A post assembly
The fibre reinforced composite sheath around the post assembly addresses decay and corrosion issues by inhibiting water and ground material contact, enhancing structural integrity and longevity.
Patent Information
- Application Number
- GB2024007215
- Authority / Receiving Office
- GB · GB
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-05-21
- Publication Date
- 2025-11-26
Smart Images

Figure 00000000_0000_ABST
Abstract
Description
Posts are at least partially buried in the ground for a number of different purposes. For example, partially buried posts can be seen in fences, gates, signs, lighting, sports equipment, the support of building structures (such as floors, decking, or verandas), or the carriage of utility lines (i.e. utility poles), for example. The materials used in the manufacture of such posts vary by sector and use; however, posts can be manufactured from or include organic materials such as wood, or metals such as steel, aluminium, or iron, for example. Posts which are at least partially buried in the ground are vulnerable to decay, by rotting or corrosion, for example. Indeed, many posts are formed of wood (or other organic materials) which are susceptible to fungal attack and so to rotting. On the other hand, a steel post may be susceptible to corrosion. Eventually, this decay leads to structural failure of the post. Structural failure of posts may have serious health and safety consequences, and / or may cause damage to property. Posts at least partially buried in the ground are also prone to damage from other objects at ground level - for example, the use of plant control equipment such as lawn mowers and strimmers (i.e. “weed whackers”), A protective sheeting for posts is described in GB2546637A. This document teaches that protective sheets may be provided which comprise an impermeable layer, to prevent access of moisture to a wooden object, and a meltable-sealing solution on an inner surface of the protective sheet, which is heated once the protective sheet is installed in order to provide a more effective seal. However, the application of such protective sheeting is labour intensive and requires specialist expertise and tools. The protective sheeting, once installed, is also prone to damage and this may be from objects (e.g. plant control equipment) or even from animals, such as rodents, vermin and insects. Moreover, the protective sheeting and meltable-sealing solution (e.g. a bitumen material) increases the risk of introducing toxins or other contaminants to the ground material and also into the material of the post (e.g. discolouring the post or having an adverse effect on the ground material). In addition, the protective sheeting cannot be pre-applied to posts which are then driven into the ground, as this would damage the protective sheeting (e.g. with the ground material potentially tearing the protective sheeting from the post). There is, therefore, a need to alleviate one or more problems associated with the prior art. BRIEF DESCRIPTION OF THE INVENTION An aspect provides a post assembly, including: a post for at least partial burial in ground material; and a sheath surrounding at least an intermediate portion of the post; wherein the sheath is at least partially formed from a fibre reinforced composite material configured to provide a barrier around the intermediate portion of the post. The fibre reinforced material of the sheath may include a glass fibre reinforced composite material or a carbon fibre reinforced composite material. The sheath may be configured to provide a barrier around the intermediate portion of the post to inhibit the ingress, into the intermediate portion of the post, of water and / or the contamination of the intermediate portion of the post by the ground material. The post assembly of any preceding claim, wherein a bottom portion of the post may extend from a first end of the intermediate portion of the post and a top portion of the post may extend from a second end of the intermediate portion of the post, the first and second ends of the intermediate portion of the post opposing each other across a length of the intermediate portion of the post, the bottom portion of the post may be configured for burial and the top portion of the post may be configured to extend above the ground material. The intermediate portion may have a length along the post of about 20 cm to 50cm. The intermediate portion may have a length along the post which is about 5% to 30% of a total length of the post. The total length of the post may be more than 1 m. The sheath may include a mat of fibre material wrapped around the intermediate portion of the post and embedded within a matrix material. The mat of fibre material may include one or more overlapping sections of fibre material, and wherein the overlapping sections each have a depth of about 2 cm to 10 cm. The post assembly may further include one or more staples through at least part of the sheath and the post, to aid in securing the sheath to the post. The sheath may include an outwardly or inwardly projecting flange around a perimeter thereof. The post assembly may further include a seal member configured inhibit the passage of water between the sheath and the post. The seal member may be formed from a natural rubber material, a synthetic rubber material and / or a cured fluid or foam. The thickness of a wall of the sheath may be at least 2 mm. The post assembly wherein at least part of the post may be treated to inhibit fungal growth, and the treatment of the post to inhibit fungal growth may include one or more of: the application of an antifungal, a heat treatment and a pressure treatment. The treatment of the post may include the application of the antifungal and the sheath may inhibit egress of the antifungal from the intermediate portion of the post. The post may be formed from a wood material. The post may have a rectangular cross-section through at least a part thereof, and a radius of the corner edges of the post in the intermediate portion may be greater than a radius of the