Note: Descriptions are shown in the official language in which they were submitted.
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ANCHOR PACKAGING SYSTEM AND METHOD
Cross-Reference to Related Applications
[0001] This application claims priority to U.S. Provisional Patent Application
Serial Nos.
62/770,039, filed November 20, 2018, and 62/811,994, filed February 28, 2019,
the entire
disclosures of which are incorporated herein by reference.
Field of the Invention
[0002] The present invention relates generally to packaging processes. More
specifically,
the present invention is concerned with systems for and methods of anchoring
packages to
shipping cases.
Background of the Invention
[0001] Certain goals and objectives associated with retail packaging, such as
attracting
attention while providing information about the goods within the package, are
often
diametrically opposed to certain goals and objectives of shipping packages,
such as maximizing
visibility of shipping labels while providing at least some level of
discretion. Consequently,
shipping cases are used to ship a variety of goods, regardless of whether the
goods are pre-
packaged.
[0002] Shipping cases are rarely designed to precisely fit goods being
shipped.
Consequently, shipping cases nearly always include large empty spaces
("voids"). Unfortunately,
shipping cases are often tossed around during shipping and handling, creating
a risk of damage to
the goods and/or to the shipping case. To reduce risk of damage, most
shippers, such as Amazon
and the like, use filler material, such as foam peanuts, air pillows, bubble
wrap, foam wrap,
shredded paper, and the like.
[0003] Filler material is not always effective in preventing movement of goods
within a
shipping case, especially if an insufficient amount of filler material is used
and/or if filler
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material is improperly positioned within the shipping case. Using too much
filler material can
also result in damage to a shipping case and/or to goods within the shipping
case. Damage to a
shipping case can cause loss of filler material, thereby eliminating or
otherwise reducing any
protection afforded by such filler material. Consequently, it would be
beneficial to have a system
for and method of reducing risk of damage to goods without requiring filler
material.
[0004] Use of filler material makes it difficult to automate the packaging
process. For
instance, a worker must be used to fill voids in a shipping case with filler
material, thereby
introducing an unknown, and sometimes unreliable, variable. The main reason
for damage
returns is that the worker did not put enough filler material in the shipping
case. Consequently, it
would be beneficial if the system for and methods of reducing risk of damage
to goods could be
automated, thereby further reducing risk of damage to goods.
[0005] Even if filler material is effective in protecting goods during
shipping, filler
material is rarely reused, generating a large volume of waste. Furthermore,
filler material often
spills out of shipping cases, such as during handling prior to shipping, if
the shipping case is
damaged during shipping, when opening the shipping case upon delivery, when
removing goods
from the shipping case, or the like. It can be difficult and time consuming to
clean up filler
material that spills out of a shipping case. Failure to properly clean up
spilled filler material can
create environmental concerns and health hazards, including, but not limited
to, hazards
associated with animals and/or small children ingesting small pieces of filler
material and/or
choking on or even being suffocated by larger pieces of filler material.
Consequently, it would be
beneficial to have a system for and a method of reducing risk of damage to
goods while avoiding
environmental and health risks associated with using filler material.
[0006] Filler material complicates and/or undermines conservation efforts,
such as
recycle and/or reuse efforts. For instance, the requirement to remove and
dispose of filler
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material reduces incentives for, and complicates the process of, reusing
shipping cases, resulting
in more waste. Furthermore, filler material, which is rarely separated
completely from corrugated
board of shipping cases, contaminates the process for recycling the corrugated
board, thereby
further reducing incentives for recycling by reducing the value of the
corrugated board.
Consequently, it would be beneficial to have a system for and methods of
reducing risk of
damage to goods while simplifying and facilitating conservation efforts.
Summary of the Invention
[0007] The present invention comprises a system for and methods of protecting
goods
within shipping cases or other containers. In some embodiments, the method
includes securing
one or more good to an interior surface of the shipping case, thereby
eliminating the need for
filler material by preventing the one or more good from shifting within the
shipping case. In
some embodiments, a first good is secured to a first surface of the container.
In some
embodiments, the first good is wrapped with a sacrificial layer, such as
shrink wrap, stretch
wrap, paper, plastic, aluminum (such as aluminum sheet or foil), or the like,
regardless of
whether such material is now known or later developed. In some embodiments,
the type,
thickness, and/or other properties of the sacrificial layer is selected based
on the weight of the
goods being secured and/or is selected based on one or more other factor. In
some embodiments,
aluminum sheet or foil is used in association with heavy items. In some
embodiments, the
sacrificial layer is secured to the interior surface of the container. In some
embodiments, the
sacrificial layer wraps around a plurality of goods, such as a first and
second good and/or one or
more other good, thereby securing the plurality of goods together prior to the
goods being
secured to the shipping case. In some embodiments, a sacrificial layer is
first secured to an
interior surface of a container, then a good or a plurality of goods is
wrapped in the sacrificial
layer. In some embodiments, one or more good is wrapped with one or more
support member,
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such as a tray or the like, thereby increasing a surface area for securing the
goods to the shipping
case and/or for otherwise facilitating the same. In some embodiments, one or
more sacrificial
layer includes indicia, such as a decorative design or other ornamental
feature. In some
embodiments, the indicia is associated with one or more special event, such as
a birthday,
Christmas, or the like.
