AU2016222415B2 - Post - Google Patents

Abstract

A post 10 comprises a major flange that defines an elongate stalk 12 of the post. The post 10 also comprises minor flanges that define elongate wings 14, 16 of the post. The stalk 12 is defined by two sections 20, 22 of a single plate that is bent such that the 5 two sections generally face each other and define a stalk distal edge 24 at their interconnection. The plate is also bent such that each wing 14, 16 is defined by a section of the plate that extends at an angle from a respective one of the stalk sections 20, 22. At least one aperture 30 is formed in the stalk 12. The aperture 30 is generally N-shaped when formed in the plate prior to it being bent. 10 15 8041776_1 (GHMatters) P100132.AU.131/08/16 %Y"I .. .. .... .. .. . ... .. . ... .. .. ..

Description

%Y"I ... ...... .... ..... . ......... POST

TECHNICAL FIELD Disclosed herein is a post that may have a Y-shaped or T-shaped profile (i.e. in end view). The post comprises a major flange (stalk) that has a generally N-shaped aperture defined therein for retaining at the post an elongate element such as a strand (e.g. wire strand). The post may be employed in applications such as fencing, demarcation, signage, retention, barricades, etc.

BACKGROUNDART Posts for use in applications such as fencing, demarcation, signage etc are known. Such posts are usually formed from steel, though in some applications it is known to mould posts from a plastic material (e.g. for use in electric fencing). Steel fence posts have been known for many years that are roll-formed to have a Y-shaped or T-shaped profile (i.e. in end view). The post may take the form of a picket and, in this case, may be provided (e.g. cut) with a pointed end to facilitate post driving into the earth. Fence posts, especially those for use in e.g. rural applications, require a combination of strength (to enable the post to be driven into the earth) and ductility (so the post can deform without breaking when pressure is applied to it by e.g. livestock). Such steel fence posts are usually provided with a series of spaced holes in a flange thereof (i.e. in the so-called "stalk" or "stem" of the post) to enable strands of fencing wire to be secured to the post, usually by tying each wire strand to the post with a separate short length of wire tie threaded through an individual hole, or by employing a wire "clip". However, the wire can also be directly threaded through such holes. These holes are typically punched, cut, machined or drilled into an already roll-formed post in a separate step. In addition (or as an alternative) to the series of holes, the posts can be provided with a series of spaced passages or notches that are usually cut or machined to project right into the stalk from a distal edge thereof. These passages enable a strand of fencing wire to be moved into and retained in the passage, thereby securing the wire directly to the post. An additional latch can be mounted to the post in the vicinity of the passage

17905024_1 (GHMatters) P100132.AU.123/07/21 that allows the fencing wire strand to be moved there past, and that retains the wire once located in the passage. Usually this latch is factory-fitted to the post in a separate stage. Again, it has been observed that these passages/notches are typically cut, punched, drilled or machined into an already roll-formed post in a separate step, adding additional manufacturing complexity and cost. In addition, the passages and the attachment of the latches can compromise the strength, integrity, corrosion resistance, etc of the stalk and thus of the entire post in use. In this regard, the fracture strength of a fence post when subjected to bending loads is an important feature of the post, more so when a stalk of the post comprises one or more passages/notches extending therein. More particularly, when excessive pressure is applied to the post (e.g. by livestock), this pressure can give rise to a bending moment in the post. When this occurs, the post can fracture at the holes and passages/notches, because these are typically a weak point of the post. When the post fractures, usually at the hole or passage/notch closest to the ground, the post can no longer be used and must be replaced. The above references to the background art do not constitute an admission that the art forms a part of the common general knowledge of a person of ordinary skill in the art. The above references are also not intended to limit the application of the post disclosed herein.

SUMMARY OF THE DISCLOSURE Disclosed herein is a post that may comprise a Y- or T- profile. The post as disclosed herein may be used in applications such as fencing, demarcation, signage, etc. The post generally comprises a central longitudinal axis, with a Y-shaped or T shaped profile defining a post major flange projecting with respect to this axis to define an elongate "stalk" of the Y-shaped or T-shaped profile of the post (i.e. a "stem" of the Y- or T- profile). In addition, post minor flanges can project with respect to this axis to define elongate "wings" of the Y-shaped or T-shaped profile of the post (i.e. the "arms" of the Y- profile, or the "top" of the T- profile).