corner edges of the post in another portion of the post. The post may include one or more mounting locations for a fence panel, a gate, a fence rail, a hinge, a cable, a cable insulator, a lock or latch, or a cross-arm. Another aspect provides a method of making a post assembly defined by claim 1, the method including: providing a post; and providing a fibre reinforced composite material around a intermediate portion of the post. Providing the fibre reinforced composited material may include: providing a mat of fibre material; wrapping the mat of fibre material around the intermediate portion of the post; providing a matrix material; and applying the matrix material to the mat of fibre material around the intermediate portion of the post. Providing the fibre reinforced composited material further may include: using a roller to press the matrix material and mat of fibre material together and against the intermediate portion of the post. Providing the post may include: providing a post with a rectangular cross-section through at least a part thereof, and forming a radius of the corner edges of the post in the intermediate portion which is greater than a radius of the corner edges of the post in another portion of the post, prior to providing the fibre reinforced composite material around the intermediate portion of the post. Another aspect provides a method of installing a post assembly, the method including: providing a post assembly; and installing the post assembly in ground material such that the sheath of the post assembly is partially buried in the ground material Another aspect provides a sheath for use in a post assembly. BRIEF DESCRIPTION OF THE FIGURES In order that the present disclosure may be more readily understood, preferable embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 is a side view of a post assembly of some versions in an installed configuration. FIGURE 2A is a detailed side view of the post assembly of FIGURE 1. FIGURE 2B is a detailed side view of the post assembly of FIGURE 2A, without the sheath. FIGURE 3 is a section view of a post of some versions, the post shown in respective a standard configuration, a configuration with curved radii at the edges, and a configuration with chamfers edges (sometimes known as bevels) at the edges. FIGURE 4 is a detailed side view of a sheath of the post assembly of FIGURE 1. FIGURE 5 is an isometric view of the post assembly of some versions. FIGURE 6 is a reverse isometric view of the installation of the sheath on the post of the post assembly of some versions. FIGURE 7 is an isometric view of the fibre reinforced composite material of the post assembly of some versions. FIGURE 8 is a reverse isometric view of the sheath on the post of the post assembly of some versions. DETAILED DESCRIPTION OF THE DISCLOSURE A post 11 may be any member which may be securable to or at least partially buried in ground material. In some examples, the post 11 may be an elongate member, wherein a dimension in one axis, Ac, is larger than in the other respective axes. The largest dimension may be a length of the post Lp. The post 11 may form part of equipment or other types of apparatus. In some example uses, the post 11 may be used as a strut, column or pillar. In some examples, the post 11 may be used as part of a building or structure, such as structural support for any one or more of a floor, a wall, a roof, a deck, or any other elevated apparatus, for example. In some versions, the post 11 may be for the support of boundary apparatuses, such as walls, fences or gates, or a combination therein. In other versions, the post 11 may be used as a utility pole (e.g. for supporting utility equipment, such as one or more electrical and telecommunication lines). Further uses of the post 11 may include fortification structures, coastal defence structures (such as groynes), various uses in sports equipment such as cricket stumps or goalposts, and to carry signage (such as traffic and road signs) or lighting (such as street lights), or a combination thereof. In some uses, the post 11 may be supported by auxiliary equipment such as a stand, which may sit on top of a surface of the ground 13a. In some versions, the post 11 and / or auxiliary equipment (e.g. the stand) may be secured to the ground by hardware. Securing the post and / or the stand to the ground may be suitable for temporary use and may negate the need to bury the post 11 at least partially in the ground. Such configurations are, however, prone to being defective in adverse weather conditions (such as high winds), and are prone to malicious activity (such as theft). In a variety of uses, therefore, it is preferable to bury the post 11 at least partially into the ground. The post 11 may be installed such that the ground material 13 at least partially supports the post 11. The post 11, in a partially buried configuration, may be structurally more secure and, for example, may be more resistant to adverse weather conditions (such as high winds) and more resistant to malicious activity compared to a version wherein the post 11 is not buried at least partially into the ground. A central longitudinal axis Ac may extend through the post 11 in the elongate direction (i.e. the largest dimension). The post 11 may have a cross section, wherein the section is perpendicular to the central longitudinal Ac axis. This cross section of the post 11 may be circular (see figure 8, for example), oval, triangular, rectangular, pentagonal, hexagonal, heptagonal or octagonal, for example. In yet further examples, the cross section of the post 11 may have more than eight sides. In some versions, the post 11 may have a constant cross sectional shape or size along substantially the entire length of the post, Lp. In other versions, at least one of the shape or size of the cross section may vary along the length of the post Lp. The post may have three dimensions, the length Lp, a width and a depth. The length Lp may be defined between a top and a bottom end of the post 11. The length Lp of the post 11 may be the length