Note: Descriptions are shown in the official language in which they were submitted.
CA 02468481 2004-05-26
MULTI-POSITION RAIL FOR A BARRIER
The Field of the Invention.
The present disclosure relates generally to rails, and more particularly, but
not exclusively, to rails that can be used in various positions and
orientations as
part of a barrier system.
2. Description of Related Art.
Rails are known in the art for use in decks, porches, stairs, and fences for
example. Such rails are useful in providing a secure barrier and adding to the
aesthetic appearance of structures. Rails are commonly used with upright
members such as pickets, planks or balusters of various sizes, configurations
and spacing. Moreover, rails are often used as support members on the bottom
of the barrier and towards the fop of the barrier. The ~nfiguration of bottom
rails
is often different than the configuration of top rails. Thus, rails of
multiple
designs are often required in a single ban-ier system.
Also, it is common to use a particular style of rail with different types of
upright members in different settings. Therefore, manufacturing and
installation
of barrier systems often requires the use of tools and machinery to form the
rails
to the desired configuration to be compatible with the particular upright
members
to be used.
Rails made of durable materials often have a more attractive appearance,
but may be more difficult to cut or otherwise shape into condition for use
with a
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CA 02468481 2004-05-26
particular upright member. Moreover, cutting of the rails to accommodate the
upright members may weaken the rails.
The use of a different design for top rails as compared to bottom rails may
increase the difficulty in providing proper inventory of barrier components.
Also,
the need to accommodate upright members of various different shapes and
spacings may increase the amount of inventory of components required, and
may also increase the difficulty and cost of installing the barrier.
The prior art is thus characterized by several disadvantages that are
addressed by the present disclosure. The present disclosure minimizes, and in
some aspects eliminates, the above-mentioned failures, and other problems, by
utilizing the methods and structural features described herein.
The features and advantages of the disclosure will be set forth in the
description which follows, and in part will be apparent from the description,
or
may be teamed by the practice of the disclosure without undue experimentation.
The features and advantages of the disclosure may be realized and obtained by
means of the instruments and combinations particularly pointed out in the
appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the disclosure will become apparent from
a consideration of the subsequent detailed description presented in connection
with the accompanying drawings in which:
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CA 02468481 2004-05-26
FIG. 1 is a perspective break-away view of a barrier system of the present
disclosure;
FIG. 2 is a perspective break-away view of a rail in a first orientation with
a
cover attached thereto;
FIG. 3 is a perspective break-away view of a rail in a second orientation
with a cover attached thereto;
FIG. 4 is an end view of a rail with a cap attached thereto;
FIG. 5 is a perspective break-away view of the rail of FIG. 4;
FIG. 6 is a perspective break-away view of an alternative barrier system
with the rail of the present disclosure on the bottom, and an alternative rail
on the
top;
FIG. 7 is a perspective view of a rail in a first orientation with an
alternative
embodiment cover attached thereto;
FIG. 8 is a perspective view of a rail in a second orientation with the
alternative embodiment cover of FIG. 7 attached thereto;
FIG. 9 is a perspective view of a rail in a first orientation with a further
alternative embodiment cover attached thereto;
FIG. 10 is a perspective view of a rail in a second orientation with the
alternative embodiment cover of FIG. 9 attached thereto;
FIG. 11 is a perspective view of a rail in a first orientation with an
additional alternative embodiment cover attached thereto;
FIG. 12 is a perspective view of a rail in a second orientation with the
alternative embodiment cover of FIG. 11 attached thereto;
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CA 02468481 2004-05-26
FIG. 13 is a perspective view of a rail in a first orientation with another
alternative embodiment cover attached thereto;
FIG. 14 is a perspective view of a rail in a second orientation with the
alternative embodiment cover of FIG. 13 attached thereto;
FIG. 15 is a perspective break-away view of another alternative
embodiment barrier system; and
FIG. 16 is an exploded perspective view of a rail, rail cover, and post.