17905024_1 (GHMatters) P100132.AU.123/07/21

It should be understood that end edges of the wings may be flared, or may comprise a flange, enlargement, bulb, etc located along the end edge. This may or may not noticeably change the Y- or T- profile of the post (e.g. the post may assume more of a W-profile, depending on the extent of flaring or flange). Further, the post may take the form of a picket. In this regard, the post may be formed to have a pointed lower end in use. In any case, the stalk is generally the major (or larger) of the flanges in a Y- or T-post. In the post as disclosed herein, the stalk can be the major (or larger) of the flanges of the post. In the post as disclosed herein, the stalk can be defined by two sections of a single plate that is bent such that the two sections face each other and define a distal edge of the stalk at their interconnection. As a result, the stalk can generally become the strongest part of the post (e.g. when it has a Y- or T- profile). In the post as disclosed herein, at least one aperture can be formed in the stalk, the aperture being generally N-shaped in the plate (e.g. the aperture generally has an N shape before the plate is bent/formed to assume a final post profile). The terminology "plate" as employed throughout this document is intended to include strip and sheet within its scope, including continuous lengths of strip and sheet. In one embodiment, when viewed in profile, the stalk may be formed to be lengthened relative to the length of a stalk in a standard Y- or T- post, to further increase its strength. This lengthening of the stalk may also compensate for the one or more generally N-shaped apertures that are formed in the stalk. For example, such a lengthened stalk may be noticeably longer than a standard stalk as well as the standard wings when the post is viewed in profile. Reference herein to "standard" is intended to mean industry standard Y- or T posts, including the typical dimensions and configurations of such posts. The stalks and wings of such industry standard posts may have a length dimension in the vicinity of around 30mm when the post is viewed in profile. The plate is also bent such that each wing can be defined by a further section of the same plate. Each wing can extend at an angle from a respective one of the stalk

17905024_1 (GHMatters) P100132.AU.123/07/21 sections (i.e. each wing can extend from one of the two sections at a region that is opposite to the distal edge). By defining the stalk from two facing sections of the same plate, this also enables the generally N-shaped aperture to be formed at the stalk, for example, when the stalk forms part of a Y- or T-post. This is both unexpected and surprising, in that such an aperture has previously not been considered applicable with posts having Y and T- profiles. Such an aperture has only been considered suitable for posts having a generally hollow profile (e.g. a trellis post). In addition, posts having Y- and T- profiles are familiar to end users and may also offer superior performance characteristics (e.g. strength, bend resistance, etc) compared to e.g. hollow post profiles. Thus, it can be seen as highly desirable to provide a Y- or T-post with a generally N-shaped aperture. Furthermore, the generally N-shaped aperture may be optimally configured for e.g. wire retention. For example, the aperture may be able to retain a wire without requiring the use of separate/additional fasteners, clips, latches, wire-ties, etc. For example, once a length of wire has been tensioned in e.g. a fence line, the configuration of the N-shaped aperture can alone function to retain the wire at the post, as will be explained in more detail hereafter. The generally N-shaped aperture can enable other elongate strands (in addition to wire strands) to be directly secured to the post by the threading of such a strand through the aperture. The term "strand" as used herein is to be broadly interpreted to include various elongate components that can be secured to a post, including fence post wire, grid and mesh, tape, rods, bar, etc. In one embodiment, the generally N-shaped aperture may be formed in the plate to be located at the stalk distal edge (e.g. the aperture becomes located at the distal edge once the post has been formed from the plate). This is an optimal location for e.g. wire retention purposes, as will be explained in more detail hereafter. In one embodiment, the generally N-shaped aperture may be defined to extend into each of the two stalk sections from the stalk distal edge. For example, the aperture may be arranged such that it extends from the stalk distal edge generally to an even extent into the stalk sections. In this regard, the aperture may be seen as "wrapping around" the distal edge of the stalk, e.g. extending evenly into both sides of the stalk.

17905024_1 (GHMatters) P100132.AU.123/07/21

In one embodiment, the generally N-shaped aperture may be arranged such that a part of the diagonal portion of the N-shaped aperture extends from the stalk distal edge and into one of the stalk sections, and another part of the diagonal portion of the N-shaped aperture extends from the stalk distal edge and into the other of the stalk sections. This enables left and right stem portions of the N-shaped aperture to be located in a body of a respective section, away from the distal edge of the stalk, as will be explained in more detail hereafter. In one embodiment, the generally N-shaped aperture may be configured such that its diagonal portion extends down from a left hand stem of the N-shape to intersect with a right hand stem of the N-shape but part way up the right hand stem. In addition, the generally N-shaped aperture may be configured such that its diagonal portion extends from a location of the left hand stem that is part way down the left hand stem. This moving of the diagonal portion away from a top part of the left hand stem, and away from a bottom part of the right hand stem enables rounded comers to be formed at each of the left and right hand stems of the N-shaped aperture. These rounded corners can be optimal for retaining e.g. wire thereat. For example, opposing ends of each of the left and right hand stems may each be defined to have a semi-circular shape. Further, opposing sides of each of the left and right hand stems may each comprise a substantially straight edge (e.g. typically there are parallel edges in each stem). Each of the left and right hand stems may therefore have the form of a rounded rectangle (i.e. a rectangle having rounded corners) or may have the form of an obround (semi-circular top and bottom edges, with substantially parallel side edges). In addition, opposing sides of the diagonal may each comprise a substantially straight edge (e.g. typically parallel edges). Comers at each intersection of the diagonal with the left and right hand stems can also be rounded. In each case, such configuring of the left and right hand stems and diagonal of the aperture, including such comer rounding, can also function to reduce stress concentration in the material surrounding the aperture, such as when a bending moment is applied to the post (e.g. by livestock). This reduction of stress concentration may prolong failure of the post at the aperture. Such configuring of the left and right hand stems may also, for a given deflection, better allow the post to bend and deform before