along central longitudinal axis Ac and / or may be the length Lp between the topmost and bottommost parts of the post 11. In some versions, the width and the depth of the post 11 may be substantially equal, or may be different. The width may be defined by a first pair of sides of the post 11. The first pair of sides may be substantially parallel to each other and the central longitudinal axis Ac of the post 11. The depth may be defined by a second pair of sides of the post 11. The second pair of sides may be substantially parallel to each other and the central longitudinal axis Ac of the post 11. The first and second pairs of sides may be perpendicular to each other in some versions. In some versions, the width and / or depth may be defined by a diameter of a circular (or diameter(s) of an oval) cross section of the post 11 (as defined herein). The post 11 may be made from a single material (i.e. exclusively from one material). In some versions, the post 11 may be made from an organic material, such as wood. In other versions, the post 11 may be produced from a non-organic material, such as a metal (including steel, aluminium, or iron, for example). In some versions, the post 11 may be made form a plurality of materials. The post 11 may include one or more internal members (including one or more reinforcing members, such as rods), which may at least partially extend through the post 11 and which may be formed from a different material to another part of the post 11. In some examples, the post 11 may include a plurality sections, each made of one or more different materials, which may be joined together to form the post 11. Treatments may be used to preserve the post 11 and may seek to extend the useable life of the post 11. Treatment techniques may include at least one of application of a preservative substance, a heat treatment, or a pressure treatment, for example. The post 11 may be treated with a combination of one or more treatment techniques, for substantially the entire length Lp or one or more sections of the length, Lp, of the post 11. In some examples, one or more preservative substances may be applied to the post 11, by painting, spraying, or dipping techniques, for example. Examples of preservative substances may include one or more paints and / or one or more staining compounds, for example. Preservative substances may include substances with antifungal properties which may be configured to inhibit fungal growth or reduce the rate of fungal growth. In examples in which the post 11 is made from a wood material, the one or more preservative substances may include wood preservatives with antifungal properties, and may include a copper based substance (such as copper azole, copper naphthenate, chromated copper arsenate), linseed oil, or a silicate (such as sodium silicate or potassium silicate). Heat treatment and / or pressure treatment techniques may be applied to the wood, and may not, e.g. in the case of heat treatment, require the application of substances to the wood of the post 11. Heat treatment and / or pressure treatment may reduce the rate of decay of the wood. As discussed, partial burial of the post 11 into the ground material 13 may cause the post 11 to be prone to decay or corrosion. The conditions of the ground material 13 may change with an increase in a depth from the surface of the ground 13a. The ground material 13 may include at least two layers, wherein a first layer 131 extends down from the surface of the ground 13a and a second layer 132 extends down from the bottom of the first layer 131. The first layer 131 may include sufficient quantities of water and oxygen to increase the rate of decay or corrosion of a post 11 buried with at least a portion present in the first layer 131. For example, in the first layer 131 there may be an increased risk of oxidation of one or more materials of the post 11, or increased growth of organisms which may cause decay of one or more materials of the post 11. For example, the presence of water and oxygen may help to sustain a fungus cause fungal decay of one or more materials of the post 11. The second layer 132 of the ground material 13 may include less water and oxygen, and this may, therefore, reduce the risk of corrosion and / or decay of post 11 in a portion buried in the second layer 132. The first layer 131 of the ground material 13 may extend down to at least about 5 cm from the surface of the ground 13a. In some examples, the first layer 131 may extend down to at least about 15 cm from the surface of the ground 13a. In some examples the first layer 131 may extend down to at least about 25 cm from the surface of the ground 13a. In some examples, the post 11 may be part of a boundary apparatus such as a fence and / or a gate. The fence may include one or more posts 11 along with, for example, one or more fence panels, wire mesh, chain link, wire or barbed wire, which may be supported by the or each post 11. Similarly, the post 11 may be used to support a gate and may be used as a gate post 11. In some examples, the, Lp, length of the post 11 may be between about 1 m and about 3.5 m. In some examples, the length, Lp, of the post 11 may be between about 1.5 m and about 3 m. In some examples, the length, Lp, of the post 11 may be about 2.5 m. In some examples, the length, Lp, of the post 11 may be more than about 1 m, or about 2 m, or greater. The post 11 may be a utility pole, and may be between about 5 m and 10 m. Therefore, the post 11 may be used as part of a utility transmission apparatus which includes one or more utility poles 11. The post 11 may include a bottom portion 112, an intermediate portion 111, and a top portion 113. In some versions, the bottom portion 112 may be for burial in the ground material 13 (substantially entirely within the ground material 13). In some versions, the intermediate portion 111 may be for at least partial burial in the ground material 13. In some versions, the top portion 113 may be for standing clear of the ground material 13 and may not be in contact therewith, for example. The