Note: Descriptions are shown in the official language in which they were submitted.
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LEAK-PROOF PACKAGING FOR WET BATTERIES
FIELD OF THE INVENTION
This invention related generally to packaging for transportation of hazardous
goods and, more particularly, to packaging of damaged or leaking batteries
filled with
corrosive liquids such as lead acid.
BACKGROUND OF THE INVENTION
Various types of batteries are everywhere in the modern life. And, most
batteries are considered hazardous materials (also called dangerous goods).
Some
batteries contain corrosive liquid, which can injure people or damage
property. If not
properly packaged, shipments of such batteries may cause a variety of problems
during transport. In addition, failure to comply with the regulations or
packaging
requirements may result in a fine or even jail time.
Most common example of such batteries are charged wet batteries or wet cell
batteries which are typically filled with corrosive acid or alkali and are
regulated for
shipments as Class 8 ¨ corrosive. Wet batteries are common in vehicles,
utility
systems, un-interruptible power systems and industrial machinery. These
commodities must be correctly identified, classified, packaged, marked and
labeled.
UN numbcrs provide proper shipping names for wet batteries and include UN 2794
for wct batteries used for electric storage and filled with acid, UN 2800 for
wet
batteries used for electric storage, UN 2795 for wet batteries used for
electric storage
and filled with alkali, and UN 2800 for nonspillable wet batteries.
Shipments of such batteries are subject to regulations issued by the U.S.
Department of Transportation (DOT), and International Civil Aviation
Organization
(ICAO). These regulations are devised to ensure the safe transportation of
hazardous
materials ¨ including batteries ¨ shipped by highway, rail, water, or air.
Presently, the
batteries should be packaged and tested according to 49 CFR 173.159 for U.S.
shipments, or IATA Section 5, Packing Instruction 870 (2011 edition).
Various carriers such as FedEx, DHL, or UPS, provide special packaging for
wet batteries and require their customers to comply with the regulations.
General
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wet-battery packaging guidelines include packaging of wet cell batteries in
containers
which include metal containers, with acid/alkali leakproof liner ¨sealed to
prevent
leakage. Batteries are required to be placed into a sturdy outer container and
be
securely fastened with fill openings and vents facing up to prevent short-
circuiting or
overheating. All terminals must be protected against short circuit. While many
carriers provide packaging which generally follows the guidelines, such
packaging is
typically not suitable for shipping of damaged leaking batteries. Packaging
which is
available for damaged batteries, often has an irregular shape such as round
plastic
buckets or barrels which take much extra space along other packages which are
mostly rectangular. Moreover, available packaging is typically fully sealed
with
adhesive or adhesive tape which requires at least partial breakage of the
packaging in
the event of a need to open the package for inspection prior to the package
reaching
its destination. In such event, the package has to be reassembled which
requires
additional supplies that may not bc available at the inspection site.
It would be desirable to have leak-proof packaging that is suitable for
transporting damaged or leaking wet batteries and which overcomes problems
referred to above.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an improved leak-proof packaging
for damaged or leaking batteries, such packaging overcoming some of the
problems
and shortcomings of the prior art, including those referred to above.
Another object of the invention is to provide a leak-proof packaging which is
simple in assembly and leak-proof packing of damaged or leaking batteries for
safe
transportation.
Another object of the invention is to provide a leak-proof packaging which
substantially eliminates the possibility for erroneous assembly to
substantially avoid
improper packaging of damaged or leaking batteries.
Still another object of the invention is to provide an improved leak-proof
packaging which allows easy access to the packaged batteries for inspection
during
transportation.
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Yet another object of the present invention is to provide an improved leak-
proof packaging which allows re-closing free of additional supplies.
IIow these and other objects are accomplished will become apparent from the
following descriptions and the drawings.
SUMMARY OF THE INVENTION
The present invention provides an improved protective leak-proof packaging
designed for safe transportation of defective or old batteries containing
corrosive
liquids such as lead acid.
The inventive package has at least three layers and includes an inner
container
configured to accept the battery therewithin, a fluid-impermeable intermediate
container sealing the inner container thercwithin, and an outer container
enclosing the
intermediate container.