17905024_1 (GHMatters) P100132.AU.123/07/21 it fails or fractures at the aperture. This may also allow a post that has been deformed (i.e. which would otherwise have failed and needed to be replaced), to be re-bent and thus re-used, thereby providing either a semi-permanent or temporary fix. The deformed post can be restraightened using known methods, and can provide for a significant costs saving otherwise associated with having to replace fractured posts. In one embodiment, the post may comprise a plurality of discrete, spaced generally N-shaped apertures along at least part of its length (e.g. along that part of the post which projects above the ground in use). Each aperture in the post may also be configured in the same manner as each other aperture. The apertures may be spaced evenly or according to a predetermined spacing pattern. In one embodiment, the post may be roll-formed, such as by cold- or hot roll forming of e.g. continuous strip, sheet. The post may be of steel or a steel alloy. Various steel grades and alloys may be utilised in the production of the post. Alternatively, the post may be formed (e.g. by extruding it) from a non-ferrous metal or from a polymer (plastic). In the case of an extruded post, each of the generally N-shaped apertures may be formed (e.g. machined or cut) into the extruded post at a subsequent stage. The post material may be corrosion-resistant and hence the post may be uncoated. Alternatively, the post may be coated with a barrier material, such as a metal alloy (e.g. before or after forming). For example, the coating may comprise galvanising or it may comprise e.g. a Zn-Al-Mg alloy. The coating may alternatively or additionally comprise a polymer or paint. The coating may be air-dried, force cured or may comprise a thermal diffusion coating. In use of the post in a fence line, the stalk may generally be orientated to be perpendicular to the fence plane and, because the stalk is generally thicker than the wings, when a bending moment is applied to the post, it often occurs in a direction that is planar to the stalk. The configuring and location of each aperture may be designed in consideration of the principal bending plane of a stalk in a Y- and T-post. Apertures may be located away from where a post is likely to bend in use. In use of the post in a fence line, the apertures may be placed in the stalk to enable easy threading and alignment of adjacent fence wires through the fence post. In

17905024_1 (GHMatters) P100132.AU.123/07/21 this regard, a wire strand can be aligned with the diagonal of the generally N-shaped aperture and then moved into the aperture, to then drop down to locate behind a flange defined by that part of the plate that extends in between the left hand stem and diagonal of the generally N-shaped aperture. The wire strand may then be tensioned. The dimensions of the passage for a strand that is to be moved into the generally N-shaped aperture can also be selected to correspond to the diameter of the wire. In this regard, when in use the wire extends laterally with respect to the post axis (e.g. the wire extends horizontally through the generally N-shaped aperture such as when it is tensioned), the wire diameter may be such that it is not possible for it to pass out of aperture in this orientation. Rather, for the wire to be removed from the aperture, its orientation must be changed (e.g. its tension released first) so that it can be angled out via the diagonal portion of the generally N-shaped aperture, as will be explained in more detail hereafter. A variety of aperture spacing options may allow for additional wire strands to be incorporated into a fence, and may also allow for wire mesh/grid to be secured at multiple locations along the post.

Also disclosed herein is a method for manufacturing a post as set forth above. The method comprises bending a plate (e.g. strip or sheet) so that the two sections face each other and so that each wing extends at an angle from a respective one of the sections. The method also comprises forming the at least one generally N-shaped aperture in the plate. In one embodiment, the (or each) aperture may be formed in the plate prior to it being bent to assume e.g. a Y- or T- profile. This is simpler than attempting to form the aperture in an already bent plate. The (or each) aperture may be punched, cut or machined into the plate. In one embodiment, the post may be formed continuously from an elongate (e.g. continuous) strip or sheet of the plate as part of an in-line forming operation. After forming e.g. a Y- or T- profile in the elongate strip or sheet, it can be cut to length for the post.

17905024_1 (GHMatters) P100132.AU.123/07/21

In one embodiment, the post may be roll-formed, such as by cold- or hot roll forming (e.g. of non-heated or heated strip or sheet). In one embodiment, the post may be of steel or steel alloy. In one embodiment, either prior to or after roll-forming, the post may be coated e.g. with a metal alloy, such as by hot-dipping an elongate strip or sheet of the plate.

BRIEF DESCRIPTION OF THE DRAWINGS Notwithstanding any other forms which may fall within the scope of the post as and method as set forth in the Summary, a specific post embodiment will now be described, by way of example only, with reference to the accompanying drawings in which: Figures 1 and 2 respectively show a side view of part of a post, and an end view (profile) of the post, the post having a number of discrete, generally N-shaped apertures formed in and spaced out along the stalk thereof; Figures 2A to 2F show end (profile) views of a number of different post embodiments, each of which can comprise a series of generally N-shaped apertures formed in and spaced out along the stalk of the post (i.e. as per Figure 1) - the dimensions shown in Figs. 2A-2F are indicative only; Figures 3A and 4A respectively show a schematic view (in detail) of a wide N shaped aperture and a narrow N-shaped aperture, each for use in the different post embodiments of Figures 1 and 2; Figures 3B and 4B respectively show a side view (in detail) of the wide N shaped aperture and the narrow N-shaped aperture of Figures 3A and 4A, but when arranged at a stalk of one of the post embodiments of Figures 1 and 2; Figure 5 shows a similar schematic view to Figures 3A and 3B of the N-shaped aperture but illustrating how a strand of wire W can locate therein; Figure 6 shows a similar side view to Figures 4A and 4B of the N-shaped aperture arranged at a stalk of the post but illustrating how a strand of wire W can locate therein;

