections 80-1 and 80a-l . The adaptor plate AP is configured to adapt the flange of the base sections 80-1 , 80a-l , having holes arranged at the pitch circle diameter of 233mm, to a flange or bolt arrangement that has a pitch circle diameter of 350mm. The adaptor plate AP is 300mm x 300mm with a central opening CO having a diameter of 165mm. The adaptor plate has a first set of holes Hl arranged at a pitch circle diameter of 233mm and a second set of holes H2 arranged at a pitch circle diameter of 350mm.

An embodiment of a method of manufacturing the composite pole 10 includes the following steps .

1 . In a first step , the aluminium tubular element 12 is extruded or otherwise fabricated .

2 . In a second step , the channel 50 is slid along the internal surface 14b of the tubular element 12 via the T-shaped projections 22 . The T-shaped projections 22 function as rails on which to slide the channel 50 . As can be seen from Figure 5 , the out-turned flanges 50h of the channel 50 engage and co-operate with two adjacent T-shaped projections 22 such that the channel 50 can be slid along their length . The channel 50 is slid to a predetermined position along the length of the tubular element 12 . The predetermined position is a location at which the middle section of the channel 50 is aligned with the second opening 18 in the wall 14 of the tubular element 12 .

3. Once in this position , the channel 50 is secured in place , for example , via mechanical fasteners (not shown) that are drilled through the wall 14 of the tubular element 12 and through the planar surfaces of the channel 50 . Therefore , the middle section of the channel 50 provides a housing of the control assembly - The rim of the channel 50 provides a hermetic seal with the internal surface 14b of the tubular element 12 . In a fourth step , tubes 40 for housing electrical cables for the light fixture 60 of the electrical light pole 30 are inserted into the tubular element 12 and through the apertures 50f of the partition walls 50d, 50e . In a fifth step , a slurry of the polymeric material is injected into the tubular element 12 from one end of the tubular element 12 . Typically, the injection end is what will be a lower end of the electrical light pole 30 shown in the Figures . The polymeric material moves up the tubular element 12 as it is injected . The melt flow of the polymeric material is important in that it enables it to move further up along the length of the tubular element 12 to a desired location without it solidifying too quickly and before completion of the filling process . The desired location of the polymeric material is suitably at least two thirds the length of the tubular element 12 from the injection end but may be any suitable location . The polymeric material encapsulates the channel 50 therein . The plurality of apertures 50g in the sides 50b , 50c and the web 50a of the channel 50 allow largely uninterrupted flow the polymeric material in relation to the channel 50 . The housing of the control assembly is not filled with polymeric material due to : ( 1 ) the hermetic seal of the channel 50 with the inner surface 14b of the tubular element 12 , (2 ) there being no apertures in the housing that allow polymeric material to flow into the housing , and (3) after the tubes 40 are inserted through the apertures 50f of the partition walls 50d, 50e , the middle section is not in fluid communication with the two outer sections . Because the channel 50 is secured in place using mechanical fasteners at the position , when the polymeric material is injected into the tubular element 12 , the channel 50 is not displaced by the flow of the polymeric material . The polymeric material is tied to the tubular element 12 via the T- shaped projections 22 . The T-shaped projections 22 enable better adherence of the polymeric material 100 to the tubular element 12 .

After injection of the polymeric material into the tubular element 12 , there will be shrinkage of the polymeric material as it cools and solidifies to form the lining 100 . The heat extracted from the polymeric material as it cools is transferred to and from the aluminium of the tubular element 12 .

Shrinkage in the longitudinal direction during cooling results in the polymeric material contracting along the inner surface 14b of the tubular element 12 .

This longitudinal contraction of the polymeric material during cooling has at least two advantages . Firstly, any large voids in the polymeric material are either reduced or removed . The large voids are air bubbles which cause inadequate strength of the composite pole 10 resulting in buckling of the composite pole 10 under load . Secondly, the shrinkage in a longitudinal direction causes friction with the inner surface 14b therefore creating a compression force on the wall 14 . This increases the tensile strength of the composite pole 10 by placing pole into a permanently compressed state .

As is evident from the above , the composite pole 10 is prestressed due to compressive stresses induced by the shrinkage and resultant longitudinal movement of the polymeric material along the inner surface 14b of the tubular metal element 12 before a load is applied therefore balancing the stresses imposed in the composite pole 10 during service .

One of the features of the embodiment shown in the Figures is that it can accommodate different shrinkage rates between aluminium and polymeric material of the composite pole 10 during manufacture (as discussed above) and during the service life of the composite pole 10 , for example as part of the electrical light pole 30 shown in the Figures . It is noted that this of the embodiment is independent of the selection of the materials for the metal element 12 and the polymeric material .

Significantly, the T-shaped projections 22 are configured to allow polymeric material to slide up and down the composite pole 10 as the polymeric material shrinks and expands differently to the aluminium tubular element 12 .

