Note: Descriptions are shown in the official language in which they were submitted.
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BUILDING PANEL
Field
[0001] The present invention relates to a building panel for forming a load-
bearing structure, and
especially for forming a suspended composite floor slab.
[0002] Thus, the invention is particularly designed for use in industrial
applications, and it will
be convenient to describe the invention herein in this exemplary context. It
will be appreciated,
however, that the invention is not limited to this particular application but
may also be employed
in commercial or domestic applications.
Background
[0003] Suspended floor slabs are typically constructed of concrete, which is
poured into
shuttering or formwork spanning between temporary or permanent floor supports,
such as walls,
band beams or columns, to form a concrete floor. This method has the
disadvantages, however,
that the process of erecting and stripping the shuttering or formwork is time-
consuming, labor
intensive, high risk from a safety perspective and costly. Furthermore, the
span of the concrete
floor between the support columns is often limited by the weight of the
concrete floor.
Object
[0004] It is an object of the present invention to substantially overcome, or
at least ameliorate,
one or more of the above disadvantages.
Summary
[0005] In a first aspect, the present invention provides a building panel for
forming a load-
bearing structure, the building panel comprising:
a backing member;
a strengthening element mountable to the backing member; and
a void former mountable to the backing member and disposed adjacent to the
strengthening element for forming a void in the structure;
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wherein the backing member, the strengthening element, and the void former are
configured to receive a mixture curable to form the structure.
[0006] In a preferred form, the mixture is a concrete mixture.
[0007] In a preferred form, the building panel further comprises a reinforcing
mesh spaced apart
from the strengthening element to provide tensile strength to the structure.
[0008] In a preferred form, the backing member is comprised of a fire-
resistant material to
substantially protect the structure from fire damage.
[0009] In a preferred form, the backing member is in the form of a timber
board having a
predetermined thickness, wherein the timber board is configured to char when
exposed to a fire
hazard thereby substantially protecting the structure from fire damage.
[0010] In a preferred form, the timber board has a predetermined length and
width, wherein the
void former extends substantially along the entire predetermined length of the
timber board and
at least along a majority of the predetermined width of the timber board.
[0011] In a preferred form, the strengthening element is in the form of a
steel beam having a
uniform transverse cross-sectional profile and extending substantially along
the entire
predetermined length of the timber board.
[0012] In an alternative embodiment, the strengthening element comprises a
number of truss
elements arranged in a repeating manner along the entire predetermined length
of the timber
board.
[0013] In a preferred form, the void former is comprised of polystyerene,
polyisocyanurate (PIR)
foam, rock wool or plastics, or combinations thereof.
[0014] In a second aspect, the present invention provides a building panel for
forming a load-
bearing structure, the building panel comprising:
a backing member; and
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a strengthening element mountable to the backing member such that the
strengthening
element and the backing member enclose a volume therebetween, wherein the
volume defines a
void;
wherein the backing member and the strengthening element are configured to
receive a
mixture curable to form the structure.
[0015] In a preferred form, the mixture is a concrete mixture.
[0016] In a preferred form, the building panel further comprises a reinforcing
mesh spaced apart
from the strengthening element to provide tensile strength to the structure.
[0017] In an alternative embodiment, the building panel further comprises a
reinforcing mesh
fixed to or laid on top of the strengthening element to provide tensile
strength to the structure.
[0018] In a preferred form, the backing member is comprised of a fire-
resistant material to
substantially protect the structure from fire damage.
[0019] In a preferred form, the backing member is in the form of a timber
board having a
predetermined thickness, wherein the timber board is configured to char when
exposed to a fire
hazard.
[0020] In a preferred form, the timber board has a predetermined length and
width, wherein the
strengthening element extends substantially along the entire predetermined
length of the timber
board and at least along a majority of the predetermined width of the timber
board.
[0021] In a preferred form, the strengthening element is in the form of a
folded steel sheet
having a uniform transverse cross-sectional profile and extending
substantially along the entire
predetermined length of the timber board.
[0022] In a preferred form, the cross-sectional profile of the folded steel
sheet is substantially
trapezoidal.