intermediate portion 111 may be located between the top 113 and bottom 112 portions of the post 11. Example versions of the post in the partially buried configuration (with and without a sheath 12) are shown in figures 2A and 2B respectively, with the bottom portion 112, intermediate portion 111 and top portion 113 of the post 11 as indicated. As noted, at least a part of the intermediate portion 111 may not be for burial in the ground material 13. The intermediate portion 111 may be configured to extend into at least the first layer 131 of the ground material 13. In some versions, the intermediate portion 111 may be configured to extend into the second layer 132 of the ground material 13. The bottom portion 112 may extend from a first end of the intermediate portion 111 of the post 11 and the top portion 113 may extend from a second end of the intermediate portion 111 of the post 11. The first and second ends of the intermediate portion 111 of the post 11 may oppose each other across a length of the post 11. In some versions, the intermediate portion 111 of the post 11 may extend about 20 cm to about 60 cm along the length, Lp, post 11. In some versions, the intermediate portion 111 of the post 11 may extend about 25 cm to about 40 cm along the length, Lp, of the post 11. In some versions, the intermediate portion 111 of the post 11 may extend about 30 cm to about 40 cm along the length, Lp, of the post 11. In some versions, the bottom portion 112 may extend about 20 cm to about 50 cm along the length, Lp, of the post 11. In some versions, the bottom portion 112 may extend about 25 cm to about 40 cm along the length, Lp, of the post 11. In some versions, the bottom portion 112 may extend about 30 cm to about 40 cm along the length, Lp, of the post 11. In some versions, the top portion 113 may extend about 50 cm to about 200 cm along the length, Lp, of the post 11. In some versions, the top portion 113 may extend about 75 cm to about 150 cm along the length, Lp, of the post 11. In some versions, the top portion 113 may extend about 85 cm to about 125 cm along the length, Lp, of the post 11. In some versions, for example, a total length of the intermediate portion 111 may be substantially equal to a total length of the bottom portion 112. In some versions, the total length of the intermediate portion 111 may not be equal to the total length of the bottom portion 112. In some versions, the intermediate portion 111 is shorter than the bottom portion 112. In some versions, the intermediate portion 111 is longer than the bottom portion 112. In some versions, the total length of the intermediate portion 111 may be substantially equal to or less than a total length the top portion 113. In some versions, the total length of the bottom portion 112 may be substantially equal to or less than the total length the top portion 113. In some versions, a total combined length of the intermediate and bottom portions 111, 112 may be equal to or less than the total length of the top portion 113. For example, in some versions, the intermediate portion 111 may be about 5% to about 30% of the length, Lp, of the post 11. In some versions, the intermediate portion 111 be about 15% to about 25% of the length, Lp, of the post 11. In some versions, the intermediate portion 111 may be about 18% to about 22% of the length, Lp, of the post 11. In some versions, the bottom portion 112 may be about 10% to about 35% of the length, Lp, of the post 11. In some versions, the bottom portion 112 may be about 15% to about 25% of the length, Lp, of the post 11, In some versions, the bottom portion 112 may be about 18% to about 22% of the length, Lp, of the post 11. In some versions, the top portion 113 may be about 35% to about 85% of the length, Lp, of the post 11. In some versions, the top portion 113 may be about 50% to about 70% of the length, Lp, of the post 11. In some versions, the top portion 113 may be about 56% to about 64% of the length, Lp, of the post 11. In some versions, where the cross section of the post 11 is a non-circular or oval shape (i.e. the post 11 has more than one continuous side), one or more corner edges 11a of the post 11 may be present between adjacent sides. The or each corner edge 11a may extend along at least part of the length, Lp, of the post 11. In some versions, the post 11 may initially be formed with the or each corner edge 11 a extending through at least part of the length, Lp, which includes the intermediate portion 111. For example, in the case of a wooden post 11, the post 11 may be cut and / or abraded from a larger piece of wood to form the post 11 and that process may form the or each corner edge 11 a. In some versions, the post 11 may be pre-processed (e.g. after formation). In this pre-processing, for example, the or each corner edge 11 a of the post 11, at least through the intermediate portion 111 (e.g. through substantially the entire length of the intermediate portion 111), may be pre-processed to form a radius along the or each corner edge 11a (i.e. to form one or more respective curved edges 11aa). The pre-processing may include cutting, or abrading, ora combination thereof, for example. In some versions, after the pre-processing of the post 11, the radius of the or each curved edge 11aa (e.g. through the intermediate portion 111) may be larger than a radius of the curved edge 11aa (or the corner edge 11a if not pre-processed) through at least a portion of the bottom and / or top portions 112, 113, for example. In some versions, the pre-processing may form one or more chamfered edges 11ab (sometimes known as a bevel) instead of the curved edge(s) 11aa. Example versions including comparison cross sections of the post 11 with corner edges 11a, curved edges 11aa, and chamfered edges 11ab, are shown in figure 3. In some versions, the post 11 may be provided with this pre-processing already performed and / or equivalent curved 11aa and / or chamfered edges 11ab may be formed in the making of the post 11 (without the need for subsequent pre-processing). The post 11, including one or more curved