The following data provides an indication of differences in thermal expansions of the aluminium and the polymeric material : o A typical +/-25 ° C thermal linear expansion/contraction of aluminium in a 2m length of the composite pole 10 is +/- 1 . 11 mm. o A typical +/- 25 ° C thermal linear expansion/contraction of polymeric material over a 2m length is +/- 10mm.

Extrapolating the above data to a typical -length electrical light pole 30 , unless it is prevented from doing so , as the in-service temperature decreases from 40 ° C to 0 ° C or increases from to 0 ° C to 40 ° C , the polymeric material will shrink or expand and move approximately 14mm down or up the inside of the aluminium tubular element 12 of the composite pole 10 .

The polymeric material is anchored to the housing for the above-mentioned control assembly (not shown) in the middle section of the composite pole 10 and thus is restrained from sliding movement . The rest of the composite pole 10 is designed to allow the polymeric material to slide up and down within the composite pole 10 at either end when heated or cooled . Specifically, the T-shaped projections 22 are configured to allow sliding movement .

It is also noted that , in use of the electrical light pole 30 , aluminium protects the polymeric material from UV and thereby minimises UV-degradation of polymeric material .

A selection of performance data for the embodiment of the composite pole 10 shown in the Figures is now described in the context of an electrical light pole made from the composite pole 10 . The maximum deflection allowed for poles of electrical light poles with a 1KN load at the top of the pole is 220mm. This is in line with the standards for "Guidelines to Street Lighting Design" in the State of Victoria and the AS/NZS 1170 .2 "Minimum design loads on structures - Wind loads" .

The deflection of a pole comprising only the metal tubular element 12 (without the polymeric material ) having a 1KN load at the top of the pole was found to be 244mm. This deflection is outside the set standards mentioned above and therefore not acceptable .

The deflection of the embodiment of the composite pole 10 shown in the Figures (i . e . , the composite pole 10 , lining 100 , and mechanical interlock element 22 ) with a 1KN load applied to the top of the pole was 150mm. This deflection is within and significantly less than the set standards mentioned above .

The performance data established that the composite pole 10 operated in accordance with AS/NZS 1170 .2 .

Many modifications may be made to the embodiments of the invention described above in relation to the Figures without departing from the spirit and scope of the invention .

For example , the invention is not confined to the dimensions and materials selection mentioned above in relation to the Figures . By way of further example , the composite pole 10 is not limited to use as a part of an electrical light pole 30 , and can be used in any other suitable application .

Claims

1 . A composite pole comprising a metal tubular element having a wall with an outer surface and inner surface , an inner lining of a polymeric material , and an element that mechanical interlocks the wall and the lining , wherein the mechanical interlock element is configured to accommodate shrinkage of the polymeric material during manufacture of the composite pole and shrinkage and expansion of the polymeric material in use of the composite pole .

2 . The composite pole defined in claim 1 wherein the mechanical interlock element is located in at least a third of the length of the metal tubular element .

3. The composite pole defined in claim 1 or claim 2 wherein the mechanical interlock element comprises a plurality of projections protruding inwardly from the inner surface of the wall .

4 . The composite pole defined in claim 2 wherein the projections are T-shaped .

5 . The composite pole defined in claim 3 or claim 4 wherein the projections are spaced apart in an array of projections .

6. The composite pole defined in any one of claims 3 to 5 wherein each projection is elongate and extends at least a part of the length of the tubular element .

7 . The composite pole of any one of the preceding claims further comprising (a) a housing for a control assembly for an electric light unit when the unit is mounted to the pole , with the housing being embedded in the inner lining , and (b) an opening in the wall of the tubular element to provide access to the housing , and (c) a cover that can close the opening and can be opened to provide access to the housing .

8 . The composite pole of claim 7 further comprising (a) a channel defined by a web and a pair of parallel sides extending from the web , wherein the channel is embedded in the inner lining and (b) a pair of spaced-apart transverse partitions connected to the web and to the sides , wherein the housing is defined by the partitions and sections of the web and the sides that separate the partitions .

9. The composite pole of claim 8 wherein the channel includes a central section and two outer sections , and wherein the housing is located in the central section .

10 . The composite pole of claim 8 or claim 9 wherein the parallel sides of the channel have out-turned flanges extending from upper edges of the sides .

11 . The composite pole of any one of claims 8 to 10 wherein the channel and the tubular element are configured to define a rail -type system for allowing sliding movement of the channel within the tubular element along the length of the tubular element to a predetermined operative position prior to injection of the polymeric material into the tubular element when manufacturing the composite pole .

12 . The composite pole defined in claim 10 wherein the out-turned flanges of the tubular element and the T- shaped projections are configured to allow sliding movement of the channel within the tubular element to the predetermined operative position prior to injection of the polymeric material into the tubular element when manufacturing the composite pole .

13. The composite pole of any one of claims 8 to 12 wherein the channel is secured to the tubular element at the predetermined position .