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Figure 7 shows a finite element analysis (FEA) model of the resultant stress in the first post embodiment of Figure 2A with a wide N-notch (of Figure 3) when a OON load is laterally applied at the top of the post; and Figure 8 shows an FEA model of the resultant stress in the first post embodiment of Figure 2A with a narrow N-notch (of Figure 4) when a 1OON load is laterally applied at the top of the post.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS Post embodiments that are each configured to allow one or more elongate strands (e.g. of wire W) to be releasably secured to the post will now be described with reference to Figures 1 to 6. Figures 7 & 8 show FEA models to illustrate the stress that can result in the post in use. The post 10 is formed by the bending and folding of plate (e.g. by cold-rolling a continuous metal strip or sheet (e.g. of steel)). The plate has one or more apertures formed therein (typically prior to roll bending/folding). Each aperture takes the form of an N-shaped notch 30 as will be described in further detail herein. Whilst the post 10 will generally be described in relation to its use for securing wire strands (e.g. fence wire) to a fence post, it should be understood that the post is not limited to fencing-related applications and may be used in applications such as demarcation, signage, wall-bracing, etc. Further, whilst the post to be described is of a type that, in effect, comprises three elongate flanges that each project out from a longitudinal post central axis A (see Figures 1 & 2) to generally take the form of a Y-post, it should be understood that the post may be formed to also take the form of a T-post, or may even be bent/folded to assume a W- profile (see e.g. Fig. 2F). Additionally, the flange in which the one or more N-shaped notches 30 are formed typically comprises a stalk 12 (i.e. a stem or major flange) of the post. Finally, it should be understood that the post may take the form of a picket (i.e. cut or machined to have a pointed lower end) for ease of post driving into the ground in fencing and related applications, but the post is not limited to a picket-type form.

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Referring specifically to Figures 1 and 2 (and as also shown in Figures 2A to 2E), a post embodiment that has the general form of an elongate Y-post 10 is shown. The post in Fig. 2F is more W-like in profile. The post 10 comprises a generally central longitudinal axis A, with a post major (or larger) "flange" projecting with respect to this axis to define an elongate stalk 12 of the post 10 (i.e. to define the "stem" of a Y profile). In addition, post minor flanges project with respect to this axis to define elongate wings 14, 16 of the post 10, representing the "arms" of the Y- profile (or the "top" of a T- profile). When used as a fence post, the post 10 may be given the form of a picket, whereby its lower end can be cut or machined to be pointed. However, rather than being a solid flange, the stalk 12 is defined by two sections 20, 22 of a single plate (e.g. of strip or sheet) that has been bent and folded as part of a roll-forming process (e.g. by cold roll-forming of a continuous steel strip or sheet). As a result, the two sections 20, 22 generally face each other and define a distal edge 24 of the stalk at their interconnection. As a further result, the stalk 12 generally becomes the strongest part of the post 10 (i.e. because it comprises the two closely-facing sections 20, 22). In addition, when viewed in profile, the stalk 12 is typically lengthened relative to the wings 14, 16, and may also be lengthened relative to the stalk length of a standard Y- or T- post. This lengthening further increases the strength of the stalk, as well as of the post. Further, by defining the stalk from two facing sections of plate, this enables one or more generally N-shaped apertures (e.g. in the form of N-shaped notches 30) to be employed in e.g. a Y- or T-post. The N-shaped notches 30 effectively "wrap-around" the distal edge of the stalk 12. This is both an unexpected and surprising discovery, in that such an aperture has previously not been considered applicable to posts having Y and T- profiles. Referring now to Figures 2A to 2F, end (profile) views of six different post embodiments are shown, each of which may have the general appearance according to Figure 1. In each of the six embodiments of Figures 2A to 2F, the stalk 12 is defined by two sections 20, 22 of a single plate (e.g. of strip or sheet) that has been bent and folded as part of a roll-forming process (e.g. by cold roll-forming of a continuous steel strip or