[0023] In a third aspect, the present invention provides a composite floor
slab comprising:
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at least one of the building panels according to any one of the aspects or
embodiments of
the invention described above; and
a concrete mixture cured over the at least one building panel.
[0024] In a fourth aspect, the present invention provides a method of
constructing a suspended
composite floor slab comprising:
arranging at least one of the building panels according to either the first or
second aspects
of the invention described above across floor supports;
pouring a concrete mixture over the at least one building panel; and
curing the concrete mixture to form a concrete structure.
Brief Description of Drawings
[0025] For a more complete understanding of the present invention, exemplary
embodiments of
the invention are explained in more detail in the following description with
reference to the
accompanying drawing figures, in which like reference signs designate like
parts and in which:
[0026] FIG. 1 is a perspective view of a building panel according to a first
embodiment of the
present invention;
[0027] FIG. 2 is a sectional view of the building panel of FIG. 1;
[0028] FIG. 3 is a perspective view of a building panel according to a second
embodiment of the
present invention;
[0029] FIG. 4 is a sectional view of the building panel of FIG. 3;
[0030] FIG. 5 is a perspective view of a building panel according to a third
embodiment of the
present invention;
[0031] FIG. 6 is a sectional view of the building panel of FIG. 5;
[0032] FIG. 7 is a perspective view of a building panel according to a fourth
embodiment of the
present invention;
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[0033] FIG. 8 is a sectional view of the building panel of FIG. 7;
[0034] FIG. 9 is a perspective view of a building panel according to a fifth
embodiment of the
present invention;
[0035] FIG. 10 is a sectional view of the building panel of FIG. 9;
[0036] FIG. 11 is a perspective view of a building panel according to a sixth
embodiment of the
present invention;
[0037] FIG. 12 is a sectional view of the building panel of FIG. 11;
[0038] FIG. 13 is a perspective view of a building panel according to a
seventh embodiment of
the present invention; and
[0039] FIG. 14 is a sectional view of the building panel of FIG. 13.
[0040] The accompanying drawings are included to provide a further
understanding of the
present invention and are incorporated in and constitute a part of this
specification. The
drawings illustrate particular embodiments of the invention and together with
the description
serve to explain the principles of the invention. Other embodiments of the
invention and many
of the attendant advantages of the invention will be readily appreciated as
they become better
understood with reference to the following detailed description.
[0041] It will be appreciated that common and/or well understood elements that
may be useful or
necessary in a commercially feasible embodiment are not necessarily depicted
in order to
facilitate a more abstracted view of the embodiments. The elements of the
drawings are not
necessarily illustrated to scale relative to each other. It will also be
understood that certain
actions and/or steps in an embodiment of a method may be described or depicted
in a particular
order of occurrences while those skilled in the art will understand that such
specificity with
respect to sequence is not actually required.
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Description of Embodiments
[0042] FIGS. 1 and 2 show a building panel 100 according to a first
embodiment. The building
panel 100 is suitable for use in forming a load-bearing structure such as a
suspended composite
floor slab (not shown).
[0043] With particular reference to FIG. 1, the building panel 100 includes a
backing member in
the form of a timber board 102 having a predetermined thickness preferably in
the range of about
60 mm to 100 mm, more preferably about 80 mm. In this way, the timber board
102 is designed
to a thickness so that, in the event of a fire hazard, the timber board 102 is
allowed to char when
exposed to the fire hazard thereby substantially protecting the rest of the
structure from fire
damage. It can also be envisaged that the timber board 102 is treated or
coated with a fire-
resistant material or compound for added fire protection. The timber board 102
may be
engineered as cross laminated timber (CLT), laminated veneer lumber (LVL),
nail-laminated
timber (NLT) or glue laminated timber (GLT), although other suitable
engineered wood products
may be used. The timber board 102 has a predetermined length preferably in the
range of about
4m to 12m, more preferably about 9m, and a predetermined width preferably in
the range of
about lm to 2.5m, more preferably about 1.2m and 2.4m. It will be appreciated
that the length
and width of the timber board 102 is determined based on certain design
criteria for a particular
application.