DETAILED DESCRIPTION
For the purposes of promoting an understanding of the principles in
accordance with the disclosure, reference will now be made to the embodiments
illustrated in the drawings and specifc language will be used to describe the
same. It will nevertheless be understood that no limitation of the scope of
the
disclosure is thereby intended. Any alterations and further modifications of
the
inventive features illustrated herein, and any additional applications of the
principles of the disclosure as illustrated herein, which would normally occur
to
one skilled in the relevant art and having possession of this disclosure, are
to be
considered within the scope of the disclosure claimed.
It must be noted that, as used in this specification and the appended
claims, the singular forms °a " "an ° and "the° include
plural referents unless the
context clearly dictates otherwise.
In describing and claiming the present disclosure, the following
terminology will be used in accordance with the definitions set out below.
CA 02468481 2004-05-26
As used herein, the terms "comprising," "including," "containing,"
"characterized by," and grammatical equivalents thereof are inclusive or open-
ended terms that do not exclude additional, unrecited elements or method
steps.
"Interference fit" as used herein shall refer to the concept of a connection
between two members in which a portion of one member abuts some portion of
the other member in a manner that contactibly blocks the separation of the two
members.
Referring now to FIG. 1, an exemplary perspective break-away view is
shown of a barrier system of the present disclosure, indicated generally at
10.
The barrier system 10 may form a railing system for use with decks, porches,
stairs, or walkway, or a fence for use in defining a property boundary, for
example.
The barrier system 10 may include one or more rails 12 configured to be
supported in a laterally extending orientation. The rails 12 may be positioned
at
an upper portion and at a lower portion of the barrier system 10.
Alternatively, it
will also be appreciated that the barrier system 10 may utilize a single rail
12.
The barrier system 10 may also include a boundary-defining barrier
means 14. The boundary-defining barrier means 14 may include upright
members such as pickets, planks, balusters, or walls for example, of any of a
variety of shapes, sizes and styles, for defining a boundary. In the
embodiment
of FIG. 1, the boundary-defining barrier means 14 extends between the rails 12
to form part of a barrier system 10. It will be understood that the boundary-
defining barrier means 14 may include a plurality of upright members.
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CA 02468481 2004-05-26
The barrier system 10 may also include a rail cover 16 for receiving a rail
12. The rail cover 16 may be positioned on the top of the barrier system 10
and
may be shaped in various different styles and configurations to provide an
aesthetically pleasing appearance. Examples of some of the various different
styles of covers are depicted in FIGS. 7-14, designated by reference numerals
16a-16d. The rail cover 16 may also be configured so as to provide a gripping
surface such that the rail cover 16 can be grasped to provide support to a
person. Also, the rail cover 16 may have an exterior appearance similar to a
solid wood rail. The rail cover 16 may cover only a portion of the rail 12
such
that part of the rail 12 may remain visible even when the rail cover 16 is
attached. Ends of the barrier system 10 may be supported by a structure or
post
17, as shown in FIG. 16, for example. It will be appreciated that the certain
embodiments of the barrier system 10 may be formed with the rail cover 16,
whereas other embodiments of the barrier system 10 may be formed without the
rail cover 16.
Details of the rail 12 will now be explained with particular reference to
FIGS. 2-5. The rail 12 may include a first side wall 18 forming a first side
of the
rail 12, and a second side wall 20 forming a second side of the rail 12. The
rail
12 may also have a cross wall 22 extending between the first side wall 18 and
the second side wall 20. As shown in FIG, 2, the cross wall 22 may extend
between the first side wall 18 and the second side wall 20 at a top side 24 of
the
rail 12. However, it will be appreciated that the rail 12 may be oriented such
that
the cross wall 22 may be on a bottom side 28 of the rail 12.
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CA 02468481 2004-05-26
The rail 12 may also have one or more brace members 28 extending
between the first side wall 18 and the second side wall 20. The brace member
28 maybe a continuous wall or it may be formed as a series of discrete
members positioned along the length of the rail 12 to help provide strength to
the
rail 12. The brace member 28 may be centrally located between the top side 24
and the bottom side 28 of the rail 12. However, it will be appreciated that
the
brace member 28 may be spaced at any distance between the top side 24 and
the bottom side 26, and that any number of brace members 28 may be used.