The inner container is preferably formed by an inner-container surrounding
wall which includes an inner-container topwall. The inner container topwall
forms an
= inner-container closure of an inner-container access opening. The inner
container is
preferably made of an absorbent material. It is preferred that the package
includes at
least one absorbent pad along an inner-container bottomwall.
It is preferred that the fluid-impermeable intermediate container be a plastic
bag which has a top end forming a fluid-impermeable lock. The fluid-
impermeable
lock preferably has an interlocking groove and ridge which form a fluid-tight
seal
when engaged together. The intermediate-container bag is protected from
puncture
by being between the inner and outer containers, i.e., thc inner container
protects the
bag from being punctured by the battery and the outer container protects the
bag from
exterior elements.
The outer container is preferably formed by an outer-container surrounding
wall which includes an outer-container topwall. The outer-container topwall
forms an
outer-container closure of an outer-container access opening.
It is preferred that the inner container is of a cushioning material and the
outer
container is of a substantially stiff material. The inner and outer containers
are each
preferably made of corrugated cardboard.
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In preferred embodiments, the inner container is made of a sheet material
which is folded and erected to form a substantially rectangular box which has
the
inner-container surrounding wall. The inner-container surrounding wall
includes an
inner-container bottomwall and an inner-container sidewall which extends from
the
bottomwall. The inner-container topwall is connected to thc inner-container
sidcwall.
The inner-container surrounding wall is preferably substantially free of three-
way-corner sidewall junctions with the inner-container topwall and with the
inner-
container bottomwall. The sheet forming the inner container is preferably cut
at
positions adjacent to the three-way junctions to remove what otherwise be
pointed
corners. In other words, the corners of the inner container are preferably cut
off to
minimize puncturing of the intermediate plastic bag which envelopes the inner
container.
The outer container is made of a sheet folded and erected to form a
substantially rectangular box protecting the intermediate bag from puncture by
external elements. The outer-container surrounding wall includes an outer-
container
bottomwall and an outer-container sidewall which extendes from the outer-
container
bottomwall. The outer-container topwall is connected to the outer-container
sidewall.
The closures of the inner, outer and intermediate containers are preferably re-
closeable permitting repeated opening and closing of the leak-proof package.
The
inner and outer-container closures and the fluid-impermeable lock are
preferably
adhesive-free.
The inner-container closure is preferably formed by overlapping inner-
container topwall flaps each extending from a corresponding portion of the
inner-
container sidewall. It is preferred that the outer-container closure includes
a locking
tab which is integral with and extends from the outer-container sidewall. The
outer-
container closure preferably includes a major flap which extends from a first
portion
of the outer-container sidewall. The major flap overlaps a pair of minor flaps
each of
which extends from one of second and third portions of the outer-container
sidewall
and is adjacent to a fourth portion. The major flap preferably terminates with
a
transverse interior flange which defines an aperture therethrough. The locking
tab
preferably extends from a fourth portion of the outer-container sidewall
opposite the
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first outer-sidewall portion and through the flange aperture to hold thc
flange against
an interior surface of the fourth outer-sidewall portion.
In preferred embodiments, the package further includes a fluid-impermeable
innermost container which is configured to seal the battery therewithin and
has a top
end forming a fluid-impermeable lock. It is preferred that the innermost
container be
a plastic bag and the fluid-impermeable lock include an interlocking groove
and ridge
that form a fluid-tight seal when engaged together.
The package preferably further includes an inner spacer for positioning over
the battcry to limit battery movement. The inner spacer is preferably of a
cushioning
material. It is also preferred that a plurality of buffers be positioned
between the
intermediate container and the outer-container surrounding wall.