17905024_1 (GHMatters) P100132.AU.123/07/21 sheet). However, in a number of the embodiments, the profile of the wings 14, 16 is changed, or the profile of the distal edge is changed, etc. Referring now to Figure 2A, a post 1OA is shown that is rolled such that the stalk 12 comprises the two sections 20, 22 of close-facing plate. In the post 10A the stalk 12 is lengthened relative to the wings 14, 16, and may also be lengthened (e.g. to 32.7mm) relative to a standard Y- or T- post. The post1OA is bent/folded such that each wing 14, 16 is defined by a section of the plate that extends at an included angle of about 1220from a respective stalk section 20, 22, with the angle between the wings being about 116. Referring to Figure 2B, the post 1OB has a similar profile to the post 10A, although the stalk length (e.g. about 26mm) and wing lengths are each reduced to be comparable in length to a standard Y- or T- post. Referring now to Figure 2C, a post 1OC is shown that is rolled such that the wings 14, 16 are each curved, with the radius of curvature (e.g. of about 22.6mm) commencing from a respective one of the two sections 20, 22 of close-facing plate. The stalk length (e.g. of about 26mm) is comparable in length to a standard Y- or T- post. Referring now to Figure 2D, the post 1OD has a similar profile to the post 10A, although the stalk length is increased (e.g. to about 43mm). In addition, the distal edge 24 is formed to have a bulbous (circular) profile (e.g. having a diameter of about 13mm, c.f. with the distal edge of 9mm of post 10A). This bulbous profile increases the strength (e.g. bend resistance) and stiffness of the distal edge 24. Referring to Figure 2E, the post 1OE has a similar profile to the post 1OD, although the stalk length (e.g. about 37.5mm) and wing lengths are each reduced to be more like the lengths in a standard Y- or T- post. Referring now to Figure 2F, the stalk of the post 1OF has a similar profile and length (e.g. about 26mm) to the post 1OB. However, the wings have a very different profile to the posts 1OA, lOB, 1OD and 10E. The post 1OF is rolled such that the wings 14, 16 each curve in a pronounced manner to each define a C-profile, with the radius of curvature commencing from a respective one of the two sections 20, 22 of close-facing plate. This C-profile at each wing 14, 16 increases the strength (e.g. bend resistance) and stiffness of each wing, and hence of the post as a whole.

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It should be noted that the outer (i.e. free) end edges of the wings 14, 16 can be formed to have a different flaring, or may each comprise a flange, enlargement, bulb, lip, etc to increase the strength, bend resistance and stiffness/rigidity of the post 10. The resultant post profile may or may not have a general Y- or T- shape. However, when a more pronounced flaring or flange formation is provided at the end of each wing, this may result in the post having more of a W- profile, such as the post 1OF. Usually multiple N-shaped notches 30 are punched, cut or machined in the plate (e.g. into strip or sheet) prior to the bending and folding that forms the Y-, T- or W profile. An N-type notch 30 is optimally configured for strand (e.g. wire) retention, as best shown in Figures 5 & 6. In this regard, each N-notch 30 can retain therein a wire W without requiring the use of a separate/additional fastener, clip, latch, wire-tie, etc. Thus, a wire strand can be directly secured to the post 10 by threading it through the N notch 30 (see Figures 5 & 6). Thereafter, once the wire strand is tensioned (such as occurs in e.g. a fence line), the configuration of the N-notch 30 alone can function to retain the wire at the post, as is explained in more detail below. The N-notch 30 can also retain other elongate strands at the post 10 (i.e. as an alternative to or in addition to wire strands), such as tape, flexible rod and bar, and various elongate components that can be secured to a post, including fence grid and mesh. As shown schematically in Figures 3A and 4A, a plate (e.g. elongate strip or sheet) from which the post 10 is to be formed has one or more of the N-notches 30, 30' defined therein. The notches are formed (e.g. punched, cut or machined) in the plate such that, when the post profile is formed by bending/folding, each notch 30 locates at the distal edge 24 of the stalk 12. The notches are also formed in the plate so as to be spaced out along that distal edge according to a predetermined (e.g. a required strand or grid) spacing, which may be even or uneven. As best illustrated in Fig. 1, typically the post comprises a plurality of discrete, spaced N-notches 30 along that part of the post which projects above the ground in use, usually with each notch being configured in the same manner (i.e. same orientation and same dimensions).

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Because the post profile is typically formed by bending/folding an elongate plate/strip along a central, longitudinal axis, each N-notch 30 extends, generally to an even extent, into each of the two stalk sections 20, 22 from the distal edge 24. In this regard, each N-notch 30 wraps around the distal edge 24 (i.e. evenly on both sides), as is illustrated in Figures 3B and 4B. This location of each N-notch 30 at the distal edge 24 is observed to be an optimal location for e.g. wire retention purposes, because it presents an outwardly facing notch opening at the stalk distal edge 24. The location of each notch 30 at the stalk distal edge 24 also enables easy threading and alignment of adjacent fence wires through adjacent fence posts. In this regard, when the post 10 is used in a fence line, usually the stalk 12 is orientated to be perpendicular to the fence plane (i.e. because the stalk is generally thicker than the wings). Further, when a bending moment is applied to the post, it often occurs in a direction that is planar to the stalk. Such a bending moment can be better accommodated by the two sections 20, 22 of close-facing plate. As best illustrated in Figures 3A & 3B, usually each N-notch 30 is arranged such that a part 31 of the diagonal portion 32 of the N-notch 30 extends from the stalk distal edge 24 and into one section 20 of the plate, and another part 33 of the diagonal portion 32 extends from the distal edge 24 and into the other section 22 of the plate. This enables a left stem 34 and a right stem 36 of the N-notch 30 to be located in a body of a respective section 20, 22 (i.e. away from the distal edge 24). As can also be seen in Figures 3A and 4A, N-notch 30, 30' is configured such that its diagonal portion 32 extends down from the left stem 34 to intersect with the right stem 36, but part way up the right stem. Further, the diagonal portion 32 extends from a location of the left stem 34 that is part way down the left stem. This deliberate forming of the diagonal portion 32 away from a top part of the left stem, and away from a bottom part of the right stem, enables rounded comers to be formed in each of the left and right hand stems. In this regard, opposing ends 35, 37 of the left stem and opposing ends 38, 39 of the right stem can each have a semi-circular shape. Further, opposing sides of each of the left and right hand stems each comprise a straight edge (i.e. so that the opposing edges of each stem are parallel). Each of the left