14 . The composite pole of any one of the preceding claims comprising an hermetic seal between the channel and the wall .

15 . The composite pole of any one of claims 7 to 14 wherein the control assembly housing that is embedded in the inner lining anchors the polymeric material and prevents shrinkage and expansion of the polymeric material in that section of the composite pole in use of the composite pole .

16. The composite pole of any one of the preceding claims comprising an internal pipe embedded in the inner lining and an electrical wire in the pipe extending between the housing and one end of the metal tubular element and between the housing and another end of the metal tubular element , with the electrical wire being provided to electrically connect an electrical light unit when mounted to the other end of the pole to an electrical power source .

17 . The composite pole of any one of the preceding claims wherein the inner lining extends at least 50% the length of the pole from one end of the metal tubular element .

18 . The composite pole of any one of the preceding claims wherein the inner lining completely fills the interior of the pole in that section of the length of the pole having the inner lining .

19. The composite pole of any one of the preceding claims wherein the inner lining is an annular inner lining .

20 . The composite pole of any one of the preceding claims wherein the polymeric material includes a waste polymer as a recycled polymer material .

21 . The composite pole of any one of the preceding claims wherein the polymeric material is a fibre-reinforced polymeric material .

22 . The composite pole of any one of the preceding claims wherein the polymeric material contains a foaming agent .

23. The composite pole of any one of the preceding claims wherein the polymeric material comprises a first polymeric material and a second polymeric material having a higher melting point than that the first polymeric material .

24 . The composite pole of claim 22 comprising a continuous network of the first polymeric material and a dispersion of fragments of the second polymeric material .

25 . The composite pole of any one of the preceding claims wherein the tubular element is an extrusion .

26. The composite pole of any one of claims 1 to 24 wherein the tubular element is a fabricated element .

27 . The composite pole of any one of the preceding claims wherein the tubular element is formed from aluminium or an aluminium alloy .

28 . n electrical light pole comprising (a) the composite pole of any one of the preceding claims , (b) an electrical light unit mounted to an end section of the pole , and (c) a control assembly for the electric light unit located in the housing of composite pole .

29. A pole assembly comprising the composite pole of any one of claims 1 to 27 , and a base section extending axially from an end of the pole , the base section configured to be received in the ground .

30 . The pole assembly of claim 29 , wherein the base section comprises a tubular body .

31 . The pole assembly of claim 29 , wherein the base section comprises an inner tubular section and an outer tubular section that are telescopically arranged .

32 . The pole assembly of claim 31 , wherein the inner tubular section has a rectangular cross section and the outer tubular section as a circular cross section .

33 . The pole assembly of any one of claims 29 to 32 , wherein the base section is made from metal .

34 . The pole assembly of claim 33 , wherein the base section is corrosion protected .

35 . n electrical light pole comprising (a) the pole assembly of any one of claims 29 to 34 , (b) an electrical light unit mounted to an end section of the pole , and (c) a control assembly for the electric light unit located in the housing of composite pole .

36. A method of installing the pole assembly defined in any one of claims 29 to 35 comprising inserting the base section into the ground such that a lower end of the composite pole is elevated above a ground level .

37 . The method of claim 36 , wherein the lower end of the composite pole is positioned at a minimum height of 300mm above the ground level .

38 . An electrical light pole positioned in the ground, the pole comprising (a) the pole assembly of any one of claims 29 to 34 and (b) an electrical light unit mounted to an end section of the pole , wherein the pole assembly is positioned in the ground such that a lower end of the composite pole is elevated above a ground level .

39. The electrical light pole of claim 38 , further comprising (c) a control assembly for the electric light unit located in the housing of the composite pole .

40 . A method of manufacturing the composite pole defined in any one of claims 1 to 27 comprising the steps of :

(a) extruding or fabricating a metal tubular element ;

41 . The method defined in claim 40 wherein step (b) includes forming the housing in a channel and positioning the channel within the tubular element and securing the channel to the tubular element .

42 . The method defined in claim 40 or claim 41 wherein step (b) includes sliding the channel along the tubular element to the predetermined location from one end of the tubular element .

43. The method defined in any one of claims 40 to 42 wherein step (c) includes drawing at least a partial vacuum from another end of the cavity and injecting molten polymer material into the cavity from the one end .

44 . The method defined in any one of claims 40 to 43 wherein step (c) includes inserting a nozzle through the cavity from one end of the cavity up to a desired position along the length of the tubular element , for example proximate the other end of the cavity, and progressively withdrawing the nozzle away from the other end while injecting molten polymer material into the cavity .

45 . The method defined in any one of claims 40 to 44 includes melting mixed waste polymers at a temperature that is selected to at least partially melt a lower or lowest melting point polymer of the mix and leave other waste polymers in the mix in a solid form and forming an injectable slurry of the mixed waste polymers , whereby at least one molten waste polymer acts as a binder for the other waste polymer (s) in the mix when the mixture solidifies .