Another aspect of the present invention is a method for packaging at least one
battery containing corrosive liquid. In the inventive method, the inner
container is
enveloped with the fluid-impermeable intermediate container which has the
fluid-
impermeable lock at its top end. The inventive packaging is further assembled
by
putting the intermediate container into the outer container. The battery is
loaded into
thc inner container and the access opening of the inner container is closed
with the
battery within the inner container. The fluid-impermeable lock of the
intermediate
container is then sealed with the inner container being inside the
intermediate
container. The packaging of the battery is completed by locking the access
opening of
the outer container with the battery being inside the inner container which is
sealed
inside the intermediate container inside the locked outer container such that
the liquid-
containing defective battery is protectively packaged for leak-free
transportation.
It is preferred that the battery is loaded into the inner container after thc
inner
container is enveloped by the intermediate container. It is also preferred
that
intermediate container which envelopes the inner container is put inside the
outer
container prior to loading the battery into the inner container. The inner and
outer
containers protect the bag from puncture by the battery and external elements,
respectively.
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In preferred embodiments, the fluid-impermeable lock of the intermediate
container is sealed by engaging the interlocking groove and ridge of the fluid-
impermeable lock which forms the fluid-tight seal.
It is preferred that at least one absorbent pad be positioned along an inner-
container bottomwall before the battery is loaded into the inner container.
An inner spacer is preferably placed over the battery to limit battery
movement. It is also preferred that a plurality of buffers are inserted inside
the outer
container, each buffer being between the intermediate container and the outer
surrounding wall.
In preferred embodiments of the inventive method, prior to loading the battery
into the inner container, the battery is preferably inserted into the fluid-
impermeable
innermost container which has a top end forming a fluid-impermeable lock.
Prior to
the battery being inserted into the innermost container, the innermost
container is
preferably placed inside the inner container. The innermost container is
preferably a
plastic bag with the fluid-impermeable lock including an interlocking groove
and
ridge which form the fluid-tight seal when engaged together. The fluid-
impermeable
innermost container is sealed with the battery therewithin.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is an exploded perspective view of a leak-proof packaging of the
present invention.
FIGURE 2 is an exploded perspective view of another embodiment of the
leak-proof packaging of the present invention including a second fluid-
impermeable
container.
FIGURE 3 is an exploded perspective view of yet another embodiment of the
leak-proof packaging of the present invention with the second fluid-
impermeable
container having a hermetic seal.
FIGURE 4 is a plan view of a sheet material cut for an inner container.
FIGURE 5 is a plan view of a sheet material cut for an outer container.
FIGURE 6 is a top plan view of an inner spacer and showing exemplary length
and width of the inner spacer.
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FIGURE 7 is a side plan view of the inner spacer of FIGURE 6 and showing
an exemplary thickness of the inner spacer.
FIGURE 8 is a top plan view of a buffer and showing exemplary length and
width of the buffer.
FIGURE 9 is a side plan view of the buffer of FIGURE 8 and showing an
exemplary thickness of the buffer.
FIGURE 10 is a plan view of an absorbent pad and showing exemplary length
and width of the pad.
FIGURE 11 is another plan view of the absorbent pad of FIGURE 10 and
showing an exemplary fold line of the pad.
FIGURE 12 is a plan view of the absorbent pad of FIGURE 10 being folded
and showing the length and width of the folded pad.
FIGURE 13 is a fragmentary cross-sectional view of a bottom portion of the
inner container and illustrating positioning of the absorbent therein.
FIGURE 14 is a plan view of a plastic bag and showing exemplary
dimensions thereof.
FIGURE 15 is a perspective view of the assembled and closed the leak-proof
packaging of the prcsent invention.
FIGURE 16 is an illustration of a user loading the battery into the leak-proof
packaging of the present invention.
FIGURE 17 is a perspective view of the inner container showing cut corners
minimizing puncturing of the intermediate-container bag.
FIGURE 18 is a fragmentary perspective view of the inncr container of
FIGURE 17.
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DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIGURES 1-13 illustrate an improved protective leak-proof packaging 10
designed for safe transportation of defective or old batteries 11 containing
corrosive
liquids such as lead acid.
FIGURE 1 illustrates package as having three layers enclosing battery 11.
The three layers include an inner container 20 configured to accept battery 11
therewithin, a fluid-impermeable intermediate container 30 sealing inner
container 20
therewithin, and an outer container 40 enclosing intermediate container 30.