17905024_1 (GHMatters) P100132.AU.123/07/21 and right hand stems 34, 36 therefore takes the form of an obround (semi-circular top and bottom, with parallel sides). In addition, it will be seen that opposing sides of the diagonal portion 32 each comprise a straight edge. Furthermore, the comers defined at each intersection of the diagonal portion 32 with the left stem 34 and right stem 36 are rounded. In each of the N-notches 30, 30' of Figures 3 and 4, the left stem 34 and right stem 36 typically have a maximum dimension of 6mm wide and up to 16mm (e.g. 15.6mm) long (height). The elongate (main) axes of the left stem 34 and right stem 36 are substantially parallel to the stalk distal edge 24. The radii for each of the semi circular ends of the left stem 34 and right stem 36 are typically around 3mm. In each of the N-notches 30, 30' of Figures 3 and 4, the, the diagonal portion 32 typically has a maximum dimension of up to 5mm (e.g. 4.5mm) wide. An elongate (major) axis of the diagonal portion 32 typically extends down from the left stem 34 at an angle of about 100 with respect to the horizontal. The corner radii for each of the corners defined at each intersection of the diagonal portion 32 with the left stem 34 and right stem 36 are typically around 1mm. However, in the wider notch 30 of Figure 3, the lateral (horizontal, side-to-side) extent is up to 20mm (e.g. 19mm). This means that a leading edge 40 (see Fig. 3B) of each of the left stem 34 and right stem 36 can be spaced up to 10mm (e.g. 9.3mm) from the stalk distal edge 24. The wider notch can be employed for longer length stalks (e.g. for those post profiles shown in Figures 2A, 2D and 2E). Conversely, in the narrower notch 30' of Figure 4, the lateral (horizontal, side to-side) extent is up to 11mm (e.g. 10.4mm). This means that a leading edge 40' (see Fig. 3B) of each of the left stem 34 and right stem 36 is spaced up to 5mm from the stalk distal edge 24. The narrower notch can be employed for shorter length stalks (e.g. for those post profiles shown in Figures 2B, 2C and 2F). In either case, such deliberate configuring of the left and right stems and diagonal portion of the N-notch 30, 30' assists with a reduction of stress concentration at the notch in use, such as when a bending moment is applied to the post (e.g. by livestock). This reduction of stress concentration may prolong failure of the post. Such configuring of the N-notch 30, 30' can also, for a given deflection, better allow the post

17905024_1 (GHMatters) P100132.AU.123/07/21 to bend and deform before it fails or fractures. It may also allow a post that has been deformed (i.e. which would otherwise have failed and been replaced), to be re-bent (e.g. using known methods) and thus to be re-used, thereby providing either a semi permanent or a temporary fix, and thus providing significant costs savings. In use, a wire W (see e.g. Figures 5 & 6) can be aligned (angled) with the diagonal portion of the N-notch 30 and then moved into the notch, to eventually drop down into a lower end of each of the left stem 34 and right stem 36. Accordingly, the wire W locates behind a flange formation 44 that is defined by that part of the plate that extends in between the left stem 34 and diagonal portion 32 of the generally N-shaped aperture (see Figures 5 & 6). The wire W is now ready to be tensioned. When tensioned, the wire W extends laterally (e.g. at right angles) with respect to an elongate axis of the post 10. As shown in Figures 5 & 6, in this orientation, the diameter of the wire is greater than the top-to-bottom horizontal opening 46 defined between the diagonal portion 32 to the left stem 34 and right stem 36. This means that the tensioned wire cannot be lifted, bumped or otherwise displaced out of the N-notch 30. If the wire is displaced upwardly, it will tend to travel up and then back down each of the left stem 34 and right stem 36. Due to the orientation of the notch 30, the wire W will not be able to pass into the diagonal passage portion 32. Thus, for wire removal, the wire tension must first be released, and the wire then is angled to pass out of the diagonal portion 32. Each N-notch arrangement thereby provides a wire trap. The post 10 is typically cold roll-formed from a mild steel, or from a steel alloy. Various steel grades and alloys may be utilised in the production of the post. When formed of non-ferrous metal or a polymer (plastic), the post may be extruded, with the notches being machined (e.g. laser-cut) after extrusion. The post may also be coated e.g. with a metal alloy (e.g. before or after roll forming). The coating can comprise galvanising or may comprise hot-dipping with a Zn-Al-Mg alloy for additional corrosion protection. The coating can additionally or alternatively comprise a polymer or paint. The coating can be air-dried, force cured or may comprise a thermal diffusion coating. A non-limiting example of forming the post 10 will now be described. Example