[0044] The building panel 100 further includes a strengthening element in the
form of repeating
steel truss elements 104 (only one of the truss elements 104 is labelled in
FIG. 1 for clarity)
arranged along the entire predetermined length of the timber board 102. Each
of the truss
elements 104 include a number of web chord elements 105 (shown in FIG. 2)
which define a
substantially pyramidal arrangement in which the proximal ends of each of the
web chord
elements 105 which are located at the corners of the pyramidal arrangement are
welded to a steel
plate 106. The distal ends of each of the web chord elements 105 are welded
together to define
an apex 107 of the substantially pyramidal arrangement which in turn is welded
to a steel
bridging chord 108 extending along the entire predetermined length of the
timber board 102
parallel with the timber board 102. The steel plate 106 is mounted to the
timber board 102 via a
composite connection such as with nail fixings (not shown), screw fixings (not
shown) or an
adhesive. In this way, the truss elements 104 are designed to limit deflection
of the timber board
102 and hence the structure when under axial load.
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[0045] The building panel 100 further includes a void former 110 mounted to
the timber board
102 and disposed adjacent to the truss elements 104 for forming a void 112
(shown in FIG. 2) in
the structure. The void former 110 is preferably a block of lightweight
material such as
polystyrene, polyisocyanurate (PIR) foam, rock wool or plastics, or
combinations thereof. The
void former 110 is preferably mounted to the timber board 102 via an adhesive
or other suitable
fixing means. The void former 110 extends substantially along the entire
predetermined length
of the timber board 102 and at least along a majority of the predetermined
width of the timber
board 102, that is, the void former 110 occupies more of the width of the
timber board 102 than
the truss elements 104.
[0046] With particular reference to FIG. 2, the building panel 100 further
includes a reinforcing
mesh 114, preferably steel or fibreglass mesh, shown spaced apart from the
steel bridging chord
108 of the truss elements 104 to provide tensile strength to the structure.
Although, it is
preferred for the reinforcing mesh 114 to be fixed to or laid on top of the
steel bridging chord
108.
[0047] As shown in FIG. 2, the timber board 102, the truss elements 104, the
void former 110
and the reinforcing mesh 114 are configured to receive a concrete mixture 116
which is cured to
form a concrete structure of the composite floor slab. In this way, the void
112 formed by the
void former 110 defines a volume impenetrable by the concrete mixture 116
thereby reducing
the volume of concrete mixture required to form the composite floor slab (and
hence reducing
the total dead weight) whilst still maintaining overall strength of the
composite floor slab. The
concrete mixture 116 preferably covers the reinforcing mesh 114 to a depth of
at least about 65
mm. The thickness of the concrete mixture 116 between the reinforcing mesh 114
and the
bridging chord 108 is preferably in the range of about 30 mm to 35 mm.
Although it will be
appreciated that the depth of the concrete mixture 116 above the reinforcing
mesh 114 and the
thickness of the concrete mixture 116 between the reinforcing mesh 114 and the
bridging chord
108 can be tailored to meet particular design standards for a given
application.
[0048] It will be appreciated that more than one arrangement of repeating
truss elements 104 and
more than one void former 110 may be mounted in an alternating manner on the
one timber
board 102 per building panel 100 as depicted in FIGS. 1 and 2.
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[0049] It will also be appreciated that one or more of the building panels 100
may be entirely
pre-fabricated off-site and delivered ready to use on-site.
[0050] FIG. 3 shows a building panel 200 according to a second embodiment. The
building
panel 200 is similar to that of the building panel 100, but does not include
the truss elements 104.
Rather, the truss elements 104 are replaced with a steel beam 204.
Accordingly, features of the
building panel 200 that are identical to those of the building panel 100 are
provided with an
identical reference numeral. For features that are identical between the
building panel 100 and
the building panel 200, it will be appreciated that the above description of
those features in
relation to the building panel 100 is also applicable to the corresponding
identical features found
in the building panel 200.