It is seen in FIGURES 1-3 that inner container 20 is formed by an inner-
container surrounding wall 21 which includes an inner-container topwall 22.
Inner
container topwall 22 forms an inner-container closure 23 of an inner-container
access
opening 24.
It is further seen in FIGURES 10-13 that package 10 includes an absorbent
pad 12 along an inner-container bottomwall 25 with edges 120 of pad 12 being
turned
up, as best seen in FIGURE 13. FIGURES 10-13 illustrate the formation and
dimensions of absorbent pad. FIGURE 10 shows pad 12 being unfolded. It is
preferred that at lest two pieces of pad material be positioned together for
greater
absorbency. Shows a fold line 121 along which pad 12 is folded for double
thickness, as seen in FIGURE 12.
FIGURES 1-3 and 14 show fluid-impermeable intermediate container 30 as a
plastic bag 300. Bag 300 may be 24 inches wide and 22 1/2 inches long with 1
1/2
inches lip over lock 32, as best seen in FIGURE 14. One exemplary material for
bag
300 is a nylon/PE film which may generally be referred to as a 6 mil poly bag
and
also be described as 98 gauge nylon/4.0 mil polyethylene or bi-oriented nylon
over 4
mil linear low-density polyethlene. Such Nylon/PE film is more puncture and
tear
resistant than another exemplary material which may be referred to as LLDPE
film.
Other acid resistant materials may also be used for making bag 300 of
intermediate
container 30. Bag 300 may have thin welded edges or heat-sealed edges 36 which
are
about 1/4 inch wide and provide greater structural stability and reliability
of bag 300
than thin welded edges. Such seal edges 36 are straight and without gaps. And,
the
" bag material is preferably free from nicks, pinholes and carbon deposits,
each of
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which may diminish acid-impermeability of bag 300. It is seen in FIGURES 1-3
that
intermediate-container bag 30 is protected from puncture by being between
inner and
outer containers 20 and 40 such that inner container 20 protects bag 300 from
being
punctured by battery 11 and outer container 40 protects bag 300 from exterior
elements.
As further seen in FIGURES 1-3 and 14, bag 300 has a top end 31 forming a
fluid-impermeable lock 32. Fluid-impermeable lock 32 has an interlocking
groove 33
and ridge 34 which form a fluid-tight seal when engaged together. Such lock 32
may
also be referred to as a hermetic or no-leak zipper 320 and described as a PTC
zipper
& closure. Zipper 320 may also include a "slider" to assist the user in
sealing bag
300.
FIGURES 1-3 further illustrate that outer container 40 is formed by an outer-
container surrounding wall 41 which includes an outer-container topwall 42.
Outer-
container topwall 42 forms an outer-container closure 43 of an outer-container
access
opening 44.
Inner and outer containers 20 and 40 are each preferably made of corrugated
cardboard which provides cushioning and absorbing characteristics for inner
container
and the stiffness for outer container 40.
FIGURE 4 illustrates a sheet 26 of material which is cut for inner-container
20 surrounding wall 21 and which is folded and erected into a rectangular
box 27
forming inner container 20. It is seen in FIGURE 4 that inner-container
surrounding
wall 21 includes inner-container bottomwall 25 and an inner-container sidewall
28
which extends from bottomwall 25. As seen in FIGURE 4, inner-container topwall
22 is connected to inner-container sidewall 28. It is also seen in FIGURE 4
that
inner-container bottomwall 25 is formed by four overlapping flaps 251 which
provide
additional absorbent layers.
FIGURES 17 and 18 show inner-container surrounding wall 21 free of three-
way-corner sidewall junctions 29 with inner-container topwall 22 and with
inner-
container bottomwall 25. As best seen in FIGURE 18, sheet 26 forming inner
container 20 is cut at positions adjacent to three-way junctions 29 to remove
what
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otherwise be pointed corners to minimize puncturing of intermediate-container
plastic
bag 300 which envelopes inner container 20.