A chamber 30 may be defined by the first side wall 18, the second side
wall 20, the cross wall 22, and the brace member 28. Similarly, a channel 32
may be defined by the first side wall 18, the second side wall 20, and the
brace
member 28. It will be appreciated that the boundary-defining barrier means 14
may be received in the chamber 30 or the channel 32 as discussed more fully
below.
The brace member 28 may have one or more ridges 34 for providing
support to the brace member 28, for contacting the boundary-defining barrier
means 14, or for locating and supporting brackets 35, as shown in FIG. 16, for
attaching the rail 12 to a post 17 or support structure, for example. The
brackets
35 may be formed in any manner known to those skilled in the art and may be
attached to the rail 12 with screws or any other variety of fasteners known in
the
art. The ridges 34 may extend along a length of the brace member 28. The
brace member 28 may also include grooves 36 for locating a center of the brace
member 28 for receiving the screws or drill bits for making openings for the
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CA 02468481 2004-05-26
screws. The grooves 36 may also extend along the length of the brace member
28. It will be understood that embodiments of the brace member 28 may be
formed without the ridges 34 or grooves 36, or that the quantity, shape and
location of the ridges 34 and grooves 36 may vary within the scope of the
present disGosure.
In one embodiment, the rail 12 may be formed in a one-piece unitary
manner such that the cross wall 22 may be formed integrally with the rail 12
so
as to be inseparable from the first side wall 18 and the second side wall 20.
Accordingly, no joints or seams may be formed between the cross wall 22 and
the first side wall 18 and the second side wall 20, or between the brace
member
28 and the first side wall 18 and the second side wall 20, in this embodiment.
It
will be appreciated that other embodiments of the rail 12 may be constructed
in
separable components within the scope of the present disclosure.
The rail 12 may also include means 38 for engaging with the rail cover 16
to attach the rail 12 to the rail cover 16. The engaging means 38 may be in
the
form of protrusions extending away from the rail 12. !n one embodiment, the
first
side wall 18 and the second side wall 20 may have exterior planar portions 40
and the engaging means 38 may be formed as protrusions that extend beyond
the plane defined by the planar portions 40. The engaging means 38 may be
curved and may have a radius defining a rounded configuration. However, it
will
be appreciated that the engaging means 38 may have various different shapes
and configurations within the scope of the present disclosure. The engaging
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CA 02468481 2004-05-26
means 38 may be received in the rail cover 16 to form an interference fit to
prevent the rail 12 from being pulled out of the rail cover 16.
It will be appreciated that the first side wall 18 and the second side wall 20
may have various different configurations, such as curved or angular shapes,
and need not have the planar portions 40. The rail 12 may be inserted into an
end of the rail cover 16 such that the engaging means 38 may be received in
receiving means 42 formed in the rail cover 16. The receiving means 42 may be
shaped to abut with the engaging means 38 to hold the rail 12 in place with
respect to the rail cover 16. However, the rail 12 may slide with respect to
the
rail cover 16 in a direction along a longitudinal axis 44 of the rail 12 to
locate the
rail 12 in a desired position.
Alternatively, it will be appreciated that the rail 12 and/or rail cover 16
may
be formed with flexible elastic properties that allow the rail 12 and/or rail
cover 16
to deflect. The rail 12 can therefore be inserted into the rail cover 16 along
the
length of the rail cover 16 rather than at the end of the rail cover 16. The
rail 12
and rail cover 16 may thus be configured to be connected together with a snap
fit.
The engaging means 38 may be formed on both the top side 24 and the
bottom side 26 of the rail 12. Accordingly, as can be seen by inspection of
FIGS.
2 and 3, the rail 12 may be attached to the rail cover 16 such that the cross
wall
22 may be positioned within the rail cover 16, as shown in FIG. 2.
Alternatively,
the rail 12 may be rotated by substantially 180 degrees with respect to the
rail
cover 16, about the longitudinal axis 44, such that the channel 32 may be
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CA 02468481 2004-05-26
positioned within the rail cover 16, as shown in FIG. 3. in other words, the
rail 12
may be placed in a first orientation, as shown in FIG. 2, or the rail 12 may
be
inverted to a second orientation as shown in FIG. 3.