[0008] In some embodiments, the sacrificial layer is formed at least partially
from a bag,
such as a paper bag, a plastic bag, or the like. In some embodiments, one or
more good is placed
in one or more respective bag, thereby creating one or more sacrificial layer
around such one or
more goods.
[0009] For the purposes of clarity, the good or goods, whether wrapped or not
and
whether wrapped with a support member or not, are referred to herein as a
"package" with each
good, support member, or other item within the package being referred to as an
"item". In some
embodiments, a single package (i.e. a single item, wrapped or unwrapped, or a
plurality of items
wrapped together) is secured within a single shipping case. In some
embodiments, a plurality of
packages are secured within a single shipping case.
[0010] The foregoing and other objects are intended to be illustrative of the
invention and
are not meant in a limiting sense. Many possible embodiments of the invention
may be made
and will be readily evident upon a study of the following specification and
accompanying
drawings comprising a part thereof. Various features and subcombinations of
invention may be
employed without reference to other features and subcombinations. Other
objects and
advantages of this invention will become apparent from the following
description taken in
connection with the accompanying drawings, wherein is set forth by way of
illustration and
example, an embodiment of this invention and various features thereof
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Brief Description of the Drawings
[0011] A preferred embodiment of the invention, illustrative of the best mode
in which
the applicant has contemplated applying the principles, is set forth in the
following description
and is shown in the drawings and is particularly and distinctly pointed out
and set forth in the
appended claims.
[0012] Fig. 1 shows a system for applying adhesive to a package.
[0013] Fig. 2 shows a system for applying adhesive to a shipping case.
[0014] Fig. 3 shows a system for applying a sacrificial layer to a package.
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Detailed Description
[0015] As required, a detailed embodiment of the present invention is
disclosed herein;
however, it is to be understood that the disclosed embodiment is merely
exemplary of the
principles of the invention, which may be embodied in various forms.
Therefore, specific
structural and functional details disclosed herein are not to be interpreted
as limiting, but merely
as a basis for the claims and as a representative basis for teaching one
skilled in the art to
variously employ the present invention in virtually any appropriately detailed
structure.
[0016] Referring to Figs. 1 and 2, the present invention is directed to a
process for
securing a package 10 relative to a shipping case 20 to facilitate safe and
efficient shipping of the
same. In some embodiments, the process includes moving the package 10 along a
first surface
101 as the shipping case 20 moves along a second surface 102. In some
embodiments, one or
both of the surfaces is associated with an automatic conveying system, such as
a conveyor belt or
the like. In some embodiments, a plurality of packages 10 are moved along the
first surface 101
while a plurality of corresponding shipping case 20 are moved along the second
surface 102. At
or near the end of the first surface 101, the package 10 is loaded into the
shipping case 20 and is
secured thereto.
[0017] Referring to Fig. 1, some embodiments of the present invention utilize
a first glue
applicator 151 associated with the first surface 101, thereby facilitating
application of glue
directly to one or more exterior surface of the package and/or to another
surface associated
therewith, such as a sacrificial layer or the like. In some embodiments, the
first glue applicator
151 is a glue dot applicator (shown), a spray applicator, or any other
appropriate glue applicator
now known or later developed. The glue applicator is configured to facilitate
application of at
least one type of adhesive material, such as hot melt adhesive, cold adhesive,
tape adhesive,
and/or one or more other adhesive now known or later developed.
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[0018] Referring to Fig. 2, some embodiments of the present invention utilize
a second
glue applicator 152 associated with the second surface 102, thereby
facilitating application of
glue directly to one or more interior surface of the shipping case and/or to
another surface
associated therewith, such as a sacrificial layer or the like. In some
embodiments, the second
glue applicator 152 is a spray applicator (shown), a glue dot applicator, or
any other appropriate
glue applicator now known or later developed. The glue applicator is
configured to facilitate
application of at least one type of adhesive material, such as hot melt
adhesive, cold adhesive,
tape adhesive, and/or one or more other adhesive now known or later developed.
[0019] Some embodiments of the present invention include positioning the
package 10
relative to one or more interior surface of the shipping case 20 to facilitate
bonding thereto. In
this way, the package is moved to a shipping position relative to the shipping
case. Upon
application of the adhesive to the package and/or the shipping case, the
adhesive remains active
(capable of bonding the package to the shipping case) for at least a first
period of time, the first
period of time being defined by the time it takes to move the package to the
shipping position. In
some embodiments, the first period of time is a few seconds or less. In some
embodiments, the
first period of time is several minutes or more. In some embodiments, the
package is reoriented
(such as being flipped, as shown in Fig. 1) prior to being moved to the
shipping position.
[0020] In some embodiments, the package is biased towards the shipping
position or
otherwise held in position for a second period of time, thereby facilitating
bonding of the
package to the shipping case. In some embodiments, the second period of time
is a few seconds.