edges 11 aa or chamfered edges 11 ab, may provide an improved surface around which a sheath 12 may be wrapped, and may help to reduce the risk of one or more defects in the sheath 12 in these areas (see figure 6 for example, described in more detail herein). The post 11 may form part of a post 11 assembly 1, as shown in figure 1, for example. The post assembly 1 may include at least one post 11 and a sheath 12 which may surround at least a portion of the post 11. In some versions of the post assembly 1, the sheath 12 may be configured to extend around the intermediate portion 111 of the post 11. The sheath 12 may, therefore, provide a barrier around the intermediate portion 111 of the post 11 and may inhibit one or more substances (including ground material 13 and water, or a combination thereof) from coming into contact with one or more surfaces of the intermediate portion 111 of the post 11. In some versions, the sheath 12 may, for example, provide a barrier to inhibit water (which may be pooling on the surface of the ground 13a) from coming into contact with at least the intermediate portion 111 of the post 11. The sheath 12 may be formed from a non-porous material and / or may include a material which is water resistant (i.e. resistant to the passage of water through the sheath 12 material from the ground material 13 to the post 11). The sheath 12 material may be configured to inhibit the passage of one or more substances through the sheath 12 (e.g. substances from the ground material 13 to the post 11). Likewise the sheath 12 may inhibit the passage of one or more substances, such as one or more preservative substances, from the post 11 to the ground material 13 through the sheath 12. This may reduce the risk of contamination of the ground material 13 by the one or more preservative substances and / or help retain the preservative substance(s) in the post 11 (so prolonging the effectiveness of the treatment). The sheath 12 may define a receiving aperture 123 which may have a cross sectional shape which corresponds to the cross sectional shape of at least part of the post 11 (e.g. the intermediate portion 111). The sheath 12 may be configured to fit around at least part of the post 11 (e.g. the intermediate portion 111). The sheath 12 may, therefore, be sized and shaped to fit around at least part of the post 11 (e.g. the intermediate portion 111). In some versions, the sheath 12 may be sized and shaped to fit around only the intermediate portion 111 and may not extend around other portions of the post 11. A length of the post 11 covered by the sheath 12 may, therefore, be substantially equal to the length of the intermediate portion 111 of the post 11 as described herein. In some versions, an external shape of the sheath 12 corresponds to an internal shape of the sheath 12 (that internal shape defining the receiving aperture 123). Accordingly, for example, a sheath 12 configured to fit to a post 11 with a square cross section may define a receiving aperture 123 which is substantially square, a sheath 12 configured to fit to a post 11 with a circular cross section may define a receiving aperture 123 which is substantially circular, and so on. Likewise, a sheath 12 configured to fit to a post 11 with a square cross section may have an external cross section which is substantially square, a sheath 12 configured to fit to a post 11 with a circular cross section may have an external cross section which is substantially circular, and so on. The sheath 12 may therefore be a sleeve defined by one or more sides of the sheath 12, and the one or more sides may correspond with the one or more sides of the post 11. These one or more sides of the sheath 12 may define the receiving aperture 123. The receiving aperture 123 may extend through an entire length of the sheath 12. In some versions, the sheath 12 may include one or more flange members 122 (see figure 5, for example). The one or more flange members 122 may project inwardly or outwardly at an upper perimeter edge of the sheath 12. In some versions, for example, a substantially continuous flange member 122 may extend around the upper perimeter edge of the sheath 12. In some versions, the flange member 122 may extend, at the upper perimeter edge of the sheath 12, from each of the one or more sides of the sheath 12. In some versions, the one or more flange members 122 may project inwardly into the receiving aperture 123, such that at least a part of each of the one or more flange members 122 abuts the post 11. In some versions, the one or more flange members 122 may project outwardly from the upper perimeter edge of the sheath 12, to act as, for example, a drip feature (such that water running down the post 11 may be deflected away from the post 11 by the or each flange member 122). In some versions, the one or more flange members 122 may project from the upper perimeter edge of the sheath 12, wherein the upper perimeter edge of the sheath 12 configured to be above the surface of the ground 13a in an installed post assembly 1. In some versions, the one or more flange members 122 may each extend at least about 0.5 cm, or at least about 1 cm, or at least about 2 cm from the respective upper perimeter edge of the sheath 12. In some versions, the one or more flange members 122 may extend at least about 5 cm from the upper perimeter edge of the sheath 12. In some versions, the one or more flange members 122 may extend at least about 10 cm from the upper perimeter edge of the sheath 12. In some versions, the or each flange member 122 may be in the form of a generally flat surface or may be in the form of a rolled edge of the sheath 12, for example. In some versions, the sheath 12 may be at least partially formed from a fibre reinforced composite material 121. The fibre reinforced composite material 121 may include a mat 121a and a matrix material 121b. The mat 121a may be a mat of fibre material 121a. The mat 121a may be wrapped around at least part of the post 11 (e.g. around the intermediate portion 111 of the post 11). The mat 121a may be embedded