FIGURE 5 illustrates a sheet of material which is cut for outer-container
surrounding wall 41 and which is folded and erected into a rectangular box 45
forming outer container 40. It is seen in FIGURE 5 that outer-container
surrounding
wall 41 includes an outer-container bottomwall 46 and an outer-container
sidewall 47
which extendes from outer-container bottomwall 46 with outer-container topwall
42
being connected to outer-container sidewall 47.
FIGURES 1-5 show that closures 23, 43 and 32 of inner, outer and
intermediate containers 20, 40 and 30, respectively, are re-closeable and
adhesive-free
permitting repeated opening and closing of the leak-proof package.
As seen in FIGURES 1-4, inner-container closure 23 is formed by overlapping
inner-container topwall flaps 221 each extending from a corresponding portion
281 of
inner-container sidcwall 28. FIGURES 1-3 and 5 show that outer-container
closure
43 includes a locking tab 431 and a major flap 432. FIGURE 5 shows locking tab
431
integral with and extends from outer-container sidewall 47. It is further seen
in
FIGURE 5 that major flap 432 extends from a first portion 471 of outer-
container
sidewall 47. To lock packaging 10, major flap 432 overlaps a pair of minor
flaps 433,
each of which extends from one of second and third portions 472 and 473 of
outer-
container sidewall 47, into position adjacent to a fourth portion 474. FIGURE
5 also
shows that major flap 432 terminates with a transverse interior flange 434
which
defines an aperture 435 therethrough. As further seen in FIGURES 1-3 and 5,
locking
tab 431 extends from fourth portion 474 of outer-container sidewall 47
opposite first
outer-sidewall portion 471. In locked position, locking tab 431 extends
through
flange aperture 435 to hold flange 434 against an interior surface 48 of
fourth outer-
sidewall portion 474.
FIGURES 2 and 3 illustrate packaging 10 including a fluid-impermeable
innermost container 50 which is configured to seal battery 11 therewithin. In
FIGURE 4, innermost container 50 is shown with a top end 51 forming a fluid-
impermeable lock 52. FIGURES 2 and 3 shows innermost container 50 as a plastic
bag 500. In FIGURE 3, fluid-impermeable lock 52 is shown to include an
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interlocking groove 53 and ridge 54 that form a fluid-tight seal when engaged
together. Innermost-container bag 500 may be made according to the same
specifications as intermediate-container bag 300 and vary only in size.
It is further seen in FIGURES 1-3 that package 10 further includes an inner
spacer 13 for positioning over battery to limit movement of battery 11. Inner
spaccr
13 is preferably of a cushioning material such as corrugated cardboard or acid-
resistant corrugated plastic. FIGURES 6 and 7 illustrate exemplary dimensions
of
spacer 13. The corrugation cells may form about 0.75 inch openings.
FIGURES 1-3 also show a pair of buffers 14 for positioning between
intermediate container 30 and outer-container surrounding wall 41. Buffers 14
are
preferably of a cushioning material such as corrugated cardboard with cells
size of
about 0.75 inches. FIGURES 8 and 9 illustrate exemplary dimensions of buffers
14.
It should be understood that a larger package 10 that would be suitable for
shipping batteries up to about 150 lbs may include additional buffers 14
(honeycomb
cardboard cushioning pieces) between inner and outer containcrs 20 and 40 as
well as
within inner container 20. Such additional buffers may be placed between inner
and
outer boxes 27 and 45 on the front, back, top or bottom. Some additional
buffers 14
may be positioned inside inner container 20 surrounding battery 11. Such large
package 10 may also include additional absorbing pads 12.
FIGURES 1-3, 15 and 16 illustrate a method for packaging at least one battery
11 containing corrosive liquid. In such packaging, inner container 20 is
enveloped
with fluid-impermeable intermediate container 30 which has fluid-impermeable
lock
32 at its top end 31. Packaging 10 is then further assembled by putting
intermediate
container 30 into outer container 40. FIGURE 16 shows how battery 11 is loaded
into
inner container 20 after inner container 20 is enveloped by intermediate
container 30.
