Split fence post and method for making it

Description

TECHNICAL FIELD

[0001] This invention relates to a furcated composite post manufactured from at least two strips that are joined together along their length in a furcated manner, as well as to a method of manufacturing the post.BACKGROUND ART

[0002] Known processes for manufacturing furcated steel posts suffer from one or more of the following disadvantages: A high rate of post production is difficult and expensive. Smaller quantities of posts cannot be produced in a highly cost effective manner. The application of an anti-corrosion coating (or other anti-corrosion measure) is not possible until after a naive post has been manufactured. The process many not allow for the incorporation of post-cutting and hole-punching steps until after a naive post has been manufactured. There is inefficient use of steel as, due to the manufacturing process, the arms of the post must necessarily be tapered - as opposed to the arms not being tapered at their free ends. The use of different grades of steel in the one finished product is not possible. US 3,713,205 describes a method of producing girders / beams for the building industry, whereby flanges of a girder / beam are pre-bent prior to a welding step in anticipation of a contractive strain which occurs upon cooling of the welded girder / beam and which normally results in deformation of the flanges, and then straightening of those flanges to their correct position following the welding step. The document does not teach the manufacture of fence posts having ground-anchoring ends and openings or retainers for retaining fencing members such as fencing wire.US 3,362,056 describes a method of fabricating elongated metal structures such as I-shaped girders / beams in a substantially continuous manner, whereby metal strips are unrolled from coils and brought together in correct orientation, and welded together to form I-shaped beams / girders. The document does not teach the manufacture of fence posts having ground-anchoring ends and openings or retainers for retaining fencing members such as fencing wire.DISCLOSURE OF INVENTION

[0003] An object of the present invention is to provide a manufacturing technique or furcate composite post that overcomes or minimises one or more of the disadvantages referred to above.

[0004] Another object of the present invention is to provide the public with a useful or commercial post choice.

[0005] The invention is set out in the appended set of claims.

[0006] Each strip is made of s steel or steel alloy, stainless steel, coated steel, anodised steel, galvanised or ungalvanised steel.

[0007] Each strip has a thickness of 1-10 mm, although a thickness of about 1.5-4 mm is preferred, particularly if the strip is to be subjected to profile rolling.

[0008] The strips provide a post with each arm being 1 m to 3 m in length, 10 mm to 40 mm in width, and preferably 1.5 mm to 4.0 mm in thickness.

[0009] The post may have any suitable profile / cross-section. The arms may be shaped to provide the post with additional strength. The arms may have folds, ribs, bends or rolled-over longitudinal ends to help the post resist bending when being driven into the ground or when being forced from a normal vertical attitude by a large animal, such as a horse or cow.

[0010] Preferably, the post is generally Y-shaped when viewed on end, and the angle between two upstretched arms of the 'Y' is between about 80 to 130 degrees.

[0011] One or more arms of the post have one or more openings spaced along a length of the arm for retaining fencing members, such as fencing wire. A fencing wire may be threaded through each opening. Alternatively, each opening may be in the form of a slot for retaining a fencing wire.

[0012] Additionally, the post may comprise keepers for fencing members as described in the applicants' co-pending applications numbered PCT / AU2008 / 000856, PCT / AU2008 / 000857 and PCT / AU / 2009 / 001316.

[0013] Preferably, manufacturing involves profile rolling one or more of the strips using a roll mill, and more preferably cold profile rolling. However, hot profile rolling may also be used.

[0014] The strips are welded together manually or automatically at a welding station / line situated at the positioning rolls. High-frequency resistance, rotary spot and MIG welding are examples of suitable welding techniques.

[0015] The method may comprise the step of cutting the post to a desired final length or intermediate length for storage and transport. Cutting may be achieved in any suitable way. The roll mill may comprise a pre-cut die or a post-cut die for cutting the post to length. Similarly, the roll mill may comprise a pre-cut die or a post-cut die for forming the pointed ground anchoring base of the post.

