Note: Descriptions are shown in the official language in which they were submitted.
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LID FOR TOBACCO CONTAINER
FIELD OF THE INVENTION
[0001] This invention generally relates to lids for containers and, more
particularly, to a
lid for a tobacco container.
BACKGROUND OF THE INVENTION
[0002] Loose tobacco and related tobacco products are typically packaged and
sold in
disc-shaped containers. In many cases, the containers comprise a metal lid
seated upon
either a metal, plastic or cardboard container bottom. Often, a band-type
label is adhesively
secured over the seam between the lid and container to securely fasten the lid
and the
container. The band type label also typically will positively impact the
freshness of the
product. The label also typically includes print, images, and information
regarding the
tobacco product for a potential customer.
[0003] Conventionally, the lid includes a relatively flat top cover portion
and a
surrounding sidewall. The sidewall terminates in a cut edge. Considering that
lids are often
formed from metal (plastic lids are also common), a metal edge has the
potential to be
relatively sharp. If the sharp edges are not properly made smooth, a purchaser
of the
container may potentially risk suffering a laceration in one of their fingers
when prying the
lid from the container using the edges.
[0004] The interface between the container and the lid typically will have a
snap fit to
facilitate removal and attachment of the lid and the container. The interface
between the lid
and the container affects breathability and therefore freshness of the tobacco
product
contained therein. Thus, the interface between the lid and the container
includes multiple
configurations.
[0005] Further, the lid must be sufficiently strong to prevent flexure that
can
compromise the connection of the lid to the bottom. Typically, the strength of
the lid is
provided by using sheet metal material having a thickness of greater than or
equal to 0.007
inches.
[0006] The present invention is directed towards improvements over the state
of the art.
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BRIEF SUMMARY OF THE INVENTION
[0007] An improved lid for a tobacco container is provided. The lid includes a
strengthening feature that allows for a thin gauge sheet metal to be utilized.
In an
embodiment, the strengthening feature may be configured to be used to
additionally
interlock the lid to the container bottom.
[0008] In a further preferred embodiment, the metal lid has a sheet metal body
having a
reduced gauge thickness of less than 0.007 inches. In a further embodiment,
the sheet metal
is double reduced sheet steel. The sheet metal body is formed into a lid for a
tobacco
container and has a circular periphery of between about two and about four
inches with a
sidewall depending downward therefrom. The sidewall has a strengthening
feature formed
thereon to accommodate the reduced gauge thickness. The strengthening feature
may be
located at any height along the sidewall, from a distal end of the sidewall to
any appropriate
height to accommodate interlocking the lid to the container bottom.
[0009] In another embodiment, the invention provides a method for
manufacturing a
metal lid for a tobacco container comprising the steps of first selecting a
sheet metal that is
less than sixty five pound double reduced sheet steel material. A lid having a
circular
periphery is then formed from the sheet steel material, the lid having an
upper wall and a
sidewall with a distal end. The distal end of the sidewall is then curled
radially inward. A
further subsidiary step of this method may include folding a portion of the
sidewall radially
inward thereby displacing the curl therewith.
[0010] In yet another embodiment, a tobacco container is provided. The tobacco
container comprises a sheet metal body formed into a lid for a tobacco
container. The lid
has an upper wall with a radius of between about 1 inch to about 2-3/4 inches
and annular
sidewall depending downward from the upper wall, and having a terminating end.
A curl is
formed on the terminating end, a curl is then formed on the terminating end. A
further
subsidiary feature of this embodiment may include a container bottom having a
bottom wall
and an annular sidewall having a bead located on the sidewall that is adapted
to interlock
with the lid. The curl may be partially flattened to include top and bottom
curved segments
and a flattened extension segment joining the two, the flattened extension
being flatter
relative to the top and bottom curved segments.
[0011] In one implementation, the curl functions as a strengthening feature
allowing for
a sheet metal with a gauge thickness of less than .007 inches to be used. In
another
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implementation, the curl also functions as a connecting portion for
cooperating with a
corresponding connecting feature of the container bottom. In an even more
preferred
implementation, the strengthening feature is generally hook shaped in cross-
section, having
an arcuate head portion. More particularly, the hook shape of the illustrated
embodiment is
a circular hook shape.