Access opening 24 of inner container 20 is then closed with battery 11 within
inner
container 20. After that, fluid-impermeable lock 32 of intermediate container
30 is
sealed with inner container 20 being inside intermediate container 30.
Packaging 10
of battery 11 is completed by closing and locking access opening 44 of outer
container 40 with battery 11 being inside inner container 20 which is sealed
inside
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intermediate container 30 inside locked outer container 40 such that liquid-
containing
defective battery 11 is protectively packaged for leak-free transportation.
It is seen in FIGURES 1-3, 15 and 16 that an exterior surface 49 of outer
container 40 includes instructions for using packaging 10 and cautionary
information
printed in at least English, Spanish and French. A warning label 15 is
provided for
placement on exterior surface 49. Warning label 15 is provided separately on
adhesive sheet with a peel-off cover one the adhesive. Exterior surface 49 of
outer
container 40 includes a printed diamond of substantially thc samc size as
label 15, the
diamond may include words "EMPTY" which indicate that the packaging does not
have any hazardous contents. Instructions for placement of warning label over
the
diamond may also be printed inside the diamond or included in the general
instructions for use of packaging 10. Warning label 15 is printed with
information
according to applicable codes and rules and is attached to exterior surface 49
of outer
container 40 after locking sealed battery inside package 10.
At least one absorbent pad 12 is positioned along inner-container bottomwall
before battery 11 is loaded into inncr container 20. And, inner spacer 13 is
placed
over battery 11 to limit battery movement. A plurality of s 14 are inserted
inside
outer container 40, cach buffer 14 bcing between intermediate container 30 and
outer-
container surrounding wall 41.
20 FIGURES 2 and 3 shows that prior to loading battery 11 into inner
container
20, battery 11 is inserted into fluid-impermeable innermost container 50.
Prior to
battery 11 being inserted into innermost container 50 which is placed inside
inner
container 20. Fluid-impermeable innermost container 50 is sealed with the
battery
therewithin.
30
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The following is a specification sheet of an exemplary material for an
absorbent pad.
Item Name: Yellow HazMat SingleWeight SonicBonded Pads
Absorbency
= 31.1 gal./package (117.7 L/package)
= 19.9 oz./pad (588.4 mL/pad)
Amount: 200 pads/package
Product Dimensions
Length Width Height Depth Int. Dia. Ext. Dia.
19" 15"
(48.3 cm) (38.1 cm)
Shipping Dimensions
Length Width Height Cube
19" 15" 17" 2.8'
(48.3 cm) (38.1 cm) (43.2 cm) (85.3 cm)
Weight: 14.7(6.7 kg)
Color: Yellow
# Per Pallet: 30
Features and Benefits
= The Power of HazMat/When hazardous or unknown liquids spill, use
HazMat Sorbent Products for quick, efficient response. 100%
polypropylene absorbs most aggressive or
caustic fluids. All HazMat Sorbents are color-coded in Safety Yellow for
quick identification
= Fast-Acting for Quick Response/A layer of MeltBlown polypropylene
creates high surface area that enables SonicBonded Mat to quickly soak
up liquids.
= High Absorbency Keeps It on the Job Longer/A random assembly of large
diameter MeltBlown poly fibers creates a lofty layer.
= Ultrasonic Bond Points Keep Mat Intact/Ultrasonic bond points fuse layers
of fibers together ¨Mat keeps its shape even when completely saturated.
Top layer of SpunBond fabric provides added strength.
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= Perforations Save Money/SpunBond top layer allows for better-
defined perforations and cleaner, easier tear-offs. Rolls are perfed
every 7.5" vertically and 17" horizontally. Pads are perfed vertically at
7.5".
= Helps You comply/29 CFR 1910.22(a)(2), 29 CFR 1910.107(b)(3),
29 CFR 1910.107(g)(2), 29 CFR 1910.120(j)(1)
and 29 CFR 910.1450(e).
While the principles of the invention have been shown and described in
connection with specific embodiments, it is to be understood that such
embodiments
are by way of example and are not limiting.
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