[0016] The method comprises the step of installing one or more openings in one or more arms of the post. This may be achieved in any suitable way. The roll mill may comprise a punch for punching openings in the strip. Punching may occur before roll forming starts, during roll forming or after roll forming has been completed.

[0017] The method may comprise the step of treating the strips or post so as to reduce or prevent corrosion. This may be achieved in any suitable way. For instance, the strips or post may be coated, plated or otherwise treated for corrosion prevention before roll forming starts, during roll forming or after roll forming has been completed.BRIEF DESCRIPTION OF THE FIGURES

[0018] Figure 1 is an end view of two separate strips of a furcated composite post, according to an embodiment of the present invention; Figure 2 is the same as figure 1 but showing in detail the strips joined together; Figure 3 is a perspective view of the post (of indefinite length) shown in figure 2; Figure 4 is a detailed end view of two strips of a furcated composite post when connected together, according to another embodiment of the present invention; Figure 5 is a perspective view of the post (of indefinite length) shown in figure 4; Figure 6 is a perspective view of three separate strips of a furcated composite post (of indefinite length), and is not part of the present invention; Figure 7 is a perspective view of two separate strips of the post shown in figure 6 and is not part of the present invention; Figure 8 is a perspective view of the strips of the post of figure 6 when joined together, and is not part of the present invention; Figure 9 is a perspective view of two separate strips of a furcated composite post (of indefinite length), according to another embodiment of the present invention; Figure 10 is a perspective view of the strips of the post of figure 9 when joined together; Figure 11 is a perspective view of two separate strips of a furcated composite post (of indefinite length), according to another embodiment of the present invention; Figure 12 is a perspective view of the strips of the post of figure 11 when joined together; Figure 13 is a schematic showing steps for manufacturing a furcated composite post, according to an embodiment of the present invention; Figure 14 is an end view of two separate strips of a furcated composite post, and is not part of the present invention; Figure 15 is the same as figure 14 but showing in detail the strips joined together, and is not part of the present invention; Figure 16 is a perspective view of the post (of indefinite length) shown in figure 14, and is not part of the present invention; Figure 17 is a perspective view of the post shown in figure 15, and is not part of the present invention; Figure 18 is a perspective view of two separate strips of a furcated composite post (of indefinite length), and is not part of the present invention; Figure 19 is a perspective view of the strips of the post of figure 18 when joined together, and is not part of the present invention; and Figure 20 is a general representation of a post like that of any one of figures 1-5 and 9- 13, showing what types of openings one or more arms of the post may have and also showing a pointed ground anchoring end, according to an embodiment of the present invention. BEST MODES FOR CARRYING OUT THE INVENTION

[0019] In the figures, like reference numerals refer to like features.

[0020] Referring first to figures 1-3, there is shown a furcated composite post 1 according to an embodiment of the present invention. The post 1 has a spine 5, a longitudinal axis extending along the spine 5 and three arms 2, 3, 4 that extend along a length of the spine 5 and generally radially from the spine 5. Arms 2 and 3 extend from the spine 5 at approximately 100-120 degrees relative to one another. Free longitudinal ends of arms 2 and 3 are rolled over 10, 11 and provide the post 1 with additional strength. That is, they increase the moment of inertia, helping the post 1 resist bending when being driven into the ground or when sideways pressure is exerted against the post after installation. Arm 4 may have openings spaced along a length of the arm 4 for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in these figures, a ground anchoring end of the post 1 may be pointed (as seen in figure 20).

[0021] Figures 1 and 2 show that the post 1 is manufactured from two separate steel strips 7, 8 that are welded together. Strip 7 provides a bend 9 and arms 2 and 3 extend from each side of the bend 9. Strip 8 provides arm 4. A longitudinal end 6 of arm 4 is welded to the bend 9 along the spine 5. The weld seam is labelled numeral 12 and is barely visible in Figure 3.