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A method of manufacturing a post 10 as described above first comprised producing a continuous strip (or sheet) of steel or steel alloy in a continuous, in-line roll-forming facility. The strip was passed through a punching station in which a series of N-shaped notches 30 were punched into (through) a longitudinal centreline of the strip at predetermined spacings. The centreline passed through a central part of the diagonal portion 32 of each N-shaped notch 30. The now-punched strip was passed through a series of rolls arranged to progressively bend and fold the strip, so that the two sections 20, 22 generally faced each other, and so that the inter-connecting distal edge 24 ran along the centreline of the strip. This formed the stalk 12 and caused the series of N-shaped notches 30 to be located along the distal edge 24 of the stalk, with each notch extending into each of the two sections 20, 22 to a similar extent (i.e. generally evenly). Additional rolls caused each wing 14, 16 to be bent so as to extend at an angle or curvature from a respective one of the sections 20, 22. The strip now had its desired profile, and so was passed for hot-dipping through a bath comprising a molten Zn-Al-Mg alloy. After leaving the bath, the coating was force air-dried, and the Y-profile strip was then cut to individual lengths for each post. As required, each post was then passed to a separate machining stage to have a lower pointed end cut/machined thereat to form each post as a picket. Because the stalk 12 comprised two close-facing sections 20, 22, the post was observed to be quite strong, despite having a series of N-notches 30 formed along the distal edge 24.

FEA Analysis Referring now to Figures 7 and 8, finite element analysis (FEA) models were created to compare stresses within the general N-notched post of Figure 2A against other notched posts, and against posts having aperture and hole configurations located in a body of the stalk. The FEA model of Figure 7 showed the resultant stress in the post profile 1OA of Figure 2A with a wide N-notch 30 (of Figure 3), when a OON load was laterally

17905024_1 (GHMatters) P100132.AU.123/07/21 applied at the top of the post. The FEA model of Figure 8 showed the resultant stress in the post profile 10A of Figure 2A with a narrow N-notch 30' (of Figure 4), when a 1OON load was laterally applied at the top of the post. The FEA models did not account for cold-working in the material which would occur during the forming of each notch, aperture or hole. Further, the FEA models did not account for inconsistencies in the composition of the post. As such, the FEA modelling isolated the shape and/or location of the notch, aperture or hole to provide an indication as to stress concentrations occurring at the notches, apertures or holes. Further, the FEA post models compared folded/bent posts with solid, rolled posts comprising three elongate flanges that each project out from a longitudinal central axis of the post to generally take the form of a Y-post. The models also assumed the flange in which the notches, apertures or holes were formed comprised the stalk of the post. The finite element analysis modelling, for each of the post models, was performed on a 1.1m long post section. The base of the post was assumed to be fully restrained (i.e. 0 degrees of freedom) and a load of 1OON was applied at the top of the post section in a lateral direction, such that the stalk distal edge was placed into tension. It was noted that the bending moment may be applied from another direction (e.g. the bending moment may be applied from the other side of the post, which can result in the stalk distal edge being in compression). Each post was modelled on plain carbon steel (i.e. mild steel having 0.16 0.29% carbon). Additionally, the lowermost notch, aperture or hole on each post was located 50mm from the base of the post. This was to separate the first aperture from anomaly stresses occurring due to constraining of the post base. In the model, subsequent notches, apertures or holes (i.e. vertically above) were separated by a spacing of 37.5mm. While the spacing between apertures remained consistent for the purposes of the FEA modelling, it was noted that the spacings could be modified to correspond to known or pre-existing spacings employed for wires or wire mesh/grid in the fencing industry (e.g. in agricultural applications). Further, the spacing between apertures did not need to be consistent for the length of the post. For example, the model could be run with closer spacings lower in the post than upper spacings. Such

17905024_1 (GHMatters) P100132.AU.123/07/21 closer spacing was noted to be suitable when arranging more densely spaced wire (e.g. for more densely spaced wire or mesh, such as to fence-off for small creatures such as vermin and pests; rabbits, foxes, etc). In Figures 7 and 8, the stresses resulting from a 1OON load being applied in a lateral direction are shown, with regions of higher stress being depicted as yellow-to red, while blue regions indicate relatively lower stress. In Figure 7, the leading edge 40 is spaced -10mm from the outermost part of the stalk distal edge 24, whereas in Figure 8, the leading edge 40' is spaced -5mm from the outermost part of the stalk distal edge 24. Results - FEA Post Models The FEA model (Figure 7) showed a maximum stress at a trailing edge of the lowermost wide N-notch 30 of-170 MPA (see red arrow). This compared favourably (i.e. it was lower than) the maximum stress for other notch shapes. The FEA model (Figure 8) showed a maximum stress at a trailing edge of the lowermost narrow N-notch 30' of-123 MPA. This was lower than the maximum stress for the wide N-notch 30 or other notch shapes. From the FEA modelling it was understood that the notch profiles as shown in Figures 3A and 4A were better able to resist the propagation of micro-cracks at the lateral (side) edges of each of the left stem 34 and right stem 36. The redistribution of stresses along the side edges of the left and right stems resulted in increased resistance to fracture of the major flange (stalk) and thus the post as a whole.