within the matrix material 121 b to form the fibre reinforced composite material 121, around at least part of the post 11. The matrix material 121b may be a binder material which may be configured to bind together fibres of the fibre material of the mat 121a of some versions. The fibre reinforced composite material 121 may be a glass fibre reinforced composite material 121 or a carbon fibre composite reinforced material, for example. In some versions, the mat 121a may include a chopped strand mat. In some versions, the mat 121a includes generally randomly oriented fibres which are held together by a mat binder material. In some versions, the mat 121a (e.g. a chopped strand mat) may be between about 300 grams per square metre (gsm) and about 450 gsm. In some versions, a plurality of layers of the mat 121a may be used to form the fibre reinforced composite material 121. In some versions, each layer of the mat 121a may be from copped strand layers, as shown in figure 7. In some versions, the or each layer of the mat 121a may be less than about 200 gsm. In some versions, the or each layer of the mat 121a may be about 200 gsm or more, or may be about 300 gsm or more, or may be about 450gsm or more, or may be about 600 gsm or more, or may be about 900 gsm or more. In some versions, with a plurality of layers of the mat 121a, mat 121a of different material thicknesses may be used for different ones of the layers. The mat binder material may be a polyester-, vinyl- or epoxy-based binding material which may be configured to hold strands of the chopped strand mat together in what may be a flexible sheet of mat 121a material. In some versions, the mat 121a may be formed from a woven material, for example. In some versions, the mat 121a may be formed from one of a uniaxial fibre material, a biaxial fibre material, or a triaxial fibre material. The uniaxial material may be formed from one or more layers of parallel fibres laid in a single orientation. For example, the biaxial fibre material may be made from layers of parallel fibres laid in two orientations, wherein an angle between the two orientations of the fibres in the adjacent may be between about 45 and about 90 degrees. The triaxial fibre material may be made from layers of parallel fibres laid in three orientations, wherein an angle between the orientations of the fibres in adjacent layers may be between about 30 and about 60 degrees. The matrix material 121b may be a resin, for example. In some versions, the resin may be a thermoset resin or a thermoplastic resin. The resin may include at least one of an epoxy-, polyester- and vinyl- based matrix material. In some examples, the matrix material 121b may be configured to cure, with the mat 121a material, to form the fibre reinforced composite material 121 in ambient temperatures, such as a range of about 5°C to 30°C. In some versions, a catalyst may be used to assist or enable curing of the matrix material 121b. The matrix material 121b may be, for example, Stronghold Premium Resin or Stronghold Trade Resin, available from The Glass Fibre Roofing Company Ltd, Caerphilly, UK. A material thickness of the sheath 12 may be the thickness of the fibre reinforced composite material 121. The material thickness of the sheath 12 may be generally uniform around the sheath 12 (or at least within a range). In other words, each side of the sheath 12 may be a wall of the sheath and that wall or those walls may have a common thickness (or thickness range). In some versions, for example, the material thickness of the sheath 12 may be at least about 1 mm. In some versions, the material thickness of the sheath 12 may be at least about 2 mm or, in some versions, may be at least about 3 mm. The material thickness of the sheath may be the thickness after the fibre reinforced composite material 121 has cured. In some versions, the formation of the sheath 12 includes the steps of wrapping the mat 121a around the intermediate portion 111 of the post 11, the application of the matrix material 121 b to the mat 121a, and the curing of the matrix material 121b to form the fibre reinforced composite material 121 and so the sheath 12. As noted, the curing may involve the application of a catalyst to the matrix material 121b. A roller may be used to press the sheath 12 (prior to curing of the matrix material 121b) into the post 11 and / or to press the layers of the sheath 12 together (this may include one or more layers of the mat 121a and one or more layers of the matrix material 121b). Accordingly, in some versions, the mat 121a may be wrapped around the intermediate portion 111 of the post 11. The mat 121a may include an overlapping section 124, wherein a part of the mat 121a overlaps within another part ofthe mat 121a. This may be overlapping of ends of the mat 121a as depicted for example. In some versions, another layer of mat 121a may be applied on top of a first layer of mat 121a (e.g. with matrix material 121b between the two layer of mat 121a). In such versions, overlapping sections 124 of mat 121a in each layer (of which there may be more than two) may be such that they are distributed around the post 11. For example, they may be arranged such that the overlapping section 124 of one layer of mat 121a does not itself overlap with the overlapping section 124 of another layer of mat 121a. In some versions, the mat 121a may be wrapped around the intermediate portion 111 of the post 11 in a different configuration. For example, the mat 12a may be spirally wound around the post 11, such that the overlap is along a length of the mat 121a and the overlapping section itself extends spirally around the post 11. In some versions, strips of mat 121b may be arranged axially on the post 11 with linear overlaps also extending axially until the mat 121b substantially surrounds the intermediate portion 111 of the post 11. In some versions, mat 121a strips may be wrapped around the intermediate portion 111 of the post 11 with multiple strips required to cover the intermediate portion 111 of the post 11. In some versions, the overlapping