[0022] Manufacture of post 1 involves cold profile rolling strip 7 using a roll mill. In order to manufacture post 1, strip 7 (about 20-80 mm wide and about 2-5 mm thick) is unspooled from a coil dispenser at a set rate and fed to one or more sets of working rolls of the mill, until the V-shape profile with rolled-over ends 10, 11 is achieved.

[0023] Strip 8 is unspooled from a coil dispenser at the same set rate and together with strip 7 is fed through a set of positioning rollers of the roll mill such that the strips 7 and 8 are held in a correct orientation for joining by welding. The strips 7, 8 are then welded 12 together either manually or using an automated welding station.

[0024] The welded strips 7,8 are then cut to the required length using a die / flying shear system to form the post 1 or a longer intermediate post.

[0025] The post 1 may be further processed by way of being cut to produce a ground anchoring point. The post 1 may be hole- or slot-punched using a punch of the roll mill. The post 1 may be subjected to anti-corrosion techniques (eg. coated, plated, anodised etc).

[0026] Referring now to figures 4 and 5, there is shown a furcated composite post 15 according to another embodiment of the present invention. The post 15 is essentially the same as post 1, except that none of its arms 16, 17, 18 have rolled-over ends.

[0027] Figure 4 shows that the post 15 is manufactured from two separate steel strips 19, 20 that are welded together. The weld seam is labelled numeral 21.

[0028] Post 15 can be manufactured as described above for post 1.

[0029] Referring now to figures 6-8, there is shown a furcated composite post 25 that is not part of the present invention. The post 25 has a spine 26 (see figure 8), a longitudinal axis extending along the spine 26 and three arms 27, 28, 29 that extend along a length of the spine 26 and generally radially from the spine 26. The arms 27 and 28 extend from the spine 26 at approximately 100-120 degrees relative to one another. Opposed longitudinal ends of arms 27, 28 are bent such that they extended non-radially and parallel with arm 29, and provide the post 25 with additional strength.

[0030] Arm 29 may have openings spaced along a length of the arm 29 for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in the figures, a ground anchoring end of the post 25 may be pointed (as seen in figure 20).

[0031] Figure 6 shows that the post 25 is manufactured from three separate steel strips 30, 31, 32 that are welded together. Strip 30 provides arm 27, strip 31 provides arm 28, and strip 32 provides arm 29. Longitudinal ends of arms 27 and 28 are welded to a longitudinal end of arm 29 along the spine 26. (The weld seam has not been labelled.)

[0032] In order to manufacture post 25, steel strips 30 and 31 (each about 10-40 mm wide and about 2-5 mm thick) are unspooled from a pair of coil dispensers at an identical set rate, and fed to sets of working rolls of the mill until the desired profiles are achieved.

[0033] Strip 32 is unspooled from a coil dispenser at the same set rate and together with strips 30 and 31 is fed through a set of positioning rolls of the roll mill such that the strips 30, 31, 32 are held in a correct orientation for welding. The strips 30, 31, 32 are then welded together either manually or using an automated welding station.

[0034] The welded strips 30, 31, 32 are then processed into posts 25 as described for post 1.

[0035] Referring now to figures 9 and 10, there is shown a furcated composite post 40 according to an embodiment of the present invention. The post 40 has a spine 41 (see figure 10), a longitudinal axis extending along the spine 41 and three arms 42, 43, 44 that extend along a length of the spine 41 and generally radially from the spine 41. The arms 42 and 43 extend from the spine 41 at approximately 100-120 degrees relative to one another. Longitudinal free ends of arms 42 and 43 are bent such that they extended non-radially and substantially parallel with arm 44 (although they could be bent at any other suitable angle), and provide the post 40 with additional strength. Arm 44 may have openings spaced along a length of the arm 40 for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in the figures, a ground anchoring end of the post 40 may be pointed (as seen in figure 20).

[0036] Figures 9 and 10 show that the post 40 is manufactured from two separate steel strips 46, 47 that are welded together. Strip 46 provides a bend 48 and arms 42 and 43 extend from each side of the bend 48. Strip 47 provides arm 44. A longitudinal end 49 of arm 44 is welded to the bend 48 along the spine 41. (The weld seam has not been labelled.)