[0051] With reference to FIGS. 3 and 4, the steel beam 204 extends
substantially along the entire
predetermined length of the timber board 102. The steel beam 204 is preferably
comprised of
cold-formed "C" sections 205 (shown in FIG. 4) which are welded together along
their
longitudinal length back-to-back to form a uniform transverse cross-sectional
profile along the
length of the steel beam 204. The steel beam 204 is mounted to the timber
board 102 via a
composite connection such as with nail fixings (not shown), screw fixings (not
shown) or an
adhesive between a bottommost surface of the steel beam 204 and the timber
board 102. In this
way, the steel beam 204 is designed to limit deflection of the timber board
102 and hence the
structure when under axial load. The reinforcing mesh 114 is shown spaced
apart from the top
most surface of the steel beam 204. Although, it is preferred for the
reinforcing mesh 114 to be
fixed to or laid on top of the top most surface of the steel beam 204.
[0052] As shown in FIG. 4, the timber board 102, the cold-formed "C" sections
205 of the steel
beam 204, the void former 110 and the reinforcing mesh 114 are configured to
receive the
concrete mixture 116 which is cured to form the concrete structure of the
composite floor slab.
The concrete mixture 116 preferably covers the reinforcing mesh 114 to a depth
of at least about
65 mm. The thickness of the concrete mixture 116 between the reinforcing mesh
114 and the top
most surface of the steel beam 204 is preferably in the range of about 30 mm
to 35 mm.
Although it will be appreciated that the depth of the concrete mixture 116
above the reinforcing
mesh 114 and the thickness of the concrete mixture 116 between the reinforcing
mesh 114 and
the top most surface of the steel beam 204 can be tailored to meet particular
design standards for
a given application.
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[0053] It will be appreciated that more than one arrangement of the steel beam
204 and more
than one void former 110 may be mounted in an alternating manner on the one
timber board 102
per building panel 200.
[0054] It will also be appreciated that one or more of the building panels 200
may be entirely
pre-fabricated off-site and delivered ready to use on-site.
[0055] FIGS. 5 and 7 show a building panel 300 and a building panel 400
according to a third
and fourth embodiment, respectively. Both the building panel 300 and the
building panel 400
are similar to that of the building panel 200, but the steel beam 304 of the
building panel 300 and
the steel beam 404 of the building panel 400 each have a different transverse
cross-sectional
profile to that of the steel beam 204 of the building panel 200. In
particular, the steel beam 304
of the building panel 300 is comprised of cold-formed "Z" sections 305 which
are welded
together along their bottommost edges to form a generally "U" shaped uniform
transverse cross-
sectional profile along the length of the steel beam 304. The steel beam 404
of the building
panel 400 is comprised of a cold-formed box section 405 forming a generally
box shaped
uniform transverse cross-sectional profile along the length of the steel beam
404. Accordingly,
features of the building panel 300 and the building panel 400 that are
identical to those of the
building panel 200 are provided with an identical reference numeral, whereas
equivalent features
are provided with the same reference numeral to that of the second embodiment,
increased by
100 and 200 respectively. For features that are identical/equivalent between
the building panel
200 and the building panels 300, 400, it will be appreciated that the above
description of those
features in relation to the building panel 200 is also applicable to the
corresponding
identical/equivalent features found in the building panels 300, 400. It will
also be appreciated
that by virtue of the shape and configuration of the steel beam 404, less
volume of the concrete
mixture 116 is required to form the concrete structure of the composite floor
slab of the building
panel 400 compared to the volume of the concrete mixture 116 required for the
building panels
100, 200, 300.
[0056] It will also be appreciated that more than one arrangement of the steel
beams 304, 404
and more than one void former 110 may be mounted in an alternating manner on
the one timber
board 102 per building panel 300, 400.
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[0057] It will also be appreciated that one or more of the building panels
300, 400 may be
entirely pre-fabricated off-site and delivered ready to use on-site.
[0058] FIG. 9 shows a building panel 500 according to a fifth embodiment. The
building panel
500 is similar to that of the building panel 100, but does not include the
truss elements 104, nor
the void former 110. Rather, the building panel 500 includes a strengthening
element in the form
of a folded steel sheet 504. Accordingly, features of the building panel 500
that are identical to
those of the building panel 100 are provided with an identical reference
numeral. For features
that are identical between the building panel 100 and the building panel 500,
it will be
appreciated that the above description of those features in relation to the
building panel 100 is
also applicable to the corresponding identical features found in the building
panel 500.