Attachment of the barrier means 14 to the rail 12 will now be described.
The barrier means 14 may be received within the channel 32 as shown in FIG. 1.
The barrier means 14 may contact the brace member 28 at the ridges 34 to be
supported in an upward position. The first side wall 18 and the second side
wall
20 may support the barrier means 14 in a lateral direction.
To further support the barrier means 14 in a lateral direction along the
length of the rail 12, a cap 46 may be placed over the channel 32 as shown in
FIGS. 4-5. The cap 46 may have openings 48 for receiving the barrier means
14. The openings 48 may be formed in the cap 4f by any manner known in the
art such as using a router, or punching, stamping or cutting for example. As
such, the openings 48 may be placed in the cap 46 during manufacturing of the
cap 46, such that the openings 48 have predetermined spacings, sizes and
shapes. Alternatively, the openings 48 may be formed in the cap 46 at the time
of assembling the barrier system 10, such that the spacing, size and shape of
the openings 48 can be custom made. Placing the openings 48 in the cap 46
may provide an advantage in that the openings 48 need not be formed in the
rail
12. Forming openings in the rail 12 may weaken the rail 12 when the rail 12 is
formed of certain composite materials for example.
The cap 46 may be made of any suitable material known in the art such
as vinyl, metal, or composite materials, for example. The cap 46 may have
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CA 02468481 2004-05-26
attaching means 50 that may include a shaped portion of the cap 46 configured
for receiving the engaging means 38. Thus, the cap 46 may be attached to the
rail 12 with an interference fit. The shape of the attaching means 50 may
correspond to the shape of the engaging means 38 on the rail 12 to provide an
aesthetically pleasing and tight fitting connection that may not create a
protruding
ledge that may be prone to snagging or accumulating debris. It will be
appreciated that other attaching means such as fasteners or adhesives may also
be used to attach the cap 46 to the rail 12 within the scope of the present
disclosure.
Similar to the rail cover 16, the cap 46 may be attached to the rail 12 by
sliding the cap 46 over an end of the rail 12, or by deflecting the cap 46 to
snap
the cap 46 onto the rail 12. The cap 46 may also include ledges 52 to
facilitate
aligning the cap 46 on the rail 12, and holding the cap 46 in position with
respect
to the rail 12. Moreover, the rail 12 may include slots 54 for receiving an
edge
portion of the cap 46 so that the connection between the cap 46 and the rail
12
may be more secure and aesthetically pleasing.
With the cap 46 secured to the rail 12, the barrier means 14 may be
placed through the openings 48 such that the cap 46 may assist in providing
proper spacing and support for the barrier means 14. The position of the cap
46
may be moved with respect to the rail 12 so that the openings 48 can be
positioned as desired and the orientation of the barrier means 14 may be
adjusted. Thus, assembly of the barrier system may be facilitated.
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In an alternative orientation of the rail 12, as shown in FIGS. 3, 6, 8, 10,
12, and 14, a portion of the barrier means 14 may be received within the
chamber 30. Holes 56 may be formed in the cross wall 22 to accommodate the
barrier means 14, as best shown in FIG. 6. Similar to the openings 48 in the
cap
46, the holes 56 may be formed in any manner known in the art, either as the
rail
12 is manufactured, or as the barrier system 10 is assembled. Thus, the cross
wall 22 may be used to support the barrier means 14 when the rail 12 is
oriented
with the cross wall 22 in contact with the barrier means 14. It will be
understood
that in this orientation, the cap 46 may not be required.
Accordingly, the cross wall 22 and the cap 46 may collectively form a
supporting means for (i) supporting a first boundary-defining barrier means 14
in
position with respect to the rail 12 when the rail 12 is disposed in a first
orientation, and (ii) supporting a second boundary-defining barrier means 14
in
position with respect to the rail 12 when the rail 12 is disposed in a second
orientation, wherein the second orientation is rotated about the longitudinal
axis
44 by substantially 180 degrees from the first orientation.