[0037] Post 40 can be manufactured as described above for post 1.

[0038] Figure 13 shows the steps of a preferred method for manufacturing post 40. The steps include: uncoiling strips 46, 47 and feeding them to positioning rolls of a roll mill; HF forge welding the strips 46, 47 together; galvanising the strips 46, 47; and profile rolling strip 46 to the desired cross section.

[0039] Referring now to figures 11 and 12, there is shown a furcated composite post 50 according to an embodiment of the present invention. The post 50 has a spine 51 (see figure 12), a longitudinal axis extending along the spine 51 and three arms 52, 53, 54 that extend along a length of the spine 51 and generally radially from the spine 51. Arms 52 and 53 extend from the spine 51 at approximately 100-120 degrees relative to one another. Longitudinal free ends of arms 52, 53 and 54 are rolled-over and provide the post 50 with additional strength. Arm 54 may have openings spaced along a length of the arm 54 for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in the figures, a ground anchoring end of the post 50 may be pointed (as seen in figure 20).

[0040] Figure 11 shows that the post 50 is manufactured from two separate steel strips 56, 57 that are welded together. Strip 56 provides a bend 58, and arms 52 and 53 extend from each side of the bend 58. Strip 57 provides arm 54. A longitudinal end 59 of arm 54 is welded to the bend 58 along the spine 51. (The weld seam has not been labelled.)

[0041] In order to manufacture post 50, steel strip 56 (about 20-80 mm wide and about 2-5 mm thick) is unspooled from a coil dispenser at a set rate, and fed through working rolls of a progressive cold roll mill to form the bend 58 and the rolled-over ends.

[0042] Steel strip 57 (about 10-80 mm wide and about 2-5 mm thick) is unspooled from a coil dispenser at the same set rate as strip 56 and fed through working rolls of the progressive cold roll mill to form the rolled-over end.

[0043] Strips 56 and 57 are then fed through a set of positioning rolls of the roll mill such that they are held in a correct orientation for welding. The strips 56, 57 are then welded together.

[0044] Referring now to figures 14-17, there is shown a furcated composite post 70 that is not part of the present invention. The post 70 has a longitudinal axis, a tube 71 extending along the longitudinal axis, and two arms 72, 73 that extend along a length of the tube 71 and generally radially from the tube 71. The tube 71 is of rectangular profile, and arms 72 and 73 extend from opposed corners of the tube 71.

[0045] The arms 72, 73 have openings spaced along their lengths for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in the figures, a ground anchoring end of the post 70 may be pointed (as seen in figure 20).

[0046] The post 70 is manufactured from two separate steel strips 75, 76 that are welded together. Strip 75 provides a bend / corner 77 of the tube 71 as well as two sides of the tube 71. Strip 75 further provides arms 72 and 73. Strip 76 provides another bend / corner 78 of the tube 71 as well as two other sides of the tube 71. Arms 72 and 73 extend from opposing corners of the tube 71. Longitudinal ends of strip 76 are welded to bends of strip 75. The weld seams are labelled 79a and 79b in Figure 15.

[0047] Manufacture of post 70 involves cold profile rolling strips 75 and 76 (about 40-200 mm wide and about 2-5 mm thick) using a roll mill and welding as described above.

[0048] The post 70 may be further processed by way of being cut to produce a ground anchoring point. The post 70 may be hole- or slot-punched using a punch of the roll mill. The post 70 may be subjected to anti-corrosion techniques (eg. coated, plated, anodised etc).

[0049] Referring now to figures 18 and 19, there is shown a furcated composite post 80 that is not part of the present invention. The post 80 has a spine 81, a longitudinal axis extending along the spine 81, and four arms 82, 83, 84, 85 that extend along a length of the spine 81 and generally radially from the spine 81. At least one of the arms 82, 83, 84, 85 has openings spaced along its length for retaining fencing wires and other types of fencing members (see figure 20). Although not shown in the figures, a ground anchoring end of the post 80 may be pointed (as seen in figure 20).