[0012] Other aspects, objectives and advantages of the invention will become
more
apparent from the following detailed description when taken in conjunction
with the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The accompanying drawings incorporated in and forming a part of the
specification illustrate several aspects of the present invention and,
together with the
description, serve to explain the principles of the invention. In the
drawings:
[0014] FIG. 1 is a top and front perspective view of an exemplary embodiment
of a
tobacco container including a lid accordance with the teachings of the present
invention;
[0015] FIG. 2 is a cross section view of the container of FIG. 1;
[0016] FIG. 3 is a top plan view of the container of FIG. 1;
[0017] FIG. 4 is a cross-sectional view of the lid of FIG. 1;
[0018] FIG. 5 is an enlarged partial sectional view of the lid of FIG. 1;
[0019] FIG. 6 is an enlarged partial cross-sectional view of the lid of the
container of
FIG. 1 further illustrating the lid installed on a container bottom;
[0020] FIG. 7 is a cross-section view of the lid of FIG. 1 illustrating an
alternative
embodiment of the lid; and
[0021] FIG. 8 is an enlarged partial cross-sectional view of the lid of FIG.
7.
[0022] While the invention will be described in connection with certain
preferred
embodiments, there is no intent to limit it to those embodiments. On the
contrary, the intent
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is to cover all alternatives, modifications and equivalents as included within
the spirit and
scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to FIG. 1, a container 10 is illustrated. The container 10 is
typically
employed to house chewing tobacco or other goods suitable for retail purchase
by a
consumer. In that regard, the container 10 has an overall size that allows a
consumer to
comfortably hold the container within the palm of a hand and to store the
container within a
shirt pocket or in the rear pocket of a pair of blue jeans. Typically the size
for facilitating
these tobacco container functions is approximately 2 1/2 inches in diameter
and
approximately 1 inch in axial thickness. However, the container could be
larger or smaller
such as between 1 1/2 and inches in diameter and between 1/2 and 1 1/2 inches
in axial
thickness.
[0024] The tobacco container 10 may include features that make the container
more
aesthetically pleasing such as, for example, color, images or prints, labels,
embossing, and
the like. The container 10 may also be secured together by, for example, a
band-type
adhesive label (not shown) during a packaging process. After the label has
been broken, the
container 10 may be repeatedly opened and closed such that the consumer may
access, as
often as desired, a chosen amount of the contents stored in the container 10.
[0025] As shown in FIG. 1, the container 10 is formed when a generally
cylindrical
container bottom 12 receives a generally cylindrical lid 14 (a.k.a., cover).
The container
bottom 12 may be suitably formed from a variety of different materials, or
combinations
thereof, such as metal, plastic, cardboard, and the like. In the illustrated
embodiment, the
container bottom 12 is formed from a plastic material. The plastic of the
container bottom
12 may be either transparent, translucent, or opaque depending on the desired
use of the
container 10 and whether the contents, or lack of contents, within the
container are to be
externally viewable.
[0026] Now referring to FIG. 2, the container bottom 12 is illustrated as
generally
cylindrical, having a bottom 94 and a sidewall 90 generally transverse to the
bottom 94.
The sidewall 90 has an inner and an outer face 91, 92. As will be described in
more detail
below, the container bottom 12 is adapted to receive and interlock with the
lid 14.
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[0027] Still referring to FIG. 2, in the illustrated embodiment the lid 14 is
formed from
a relatively thin piece of metal (e.g., sheet metal). Preferably, the lid is
manufactured from
a double reduced sheet steel that has a reduced gauge of less than sixty five
pounds, thereby
allowing the lid 14 to have a thickness of approximately no greater than 0.007
inches.
However, due to the configuration of features of the lid 14 that are more
fully described
below, other metals such as, by way of non-limiting example only, aluminum or
other steel
materials may be used to produce the lid 14.
[0028] As illustrated in FIG. 2, the lid 14 includes an upper wall 16 and a
skirt in the
form of a cylindrical sidewall 20. The juncture of the sidewall 20 and the
upper wall 16
defines a shoulder 18 that may provide an optional upper annular recessed
pocket for
receiving an upper end of the container bottom 12. In the illustrated
embodiment, the upper
wall 16, shoulder 18, and sidewall 20 form a one piece construction, i.e.
formed from a
continuous single blank of material not from an assembly of parts. However,
the upper wall
16 and sidewall 20 may be mechanically joined by welding, brazing, or other
similar
methods forming shoulder 18 such that the lid is an assembly of parts. As
shown in FIG. 2,
when the lid 14 is positioned or seated upon the container, an enclosed
storage cavity 24 is
defined within the container 10. The storage cavity 24 is where the tobacco
products are
held until removed by the consumer.