Whilst specific post and method embodiments have been described, it should be appreciated that the post and method may be embodied in other forms. In the claims which follow, and in the preceding description, except where the context requires otherwise due to express language or necessary implication, the word "comprise" and variations such as "comprises" or "comprising" are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the post and method as disclosed herein.

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Claims (26)

1. A post that has a Y-shaped or T-shaped profile to define a major flange that defines an elongate stalk of the Y-shaped or T-shaped profile of the post, and minor flanges that define elongate wings of the Y-shaped or T-shaped profile of the post, the stalk being defined by two sections of a single plate that is bent such that the two sections face each other and define a stalk distal edge at their interconnection, the plate also bent such that each wing is defined by a section of the plate that extends at an angle from a respective one of the stalk sections, wherein at least one aperture is formed in the stalk, the aperture being generally N-shaped in the plate.

2. A post as claimed in claim 1 wherein the generally N-shaped aperture is formed in the plate to be located at the stalk distal edge.

3. A post as claimed in claim 1 or 2 wherein the generally N-shaped aperture is defined to extend into each of the two stalk sections from the stalk distal edge.

4. A post as claimed in claim 3 wherein the generally N-shaped aperture is arranged such that part of the diagonal portion of the N-shaped aperture extends from the stalk distal edge and into one of the stalk sections, and another part of the diagonal portion of the N-shaped aperture extends from the stalk distal edge and into the other of the stalk sections.

5. A post as claimed in claim 3 or 4 wherein the generally N-shaped aperture is arranged to extend from the stalk distal edge generally to an even extent into the stalk sections.

6. A post as claimed in any one of the preceding claims wherein the generally N-shaped aperture is configured such that its diagonal portion extends down from a left hand stem of the N-shape to intersect with a right hand stem of the N-shape but part way up the right hand stem.

7. A post as claimed in claim 6 wherein the generally N-shaped aperture is configured such that its diagonal portion extends from a location of the left hand stem that is part way down the left hand stem.

8. A post as claimed in claim 6 or 7 wherein each of the left and right hand stems of the generally N-shaped aperture comprises rounded corners.

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9. A post as claimed in any one of claims 6 to 8 wherein opposing ends of each of the left and right hand stems are each defined to have a semi-circular shape.

10. A post as claimed in claim 9 wherein opposing sides of each of the left and right hand stems each comprise a substantially straight edge.

11. A post as claimed in any one of the preceding claims wherein, in profile, the stalk is lengthened relative to the stalk length of a standard Y- or T- post.

12. A post as claimed in any one of the preceding claims wherein the post comprises a plurality of discrete, spaced generally N-shaped apertures along at least part of its length.

13. A post as claimed in claim 12 wherein each aperture is configured in the same manner.

14. A post as claimed in any one of the preceding claims wherein the post is roll formed, such as by cold roll-forming.

15. A post as claimed in any one of the preceding claims wherein the post is formed from steel or a steel alloy.

16. A post as claimed in any one of the preceding claims wherein the post is coated with a metal alloy.

17. A method for manufacturing a post as set forth in any one of the preceding claims, the method comprising: bending a plate so that the two sections face each other and so that each wing extends at an angle from a respective one of the sections, and forming the at least one generally N-shaped aperture in the plate.

18. A method as claimed in claim 17 wherein the (or each) aperture is formed in the plate prior to it being bent to assume a Y- or T- profile.

19. A method as claimed in claim 17 or 18 wherein the (or each) aperture is punched, cut or machined into the plate.

20. A method as claimed in any one of claims 17 to 19 wherein the post is formed continuously from an elongate strip or sheet of the plate as part of an in-line forming operation.

21. A method as claimed in claim 20 wherein, after forming a Y- or T- profile in the elongate strip or sheet, it is cut to length for the post.

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22. A method as claimed in any one of claims 17 to 21 wherein the post is roll formed such as cold roll-formed.

23. A method as claimed in any one of claims 17 to 22 wherein the post is of steel or steel alloy.

24. A method as claimed in claim 22 or 23 wherein, prior to or after roll forming, the post is coated with a metal alloy, such as by hot-dipping an elongate strip or sheet of the plate.

25. A method for using a post as set forth in any one of claims I to 16, the method comprising: arranging the post to be generally upright with respect to a surface, aligning a strand with a diagonal of the generally N-shaped aperture, moving the strand into the aperture, such that it is able to drop down and locate behind a flange defined by that part of the plate that extends in between a left hand stem and diagonal of the generally N-shaped aperture.

26. A method as claimed in claim 25 further comprising tensioning the strand such that it extends laterally with respect to an elongate axis of the post.

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