[0050] Figure 18 shows that the post 80 is manufactured from two separate steel strips 87, 88 that are welded together. Strip 87 provides a bend 89, and arms 82 and 83 extend from each side of the bend 89. Strip 88 also provides a bend 90, and arms 84 and 85 extend from each side of the bend 90. The bends 89, 90 are welded together to form the spine 81. The weld seam is labelled numeral 92 in figure 19.

[0051] Manufacture of post 80 involves cold profile rolling strips 87 and 88 (about 40-200 mm wide and about 2-5 mm thick) using a roll mill and welding as described above.

[0052] The post 80 may be further processed by way of being cut to produce a ground anchoring point. The post 80 may be hole- or slot-punched using a punch of the roll mill. The post 80 may be subjected to anti-corrosion techniques (eg. coated, plated, anodised etc).

[0053] As mentioned, figure 20 is a general representation of a post 100 like that of any one of figures 1-5 and figures 9 - 13, showing what types of openings 101-105 one or more arms 107 of the post 100 may have, and also showing a pointed ground anchoring end 108.

[0054] Figure 20 also shows a keeper / retainer assembly 120 pivotally mounted to a post arm 107 that can pivot between fencing member holding and release positions. The retainer 120 comprises a post mounting region 121, a fencing member engaging region 122 and a counter-balance region 123. A travel stop pin 124 extends laterally of the fence post arm 107 adjacent the counter-balance region 123. A pivot pin 125 extends through the post arm 107 and mounting region 121, and enables the fencing member engaging region 122 to pivot relative to the post arm 107. The fencing member engaging 122 region has a tapered nose that is shaped to both allow a fencing member to locate within a blind end 127 of the slot opening 101 and to be retained within the blind end 127. Keeper / retainer assemblies like retainer assembly 120 are described in greater detail in the applicants' co-pending applications numbered PCT / AU2008 / 000856, PCT / AU2008 / 000857 and PCT / AU / 2009 / 001316.

[0055] The advantages of the present invention include that: posts can be readily and cost effectively produced from coil strip / sheet metal by profile rolling; pre-galvanised strips or stainless steel can be used, which may be a cheaper option than galvanising the post after roll forming; the strength to weight property of the post is more effective than that produced by traditional rolling; many different types of post profiles / cross sections can be really produced; and punching and cutting operations may be incorporated prior to, during or after roll forming.

[0056] The term "comprise" and variants of the term such as "comprises" or "comprising" are used herein to denote the inclusion of a stated integer or stated integers but not to exclude any other integer or any other integers, unless in the context or usage an exclusive interpretation of the term is required.

Claims

1. A method of manufacturing a furcated composite fence post (40), with said post (40) comprising: a spine (41) and a longitudinal axis extending along the spine (41); first, second and third interconnected arms (42, 43, 44, 107), each of which extends along a length of the spine (41) and generally radially from the spine (41); and characterised in that the furcated composite post (40) comprises one or more openings (102, 103, 104, 105) or retainers (120) spaced along a length of at least one of said arms (107) for retaining a fencing member, such as fencing wire; and a pointed ground anchoring base (108) that may be driven into the ground, wherein said first, second and third interconnected arms (42, 43, 44, 107) are provided by a first 1-10 mm thick steel or steel alloy strip (47) and a second 1-10 mm thick steel or steel alloy strip (46), said arms are each 1 m to 3 m in length, and said arms are each 10 to 40 mm in width, said method comprising the steps of: feeding the strips (46, 47), at the same set rate to one or more positioning rolls of the roll mill such that the strips (46, 47) are held in a correct orientation for joining by welding at a welding station situated at the one or more positioning rolls; welding together the first strip (47) and the second strip (46), wherein the second strip (46) provides a bend (48) and first and second arms (42, 43) extend from each side of the bend (48), wherein the first strip (47) provides a third arm (44) and wherein a longitudinal end (49) of the third arm (44) is welded to the bend (48) along the spine (41); installing one or more openings (101, 102, 103, 104, 105) or retainers (120) in at least one arm (107) of the fence post (100) for retaining a fencing member, such as fencing wire; and cutting to form the pointed ground anchoring base (108).