[0029] As depicted in FIG. 3, because the lid 14 and the container bottom 12
are both
generally circular in shape, they define and share a common center point 26.
The upper
wall 16 of the lid 14 generally extends radially outwardly from the center
point 26 between
about 1/2 inch and about 2 inches. Therefore, the lid has a diameter 47 of
between about
one inch and about 4 inches. However, the diameter may be larger or smaller in
other
embodiments. In the illustrated embodiment of FIG. 2, the diameter 47 of the
lid 14 is
about 2.3 inches. Although a generally circular shape is illustrated, in other
embodiments,
the lid 14 and the container bottom 12 may be provided in other shapes.
[0030] Referring back to FIG. 2, the upper wall 16 includes both a bottom and
a top
surface 15, 17 (i.e., interior and exterior surface) facing in opposing
directions. As the lid
14 is formed from sheet metal, the bottom and top surfaces 15, 17 are parallel
to each other
such that the upper wall 16 may be considered generally planar or flat.
Although not
shown, the upper wall 16 may include embossed letters, numbers, images, and
the like
(collectively "characters"). The embossed characters may project upwardly away
from the
container or project downwardly into the storage cavity 24. In that regard,
the embossed
characters either have a height or depth of about 0.015 of an inch or less.
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[0031] In the illustrated embodiment of FIG. 3, any embossed characters formed
on the
upper wall 16 are situated radially inward of an embossing limit 32
(represented by a dashed
line) and within an embossing portion 34 of the upper wall 16. As shown, the
embossing
limit 32 generally extends radially outwardly from the center point 26 of the
upper wall 16
about half an inch to about one inch. Therefore, a diameter 49 of the
embossing limit 32 is
about one inch to about two inches. In the illustrated embodiment of FIG. 3,
the diameter
49 of the embossing limit 32 is 1.85 inches.
[0032] Still referring to FIG. 3, in the illustrated embodiment, an annular
non-embossed
flat portion 36 of the upper wall 16 separates the shoulder 18 and the
embossing portion 34.
The purpose of this flat non-embossed portion 36 is to facilitate proper
bending and folding
operations (a.k.a. hemming operations) of the lid 14 sidewall 20 within tight
tolerances
during metal forming operations for proper interface, snap-fit and freshness
functions. The
inside diameter of the annular flat portion 36 is spaced apart from the center
point 26 of the
upper wall 16 between about 3/4 inch and about 1 1/4 inches.
[0033] Moving to FIG. 4, as illustrated, the shoulder 18 is unitarily formed
with the
upper wall 16 and the sidewall 20. The shoulder 18 extends radially between
about 0.05 of
an inch and about 0.3 of an inch, and upwardly from the upper wall about 0.01
of an inch
and about 0.2 inches. Alternatively, when there is no optional recessed
section, the shoulder
will not extend upwardly from the upper wall 16 at all and will merge directly
into the upper
wall 16.
[0034] Although illustrated in FIG. 5 as including the shoulder 18 having a
radius 100
and a ramped portion 102 causing a recess to be formed in the upper wall 16,
the upper
wall 16 and sidewall 20 may form a juncture at the radius 100 and not
incorporate a ramped
portion 102. See for example FIGS. 7 and 8. In such an embodiment, the upper
wall 16 is
generally planar from the center of the lid 14 to its circular periphery.
Further, as illustrated
in FIG. 4, a flat may be formed between the radius and the ramped portion.
[0035] Returning to FIG. 5, an enlarged, partial cross-section of the lid 14
is illustrated.
In the illustrated embodiment, the shoulder 18 includes the ramped segment 102
and the
radius 100 that facilitates the transition from the upper wall 16 to sidewall
20. Extending
circumferentially about the center 26 (See FIG. 3) and downwardly from the
shoulder 18 is
the sidewall 20. The sidewall 20 includes an outer annular wall segment 54, a
fold 40, an
inner annular wall segment 52, a transitional segment 112, and a curl 114, all
of which also
extend circumferentially about the center 26, forming generally annular
features. As used
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herein annular may encompass more than circular and can include, for example,
oblong,
oval, elliptical, etc.