[0059] With reference to FIGS. 9 and 10, the folded steel sheet 504 is
mountable to the timber
board 102 such that the folded steel sheet 504 and the timber board 102
enclose a volume
therebetween so that the volume defines a void 112. The folded steel sheet 504
is comprised of a
cold-formed top hat section 505 which is mounted at its bottommost flanges to
the timber board
102 via composite connections such as those described above. The folded steel
sheet 504
preferably defines a uniform transverse cross-sectional trapezoidal profile
and extends
substantially along the entire predetermined length of the timber board 102.
In this way, the
folded steel sheet 504 is designed to limit deflection of the timber board 102
and hence the
structure when under axial load whilst simultaneously forming the void 112.
The reinforcing
mesh 114 is shown spaced apart from the top most surface of the folded steel
sheet 504.
Although, it is preferred for the reinforcing mesh 114 to be fixed to or laid
on top of the top most
surface of the steel sheet 504.
[0060] The timber board 102 and the folded steel sheet 504 are configured to
receive a concrete
mixture 116 which is cured to form a concrete structure of the composite floor
slab. In this way,
the void 112 formed by the folded steel sheet 504 and the timber board 102
defines a volume
impenetrable by the concrete mixture 116 thereby reducing the volume of
concrete mixture
required to form the composite floor slab (and hence reducing the total dead
weight) whilst still
maintaining overall strength of the composite floor slab. The concrete mixture
116 preferably
covers the reinforcing mesh 114 to a depth of at least about 65 mm. The
thickness of the
concrete mixture 116 between the reinforcing mesh 114 and the top most surface
of the steel
sheet 504 is preferably in the range of about 30 mm to 35 mm. Although it will
be appreciated
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that the depth of the concrete mixture 116 above the reinforcing mesh 114 and
the thickness of
the concrete mixture 116 between the reinforcing mesh 114 and the top most
surface of the steel
sheet 504 can be tailored to meet particular design standards for a given
application. By this
arrangement, the building panel 500 is more cost efficient to fabricate
compared to the building
panel 100.
[0061] It will be appreciated that more than one arrangement of the folded
steel sheet 504 may
be mounted in a repeating manner on the one timber board 102 per building
panel 500.
[0062] It will also be appreciated that one or more of the building panels 500
may be entirely
pre-fabricated off-site and delivered ready to use on-site.
[0063] FIGS. 11 and 12 show a building panel 600 according to a sixth
embodiment. The
building panel 600 is similar to that of the building panel 500, but the
folded steel sheet 604 of
the building panel 600 has a different transverse cross-sectional profile.
Accordingly, features of
the building panel 600 that are identical to those of the building panel 500
are provided with an
identical reference numeral. For features that are identical between the
building panel 500 and
the building panel 600, it will be appreciated that the above description of
those features in
relation to the building panel 500 is also applicable to the corresponding
identical features found
in the building panel 600.
[0064] Like the folded steel sheet 504, the folded steel sheet 604 is
comprised of a cold-formed
top hat section 605 which is mounted at its bottommost flanges to the timber
board 102 via
composite connections such as screws 601 (shown in FIG. 12) or those described
above. These
connections / fixings may extend into the concrete mixture to act as shear
studs, connecting the
concrete mixture 116 to the timber board 102. Differently, however, the top
hat section 605
includes a trough portion 606 extending along the length of the folded steel
sheet 604 which is
configured to receive the concrete mixture 116. A further point of difference
is that the
reinforcing mesh 114 rests on the uppermost surface of the folded steel sheet
604 as shown in
FIG. 12. By this arrangement, the trough portion 606 is configured to receive
a portion of the
concrete mixture 116 so that the thickness of the concrete mixture 116 between
the reinforcing
mesh 114 and the bottommost surface of the trough portion 606 is preferably in
the range of
about 30 mm to 35 mm, although it will be appreciated that this thickness of
the concrete
mixture 116 can be tailored to meet particular design standards for a given
application.
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[0065] It will be appreciated that more than one arrangement of the folded
steel sheet 604 may
be mounted in a repeating manner on the one timber board 102 per building
panel 600.
[0066] It will also be appreciated that one or more of the building panels 600
may be entirely
pre-fabricated off-site and delivered ready to use on-site.