section 124 may have a depth of about 2 cm to about 10 cm. In some versions, for example, the overlapping section 124 may have a depth of about 4 cm to about 8 cm. In some versions, for example, the overlapping section 124 may have a depth of about 5 cm to about 7.5 cm. The or each layer of mat 121a may be stapled to the post 11 and / or to another of the layers of mat 121a (e.g. in the overlapping section 124 of that layer of mat 121a). Accordingly, one or more staples 125 may be applied to the mat 121a and may be applied before application of the matrix material 121b (see figure 4, for example). In some versions, an adhesive may be used to help to attach the sheath 12 to the post 11, wherein the adhesive inhibits axial movement of the sheath 12 along the length, Lp, of the post 11. The adhesive may be the matrix material 121b forming the fibre reinforced composite material 121, or may be a different adhesive. The adhesive may resist forces applied by ground material 13 during installation of the post 11, which may otherwise cause the sheath 12 to slide along the length of the post 11. As will be understood, such an effect may be provided or assisted by the one or more staples 125 if provided (and if stapled to the post 11). The post assembly 1 may be installed in a number of different manners. For example, a hole may be dug in the ground material 13 and the post assembly 1 may then be at least partially lowered into the hole and buried. In such examples, gravel may be provided at a bottom of the hole (prior to the installation of the post assembly 1) to encourage drainage of water. In other examples, the post assembly 1 may be driven into the ground (e.g. using a post driver). The post assembly 1 may be positioned within the ground material 13 such that the intermediate portion 111 is located at the ground surface 13a. For example, the ground surface 13a may be located along a part of the length of the intermediate portion 111. In some versions, the post assembly 1 is positioned such that the intermediate portion 111 extends through at least the first layer 131 of ground material 13 and may extend above the ground surface 13a. The intermediate portion 111 may extend above the ground surface 113a and that extension may be more than about 2 cm, or 5 cm, or 10 cm. In the case of a post assembly 1 which is driven into the ground material 13, the sheath 12 (applied as described herein) will resist axial movement along the post 11 during the process - e.g. due to the bonding of the matrix material 121 b to the post 11, and / or the use of one or more staples 125, and / or the use of the adhesive. In some versions, the sheath 12 may be pre-formed and may be slide onto the post 11 to form the post assembly 1. In such versions, a mechanical fixing (such as one or more staples, screws, rivets, or bolts) may be provided to secure the sheath 12 to the post 11 in the intermediate portion 111. In other versions, the sheath 12 may be formed on the post 11, as described herein. The sheath 12, so provided around the intermediate portion 111, may inhibit decay of the post 11 in the intermediate portion 111 and so prolong the lifespan of the post 11 and post assembly 1. The sheath 12 may provide resistance to mechanical damage, e.g. from plant control equipment such as lawn mowers and strimmers (i.e. “weed whackers”), or damage caused by animals. Versions of the present technology include the post assembly 1, the post 11 and sheath 12 (with the sheath 12 being configured to be applied to the post 11), the sheath 12 (for application to the post 11), and an apparatus including one or more post assemblies 1. In some versions, a kit may be provided which include mat 121a and matrix material 121b along with instructions regarding how to form the sheath 12 on the post 11. Such a kit may include the post 11 and / or may include one or more staples 125 and / or the adhesive and / or the catalyst. The post 11 may have: a width of about 3 inch and a depth of about 3 inches (i.e. about 76 mm by about 76 mm), or a width of about 4 inches and a depth of about 4 inches (about 102 mm by about 102 mm), or a diameter of about 125 mm, or about 150mm, or about 175 mm, or about 200 mm. In some versions, the matrix material 121b may be applied to the or each layer of mat 121a. In some versions of manufacture, the roller may be used to spread the matrix material 121b substantially uniformly across the mat 121a. The roller may also be used to press the matrix material 121b and the or each layer of mat 121a together, causing the matrix material 121b to consume the mat 121a. The matrix material 121b may, for example, form a layer on either side of the mat 121a of fibre material and the layers may be connected by matrix material 121b between discrete fibres in the mat 121a of fibre material. In other words, the mat 121a may be sandwiched between layers of matrix material 121b and the layers may be, when the matrix material 121b is initially introduced to the mat 121a, in fluid communication through the mat 121a. The present invention may realise environmental benefits, by extending a lifespan of the post 11 after installation through the provision of a barrier to inhibit, or substantially inhibit, water and ground material 13 from contacting at least the intermediate portion 111 of the post 11. This may reduce the rate of decay or corrosion of the post 11, thus extending the usable life of the post 11 and inherently reducing the rate of replacement of posts 11. The invention may also broadly consist in the parts, elements, steps, examples and / or features referred to or indicated in the specification individually or collectively in any and all combinations of two or more said parts, elements, steps, examples and / or features. In particular, one or more features in any of the embodiments described herein may be combined with one or more features from any other embodiment(s) described herein. Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure. Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and / or to encompass equivalents.