[0036] The inner and outer annular wall segments 52, 54 radially overlap and
are joined
by the fold 40. The outer annular wall segment 54 extends axially straight and
away from
the upper wall 16 and terminates at the fold 40. The inner annular wall
segment 52 extends
axially straight and toward the upper wall 16 starting from the fold 40 and
terminating at the
transitional segment 112. In a preferred embodiment, the inner annular wall
segment 52 is
generally parallel to the outer annular wall segment 54, albeit radially
spaced inward
therefrom. The inner annular wall segment 52 may extend axially upward a
distance that
may be varied in different embodiments in order to adjust the strength and
rigidity of the lid,
as well as accommodate interlocking with various configurations of container
bottom 12.
Further, the inner annular wall segment 52 may be entirely omitted, as will be
discussed in
more detail below.
[0037] Interposed between the inner and outer annular wall segments 52, 54 is
an
annular gap 110, due to the wall segments 52, 54 being generally parallel to
one another and
radially overlapping. However, in alternative embodiments the gap 110 could be
eliminated
such that wall segments 52, 54 radially contact and/or the inner and outer
annular wall
segments 52, 54 be skewed and not parallel. Further, wall segments 52, 54 may
extend at
slight angles relative to one another.
[0038] The transitional segment 112 extends radially inward of and away from
the inner
annular wall segment 52, and terminates at the curl 114. Once in its folded
configuration
described above, lid 14 has an overall height extending from the shoulder 18
to the fold 40
of between about 0.1 to about 0.5 inches, and more preferably about 0.25
inches.
[0039] Fold 40 provides a periphery that is rounded and smooth. Therefore,
because the
sidewall 20 incorporates the fold 40, it need not be smoothed, ground, buffed,
or otherwise
machined to eliminate a sharp edge. The fold 40 may therefore serve as a
safety at the
bottom of the lid 14. Also, the fold 40 allows the lid 14 to be more quickly,
easily, and
cost-effectively fabricated since there is no additional machining required to
remove a sharp
edge.
[0040] Still referring to FIG. 5, the curl 114, as illustrated, is hook shaped
and includes
a first curl segment 118, a radial apogee 120, a second curl segment 122, and
a third curl
segment 124. In the illustrated embodiment, the curl 114 is formed by a
terminating end of
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sidewall 20. The curl 114 acts as a strengthening feature as well as a
connecting feature for
connecting the lid 14 to container bottom 12 as will be more fully described.
[0041] The first curl segment 118 is arcuate generally and extends generally
radially
inward. The first curl segment 118 begins at the transitional segment 112 and
terminating at
the radially inward radial apogee 120. The second curl segment 122 is arcuate
generally
and begins at the radial apogee 120 and extends radially outward to an axial
apogee, closest
to shoulder 18.
[0042] The third curl segment 124 begins at the axial apogee and bends axially
back
towards fold 40 and axially away from shoulder 18. The third curl segment 124
includes a
portion that is generally tangent to an inner surface 126 of the outer annular
wall segment
54. In one embodiment, the third curl segment 124 maintains engagement with
the inner
surface 126 of the outer annular wall segment 54. However, in other
embodiments, third
curl segment 124 need not contact sidewall 54. The first, second, and third
curl segments
118, 122, 124 together define an annular channel 116.
[0043] While, as illustrated, curl 114 generally has a hook shape, it may be
formed into
a variety of other configurations. Typically, the radial apogee 120 of the
curl 114 is radially
inward from the inner surface 126 a distance of about 0.015 to about 0.15
inches, but is
preferably about 0.025 inches. The curl 114 is typically interposed between
the upper wall
16 and the transitional segment 112.
[0044] Further, the hook shape formed by the curl 114 and inner annular wall
segment
52 radially inwardly offsets the radially inner apogee 120 of curl 114 inward
from an inner
surface of the inner annular wall segment 52. Thus, the hook shape, in cross-
section, forms
a generally "?" profile. These hook shapes are only when viewed in cross-
section, and are
actually annular structures.