[0067] FIGS. 13 and 14 show a building panel 700 according to a seventh
embodiment. The
building panel 700 is suitable for use in forming a load-bearing structure
such as a suspended
composite floor slab (not shown). The building panel 700 includes a laminated
backing member
702 having a plurality of treated or untreated timber lamellas 703 that are
adhered to each other.
The lamellas 703 can also be dowelled or nailed together.
[0068] The building panel 700 further includes a plurality of strengthening
elements in the form
of N20 reinforcing bars 704 arranged along the entire predetermined length of
the laminated
blacking member 702. The N20 reinforcing bars 704 are designed to limit
deflection of the
backing member 702 and hence the structure when under axial load.
[0069] The building panel 700 further includes a void former 710. The void
former is formed by
providing that a number of lamellas 706 have a longer width than the other
lamellas 703. A
cross-member 708 in the form of an 18mm formply panel is secured to two longer
lamellas 706
as shown to form a void 712. The void former 710 extends substantially along
the entire
predetermined length of the backing member 702.
[0070] With particular reference to FIG. 14, the building panel 700 further
includes a reinforcing
mesh 714, preferably steel or fibreglass mesh, shown spaced apart from the
cross-members 708
to provide tensile strength to the structure.
[0071] The backing member 702, strengthening elements 104, void formers 110
and the
reinforcing mesh 714 are configured to receive a concrete mixture 716 which is
cured to form a
concrete structure of the composite floor slab. In this way, the void 712
formed by the void
former 710 defines a volume impenetrable by the concrete mixture 716 to reduce
the volume of
concrete mixture required to form the composite floor slab. To secure the
backing member 702
in position a number of dowels 718 spaced along the length of the backing
member 702. The
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concrete mixture 716 is connected to the backing member 702 by non-illustrated
shear studs or
steel rods located between the wider lamellas.
[0072] It will be appreciated that more than one arrangement of repeating
truss elements 104 and
more than one void former 110 may be mounted in an alternating manner on the
one timber
board 102 per building panel 100 as depicted in FIGS. 1 and 2.
[0073] It will also be appreciated that one or more of the building panels 100
may be entirely
pre-fabricated off-site and delivered ready to use on-site.
[0074] A preferred method of constructing a suspended composite floor slab
will now be
described. The method comprises the initial step of arranging at least one of
the building panels
100, 200, 300, 400, 500, 600, 700 to span across temporary or permanent floor
supports such as
columns, band beams or wall. The building panel 100, 200, 300, 400, 500, 600,
700 may be
arranged adjacent to many of the same or different building panels 100, 200,
300, 400, 500, 600,
700 to span a desired area. A concrete mixture is then poured over the one or
more building
panels 100, 200, 300, 400, 500, 600, 700 and allowed to cure using typical
techniques to form a
concrete structure.
[0075] Although specific embodiments of the invention are illustrated and
described herein, it
will be appreciated by those of ordinary skill in the art that a variety of
alternative and/or
equivalent implementations exist. It should be appreciated that the exemplary
embodiment or
exemplary embodiments are examples only and are not intended to limit the
scope, applicability,
or configuration in any way. Rather, the foregoing summary and detailed
description will
provide those skilled in the art with a convenient road map for implementing
at least one
exemplary embodiment, it being understood that various changes may be made in
the function
and arrangement of elements described in an exemplary embodiment without
departing from the
scope as set forth in the appended claims and their legal equivalents.
Generally, this application
is intended to cover any adaptations or variations of the specific embodiments
discussed herein.
[0076] It will also be appreciated that in this document the terms "comprise",
"comprising",
"include", "including", "contain", "containing", "have", "having", and any
variations thereof, are
intended to be understood in an inclusive (i.e. non-exclusive) sense, such
that the process,
method, device, apparatus or system described herein is not limited to those
features or parts or
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elements or steps recited but may include other elements, features, parts or
steps not expressly
listed or inherent to such process, method, article, or apparatus.
Furthermore, the terms "a" and
"an" used herein are intended to be understood as meaning one or more unless
explicitly stated
otherwise. Moreover, the terms "first", "second", etc. are used merely as
labels, and are not
intended to impose numerical requirements on or to establish a certain ranking
of importance of
their objects.