It will be appreciated that the rail 12 may be configured to be versatile to
be used in various positions and orientations in the barrier system 10 within
the
scope of the present disclosure. For example, as shown in FIG. 1, the rail 12
may be used as part of the top rail and the bottom rail within the barrier
system
10. Moreover, embodiments of the rail 12 may be positioned in a central
portion
of the barrier system 10. Various different shapes and styles of rail covers
16
may be accommodated by the rail 12. An alternative embodiment barrier system
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CA 02468481 2004-05-26
10a, is shown in FIG. 6, in which the rail 12 may be used for only a bottom
rail,
and a different variety of rail, such as a connection rail or U-rail 58, may
be used
for a top rail. Similarly, the rail 12 may be used for only the tap rail.
Also, the rail
12 may be oriented such that the barrier means 14 may be received in the
channel 32, or in the chamber 30.
In one embodiment, the U-rail 58 may include recesses 60. The recesses
60 may be configured to receive fasteners for attaching the U-rail 58 to the
barrier means 14. It will be understood that the barrler means 14 may be
substantially hollow and may have a central bore extending along a length of
the
barrier means 14. The bore may be defined by interior brace structure and the
bore may be used for receiving fasteners to attach the U-rail to the barrier
means
14. Alternatively, the barrier means 14 may be solid such that fasteners may
be
located as desired. The recesses 60 may be located in the top of the U-rail 58
and/or the sides of the U-rail. Accordingly, when a fastener is placed in the
recess 80, the cover 16 may slide over the U-rail 58 without the fastener
contacting the cover 16 to interfere with the sliding movement between the
cover
16 and the U-rail 58. If will also be understood that recesses 60 may be
formed
in the rail 12 in a similar manner.
The engaging means 38 may be confgured, in one aspect of the
disclosure, to provide an aesthetically pleasing appearance. The rail 12 may
be
fom~ed to be symmetrical, such that the external appearance of the rail 12 may
be similar regardless of whether the rail 12 is oriented with the channel 32
on the
top, or the cross wall 22 on the top.
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CA 02468481 2004-05-26
The components of the barrier system 10 may be formed of various
different suitable materials within the scope of the present disclosure. For
example, components of the barrier system 10 may be formed of a PVC
material, andlor a metal material. Also, the barrier system may be formed of a
composite material made from materials such as a blend of wood flour and PVC
resin, for example, and the components may have an extruded PVC vinyl top
coating. The components of the present disclosure may also be formed of a
composite of polypropylene or polyethylene and wood. Some embodiments may
include inserts made of metal, such as aluminum, for added strength. Also, the
barrier system components may be made from a pultrusion process with fiber
reinforced material made from a blend of fiberglass and PVC resin, for
example,
with an extruded acrylic top coating, or any other suitable material known in
the
art may also be used to form the components of the barrier system 10.
As used herein, the term "pultrusion" refers to a process for
manufacturing reinforced profiles wherein a set of fibers is pulled through a
resin
bath and then through a heated die giving the profile its shape. After the
profile
passes through the die the profile may be cooled by air or water and cut into
desired lengths. The resin used may be of various materials such as
polyesters,
vinyl esters, and epoxies for example. Furthermore, various types of fibers
may
be added in the pultrusion process to produce profiles having different
characteristics, such as different strengths, hardnesses, or elasticities. The
fiber
may be either a fiber mat or a series of continuous fibers, or any other
suitable
fiber reinforcement. The pultruded fiber reinforced material may provide
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CA 02468481 2004-05-26
components having high hardness and strength characteristics and an attractive
high quality appearance.
Reference will now to made to FIG. 15 to describe another alternative
embodiment barrier system, indicated generally at 10b. As previously
discussed,
the presently disclosed embodiments illustrated herein are merely exemplary of
the possible embodiments of the disclosure, including that illustrated in FIG.
15.
It will be appreciated that the alternative embodiment illustrated in FIG. 15
contains many of the same structures represented in FIGS. 1-14 and only the
new or different structures will be explained to most succinctly explain the
features of the embodiment illustrated in FiG. 15.