[0045] The sidewall 20 and particularly the inclusion of the strengthening
feature in the
illustrated form of curl 114 provide a sufficient amount of strength and
rigidity to allow the
lid 14 to have a reduced wall thickness t than that of typical lids,
preferably less than .007
inches thick.
[0046] Further, as the curl 114 is formed from a distal end portion of the
inner annular
wall segment 52, rather than a bead formed in the outer annular wall segment
54, the outer
annular wall segment 54 has an outer surface that is substantially cylindrical
(i.e. excluding
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the portions of the shoulder 18 and fold 40) with a constant radius at all
axial locations
along the outer annular wall segment 54. Thus, the container 10, when
assembled, can form
a substantially cylindrical container (i.e. excluding the shoulder 18, fold 40
and any gaps
formed between the container lid 14 and container bottom 12).
[0047] The lid 14 is typically manufactured by forming the lid 14 in stages
using a
plurality of progressive tooling, such as progressive dies, rollers and the
like. These stages
may also be referred to as hemming.
[0048] After forming a generally cup-shaped member, a first tool is typically
used to
form the curl 114. A second tool may then be used to form fold 40 thereby
defining the
inner and outer annular wall segments 52, 54 such that they are in an angular
relationship
and generally transverse and typically perpendicular to one another. A third
tool may then
be used to orient the inner and outer annular wall segments 52, 54 such that
they are
generally parallel to one another. A fourth tool may be used to form the
transitional
segment 112 and place the inner annular wall segment 52 proximate to the inner
surface 126
of the outer annular wall segment 54 and the third curled segment 124 against
and in
engageable contact with the inner surface 126.
[0049] In other embodiments, a single tool may be used to form the curl 114
and fold
the inner and outer annular wall segments 52, 54 such that they are generally
transverse and
typically perpendicular to one another. Also in other embodiments, and as
opposed to using
a progressive tooling process for locating the curl 114 in its final position,
a single tool may
be used to orient the inner and outer annular wall segments 52, 54 such that
they are parallel
and the third curl segment 124 is located in contact with the inner surface
126 of the outer
annular wall segment 54, thus removing the need for the third tool as
described above.
[0050] In the illustrated embodiment of FIG. 2, the inner surface 15 of the
upper wall
16, interior surface 126 of the outer annular wall segment 54, the inner
annular wall
segment 52, and the curl 114 are coated with a gold phenolic finish. Even so,
in other
embodiments other types of coatings or finishes may be applied to, or formed
on, these
interior surfaces.
[0051] Referring now to FIG. 6, the lid 14 is illustrated installed on the
container
bottom 12. An outer surface 92 of the container bottom 12 contains a
circumferential bead
78. As such, when the lid 14 is installed and interlocked on the container 12,
the curl 114
and the bead 78 are in direct contact and engaged with one another. As such,
the curl 114 of
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the illustrated embodiment acts as both a strengthening feature as indicated
above as well as
a connector (a.k.a. a connecting feature) for securing the lid 14 to the
container bottom 12.
Once installed, there is an annular gap 56 radially between the inner annular
wall segment
and the outer surface 92 of the container 12. The annular gap 56 is typically
between about
0.005 and about 0.050 of an inch.
[0052] The gap 56 aids in guiding the lid 14 onto the container 12. As
illustrated, the
lid 14 and the container bottom 12 may be telescopically coupled together to
form the
container 10 and hold the product. In addition, the gap 56 enables the
consumer to better
grasp or grab the lid 14, particularly the fold 40, with their fingers when
separating the lid
14 from the container 12. To secure the lid 14 to the container, the lid 14 is
biased axially
downward until the curl 114 slips over the bead 78 forming an axial snap fit
and/or
interference fit therebetween.
[0053] An inner surface 93 of the shoulder 18 is in contact with a distal end
19 of the
container sidewall 90, preventing the lid 14 from further downward axial
movement.
However, as described above, the lid 14 may also be supplied in a
configuration that does
not incorporate a shoulder 18 as illustrated. When supplied as such, the
bottom surface 15
of the upper wall 16 may be in contact with the distal end 19 when the lid 14
is installed
upon the container bottom 12. This contact provides a seal between the
container bottom 12
and the lid 14.