Claims
1. A post assembly, including:a post for at least partial burial in ground material; anda sheath surrounding at least an intermediate portion of the post;wherein the sheath is at least partially formed from a fibre reinforced composite material configured to provide a barrier around the intermediate portion of the post.
2. The post assembly of claim 1, wherein the fibre reinforced material of the sheath includes a glass fibre reinforced composite material or a carbon fibre reinforced composite material.
3. The post assembly of any preceding claim, wherein the sheath is configured to provide a barrier around the intermediate portion of the post to inhibit the ingress, into the intermediate portion of the post, of water and / or the contamination of the intermediate portion of the post by the ground material.
4. The post assembly of any preceding claim, wherein a bottom portion of the post extends from a first end of the intermediate portion of the post and a top portion of the post extends from a second end of the intermediate portion of the post, the first and second ends of the intermediate portion of the post opposing each other across a length of the intermediate portion of the post, the bottom portion of the post being configured for burial and the top portion of the post being configured to extend above the ground material.
5. The post assembly of any preceding claim, wherein the intermediate portion has a length along the post of about 20 cm to 60 cm.
6. The post assembly of any preceding claim, wherein the intermediate portion has a length along the post which is about 5% to 30% of a total length of the post.
7. The post assembly of claim 4 or 5, wherein a total length of the post is more than about 1 m.
8. The post assembly of any preceding claim, wherein the sheath includes a mat of fibre material wrapped around the intermediate portion of the post and embedded within a matrix material.
9. The post assembly of claim 8, wherein the mat of fibre material includes one or more overlapping sections of fibre material, and wherein the overlapping sections each have a depth of about 2 cm to 10 cm.
10. The post assembly according to any preceding claim, further including one or more staples through at least part of the sheath and the post, to aid in securing the sheath to the post.
11. The post assembly of any preceding claim, wherein the sheath includes an outwardly or inwardly projecting flange around a perimeter thereof.
12. The post assembly of any preceding claim, further including a seal member configured inhibit the passage of water between the sheath and the post.
13. The post assembly of claim 12, wherein the seal member is formed from a natural rubber material, a synthetic rubber material, and / or a cured fluid or foam.
14. The post assembly of any preceding claim, wherein a thickness of a wall of the sheath is at least 2 mm.
15. The post assembly of any preceding claim, wherein at least part of the post is treated to inhibit fungal growth; andthe treatment of the post to inhibit fungal growth includes one or more of: the application of an antifungal, a heat treatment, and a pressure treatment.
16. The post assembly of claim 15, wherein the treatment of the post includes the application of the antifungal and the sheath inhibits egress of the antifungal from the first portion of the post.
17. The post assembly of any preceding claim, wherein the post is formed from a wood material.
18. The post assembly of any preceding claim, wherein the post has a rectangular crosssection through at least a part thereof, and a radius of the corner edges of the post in the intermediate portion is greater than a radius of the corner edges of the post in another portion of the post.
19. The post assembly of any preceding claim, wherein the post includes one or more mounting locations for a fence panel, a gate, a fence rail, a hinge, a cable, a cable insulator, a lock or latch, or a cross-arm.
20. A method of making a post assembly, the method including: providing a post; andproviding a fibre reinforced composite material around an intermediate portion of the post.
21. The method of claim 20, wherein providing the fibre reinforced composited material includes:providing a mat of fibre material;wrapping the mat of fibre material around the intermediate portion of the post;providing a matrix material; andapplying the matrix material to the mat of fibre material around the intermediate portion of the post.
22. The method of claim 21, wherein providing the fibre reinforced composited material further includes:using a roller to press the matrix material and mat of fibre material together and against the intermediate portion of the post.
23. The method of any of claims 20-22, wherein providing the post includes: providing a post with a rectangular cross-section through at least a part thereof, and forming a radius of the corner edges of the post in the intermediate portion which is greater than a radius of the corner edges of the post in another portion of the post, prior to providing the fibre reinforced composite material around the intermediate portion of the post.
24. A method of installing a post assembly according to any of claims 1 to 19, the method including:providing the post assembly; andinstalling the post assembly in ground material such that the sheath of the post assembly is partially buried in the ground material.
25. A sheath for use in a post assembly, according to any of claims 1 to 19.21
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