The alternative embodiment barrier system 10b may include a rail 12a.
The rail 12a may include a first side wall 18a, a second side wall 20a, and a
cross wall 22a. The first side wall 18a and the second side wall 20a may be
characterized by an absence of protrusions. Moreover, the rail 12a may not
include openings in the cross wail 22a, and the rail 12a may be utilized
without a
cap. A cover 16e may be configured to receive the rail 12a, and the rail 12a
may
be oriented in two positions. For example, the rail 12a may be oriented such
that
the cross wall 22a is be on the top to form a top rail, or the rail 12a may be
oriented such that the cross wall 22a is on the bottom to form a bottom rail.
It will be appreciated that the structure and apparatus disclosed herein is
merely one example of a means for engaging (or engaging means), and it should
be appreciated that any structure, apparatus or system for engaging which
pertorms functions the same as, or equivalent to, those disclosed herein are
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CA 02468481 2004-05-26
intended to fall within the scope of a means for engaging, including those
structures, apparatus or systems for engaging which are presently known, or
which may become available in the future. Anything which functions the same
as, or equivalently to, a means for engaging falls within the scope of this
element.
Similarly, it will be appreciated that the structures and apparatus disclosed
herein are merely exemplary of a boundary-defining barrier means, receiving
means, supporting means, and attaching means, and it should be appreciated
that any structure, apparatus or system which performs functions the same as,
or
equivalent to, those disclosed herein are intended to fall within the scope of
a
boundary-defining barrier means, receiving means, supporting means, or
attaching means, including those structures, apparatus or systems which are
presently known, or which may become available in the future. Anything which
functions the same as, or equivalently to, a boundary-defining barrier means,
receiving means, supporting means, and attaching means falls within the scope
of these elements, respectively.
In accordance with the features and combinations described above, a
useful method of forming barriers includes the steps of:
(a) providing a plurality of rails each having a longitudinal axis, a channel
on one side and a cross wall on an opposing side;
(b) orienting one of the rails in a first orientation and placing a first
boundary-defining barrier means in the channel;
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CA 02468481 2004-05-26
(c) orienting another of the rails in a second orientation rotated
substantially 180 degrees from the first orientation about the longitudinal
axis;
(d) forming at least one hole in the cross wall; and
(e) placing a second boundary-defining barrier means in the hole.
Those having ordinary skill in the relevant art will appreciate the
advantages provide by the features of the present disclosure. For example, it
is
a feature of the present disclosure to provide a rail and barrier system that
is
simple in design and manufacture. Another feature of the present disclosure is
to provide such a rail that is versatile to be used in various orientations
and
positions within the barrier system, such that inventory of barrier system
components may be reduced. It is a further feature of the present disclosure,
in
accordance with one aspect thereof, to provide such a rail that has an
aesthetically pleasing appearance and which allows for assembly with or
without
cutting holes in the rail.
In the foregoing Detailed Description, various features of the present
disclosure are grouped together in single embodiments for the purpose of
streamlining the disclosure. This method of disclosure is not to be
interpreted as
reflecting an intention that the claimed disclosure requires more features
than
are expressly recited in each claim. Rather, as the following claims reflect,
inventive aspects lie in less than all features of the foregoing disclosed
embodiments. Thus, the following claims are hereby incorporated into this
Detailed Description by this reference, with each claim standing on its own as
a
separate embodiment of the present disclosure.
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CA 02468481 2004-05-26
It is to be understood that the above-described arrangements are only
illustrative of the application of the principles of the present disclosure.
Numerous modifications and alternative arrangements may be devised by those
skilled in the art without departing from the spirit and scope of the present
disclosure and the appended claims are intended to cover such modifications
and arrangements. Thus, while the present disclosure has been shown in the
drawings and described above with particularity and detail, it will be
apparent to
those of ordinary skill in the art that numerous modifications, including, but
not
limited to, variations in size, materials, shape, form, function and manner of
operation, assembly and use may be made without departing from the principles
and concepts set forth herein.
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