2. A method according to claim 1, wherein one or more of the strips (47, 46) are profile rolled using the roll mill.

3. A method according to claim 2, wherein said strip (46, 47) requiring profile rolling is fed at a set rate from a coil dispenser to the roll mill, and shaped to the appropriate cross section using one or more sets of working rolls of the roll mill.

4. A method according to claim 1, 2 or 3, further comprising the step of cutting the fence post (100) to a desired length, or treating the strips or fence post (100) so as to reduce or prevent corrosion.

5. A method according to any one of the preceding claims, wherein the fence post (100) manufactured by the method is substantially T-shaped or Y-shaped when viewed on end.

6. A method according to any one of the preceding claims, wherein at least one arm (42, 43) of said fence post (40) manufactured by the method has a fold, rib, bend or a rolled-over longitudinal end to help the fence post (40) resist bending when being driven into the ground or when being forced from a normal attitude.

7. A method according to any one of the preceding claims, wherein only one said arm (107) of said fence post manufactured by the method has one or more openings (101, 102, 103, 104, 105) or the retainers (120) spaced along a length of the arm (107) for retaining a fencing member, such as fencing wire.

8. A method according to any one of the preceding claims, wherein a punch is used to install openings (101, 102, 103, 104, 105) in the at least one strip (46, 47).

9. A method according to any one of the preceding claims, wherein a cutting die is used to form the pointed ground anchoring base (108) of the fence post.

10. A method according to any one of the preceding claims, wherein said arms (42, 43, 44, 107) are provided by a first 1.5 to 4.0 mm thick steel or steel alloy strip (47), and a second 1.5 to 4.0 mm thick steel or steel alloy strip (46).

11. A method according to claim 4, wherein a cutting die is used to cut the fence post (40) to length.

12. A furcated composite fence post (40) comprising: a spine and a longitudinal axis extending along the spine; and first, second and third interconnected arms (42, 43, 44, 107), each of which extends along a length of the spine and generally radially from the spine, characterised in that the first, second and third interconnected arms (42, 43, 44, 107) are provided by a first 1-10 mm thick steel or steel alloy strip (47) and a second 1-10 mm thick steel or steel alloy strip (46), said arms (42, 43, 44) are each 1 m to 3 m in length, and said arms (42, 43, 44) are each 10 to 40 mm in width, wherein the first strip (47) and the second strip (46) are welded together, the second strip (46) provides a bend (48) and the first and second arms (42, 43) extend from each side of the bend (48), the first strip (47) provides the third arm (44), and a longitudinal end (49) of the third arm (44) is welded to the bend (48) along the spine (41), wherein preferably the fence post (40) is substantially T-shaped or Y-shaped when viewed on end, wherein one or more openings (101, 102, 103, 104, 105) or retainers (120) are spaced along a length of at least one of said arms (107) for retaining a fencing member, such as fencing wire, and wherein the fence post (40) comprises a pointed ground anchoring base (108) that may be driven into the ground.

13. The furcated composite fence post (40) of claim 12, wherein only one said arm (107) of said fence post (100) has the one or more openings (101, 102, 103, 104, 105) or retainers (120) spaced along said length of the arm (107) for retaining a fencing member, such as fencing wire.

14. The furcated composite fence post (40) of claim 12 or claim 13, wherein at least one of said arms (42, 43, 44, 107) has a fold, rib, bend or a rolled-over longitudinal end to help the fence post (40) resist bending when being driven into the ground or when being forced from a normal attitude.

15. The furcated composite fence post (40) of claim 12, 13 or 14, wherein said arms (42, 43, 44, 107) are provided by a first 1.5 to 4.0 mm thick steel or steel alloy strip (47), and a second 1.5 to 4.0 mm thick steel or steel alloy strip (46).