[0054] To separate the lid 14 from the container bottom 12, the lid is biased
axially
upward until the curl 114 again slips over the bead 78. Once the curl 114 is
vertically above
the bead 78, the lid 14 may be freely lifted clearly of the container bottom
12 without
further interference. The process of securing and removing the lid 14 to and
from the
container 12 may be repeated as often as access to the contents of the storage
cavity 24 is
desired. The bead 78 may be defined by a single continuous rib, projection or
shoulder
extending circumferentially about the container sidewall 90 or alternatively
by a plurality of
angularly spaced intermittent ribs, shoulders or projections.
[0055] Turning now to FIGS. 7 and 8, an alternative embodiment of the lid 214
is
illustrated. A terminating end of the sidewall 220 is curled radially inward
at fold 240
forming curl 252. In this embodiment, the upper wall 216 of lid 214 does not
incorporate a
recess. In this embodiment as illustrated, the upper wall 216 of the lid 214
meet at a
junction defined by a shoulder 153.
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[0056] Referring particularly to FIG. 8, a more detailed view of the curl 252
is
illustrated. In the illustrated embodiment, the curl 252 has been mechanically
flattened. As
such, curl 252 includes fold 240 (a.k.a. a bottom curved segment), a flattened
extension
segment 258, and a top curved segment 260. The flattened extension segment 258
is
thereby radially inward of the outer annular wall segment 254 a distance
greater than at least
the thickness of the sidewall 220. As illustrated, top curved segment 260 of
the sidewall
220 does not engage the outer annular wall segment 254, thereby creating a
radial gap 253
between a distal end of top curved segment 260 and the outer annular wall
segment 254.
The distal end of the top curved segment radially faces the inner surface of
outer annular
wall segment 254. However, the curl 252 may also be formed such that the top
curved
segment 260 engages the outer annular wall segment 254. The fold 240, the
flattened
extension segment 258, and the top curved segment 260 together define an
annular channel
262 having a width greater than the thickness of the sidewall 20.
[0057] Still referring to FIG. 8, although illustrated as a flattened curl
252, the curl may
also remain in an unflattened state, as shown in FIG. 6, i.e. by not
flattening extension
segment 258.
[0058] From the foregoing, those skilled in the art will recognize that the
lid for the
tobacco container has an improved strengthening feature, the curl, that allows
for the lid to
be machined from a sheet metal having wall thickness less then 0.007 inches,
thus reducing
overall material cost.
[0059] All references, including publications, patent applications, and
patents cited
herein are hereby incorporated by reference to the same extent as if each
reference were
individually and specifically indicated to be incorporated by reference and
were set forth in
its entirety herein.
[0060] The use of the terms "a" and "an" and "the" and similar referents in
the context
of describing the invention (especially in the context of the following
claims) is to be
construed to cover both the singular and the plural, unless otherwise
indicated herein or
clearly contradicted by context. The terms "comprising," "having,"
"including," and
"containing" are to be construed as open-ended terms (i.e., meaning
"including, but not
limited to,") unless otherwise noted. Recitation of ranges of values herein
are merely
intended to serve as a shorthand method of referring individually to each
separate value
falling within the range, unless otherwise indicated herein, and each separate
value is
incorporated into the specification as if it were individually recited herein.
All methods
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described herein container be performed in any suitable order unless otherwise
indicated
herein or otherwise clearly contradicted by context. The use of any and all
examples, or
exemplary language (e.g., "such as") provided herein, is intended merely to
better
illuminate the invention and does not pose a limitation on the scope of the
invention unless
otherwise claimed. No language in the specification should be construed as
indicating any
non-claimed element as essential to the practice of the invention.
[0061] Preferred embodiments of this invention are described herein, including
the best
mode known to the inventors for carrying out the invention. Variations of
those preferred
embodiments may become apparent to those of ordinary skill in the art upon
reading the
foregoing description. The inventors expect skilled artisans to employ such
variations as
appropriate, and the inventors intend for the invention to be practiced
otherwise than as
specifically described herein. Accordingly, this invention includes all
modifications and
equivalents of the subject matter recited in the claims appended hereto as
permitted by
applicable law. Moreover, any combination of the above-described elements in
all possible
variations thereof is encompassed by the invention unless otherwise indicated
herein or
otherwise clearly contradicted by context.