In some embodiments, the second period of time is about one second. In some
embodiments, the
second period of time is less than a second. In some embodiments, the package
is bonded to the
shipping case upon moving (and/or allowing movement of) the package towards
the shipping
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case (and/or vice versa). In some embodiments, moving the package into contact
with the
shipping case results in instantaneous (or at least nearly instantaneous)
bonding of the same.
[0021] In some embodiments, the adhesive retains the package in the shipping
position
for a third period of time, thereby facilitating shipping of the package
within the shipping case.
In some embodiments, the third period of time is a few days or more. In some
embodiments, the
third period of time is several weeks or more.
[0022] In some embodiments, the adhesive is configured to retain the package
in the
shipping position for a variety of environmental conditions and/or
circumstances. In some
embodiments, the environmental conditions include wide temperature
fluctuations and/or rough
handling associated with shipping.
[0023] Referring to Fig. 3, some embodiments of the present invention apply a
sacrificial
layer to the package, such as by utilizing a shrink wrap mechanism 110 to wrap
a sacrificial layer
around the package and/or a shrink heat tunnel 120 for bonding the sacrificial
layer thereto. In
some embodiments, the sacrificial layer is formed at least partially from a
bag, such as a paper
bag, a plastic bag, or the like.
[0024] In some embodiments, the present invention includes applying an
adhesive
directly to a package (i.e. by applying the adhesive to an item and/or to a
sacrificial layer
associated with one or more item). In some embodiments, the adhesive is hot
melt adhesive, cold
set adhesive, glue dots, or the like. In some embodiments, the adhesive is
applied using a dab
technique, such as with an automated applicator moving vertically with respect
to a top or
bottom surface of the package to apply adhesive to the top or bottom surface
of the package. In
this way, a number of discrete adhesive dots can be applied to an applicable
surface. It will be
appreciated that in some embodiments the package moves vertically with respect
to the dab
applicator. It will further be appreciated that in some embodiments the dab
applicator applies
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adhesive to one or more other surface of the package in addition to and/or in
lieu of applying
adhesive to the top or bottom surface of the same. It will still further be
appreciated that in some
embodiments at least some of the adhesive dots are applied by hand.
[0025] In some embodiments, the adhesive is applied using a roll technique,
such as with
a roller or the like. In some embodiments, the adhesive is rolled onto one or
more surface of a
package, thereby facilitating bonding of the same to one or more respective
surface of a shipping
case. In some embodiments, the roller moves in a horizontal and/or vertical
orientation relative to
the package, thereby causing the roller to roll across one or more surface of
the same. In some
embodiments, the package moves relative to the roller.
[0026] In some embodiments, the present invention utilizes adhesive tape. In
some
embodiments, at least some of the tape is double-sided tape. In some
embodiments, an associated
container is moveable from a flat configuration, such as for shipping or
storing the container, and
an erected configuration, such as for loading the container, storing or
shipping goods within the
container, or unloading the container. In some embodiments, tape is applied to
a container in
association with a loading process, such as by a worker after the container is
moved to an erected
configuration. In some embodiments, at least some tape is applied to the
container in association
with a manufacturing process, such as by the manufacturer of the container
while (or before) the
container is in the flat configuration. In some embodiments the tape is
capable of securing to the
container items of substantial weight.
[0027] In some embodiments, the present invention includes applying an
adhesive
directly to an interior surface of a shipping case, such as an interior
surface of a bottom panel of
the shipping case. In this way, one or more package can be secured within the
shipping case by
moving the package into contact with the adhesive.
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[0028] In some embodiments, the adhesive is applied directly to one or more
package
prior to one or more package being placed in a shipping case. In some
embodiments, one or more
package is placed in a shipping case prior to applying an adhesive. In this
way, the one or more
package can be arranged or preferentially situated in the shipping case prior
to applying
adhesive. In some embodiments, once a preferred arrangement within the
shipping case has been
achieved, an adhesive is applied to the one or more package within the
shipping case.
[0029] In some embodiments, applying adhesive to the shipping case and/or to
one or
more package includes spraying adhesive. In some embodiment, the system
includes an adhesive
sprayer applicator that is configured to spray hot melt adhesive and/or cold
set adhesive. In some
embodiments, certain aspects of the present invention are at least partially
automated, such as the
adhesive sprayer applicator, the process of wrapping and/or securing a
sacrificial layer to items,
the packaging process, or the like. In some embodiments, certain aspects of
the present invention
are performed manually, such as application of adhesive with the adhesive
sprayer applicator, or
otherwise, wrapping packages, securing wrapping to packages, moving packages
between
stations, stacking items, loading items and/or packages into a shipping case,
or the like.
[0030] In some embodiments, the adhesive is a hot melt glue, a cold set glue,
a glue dot,
or a tape adhesive. In some embodiments, the adhesive can be applied directly
to the product
after the product is wrapped in a sacrificial layer. In some embodiments, the
sacrificial layer can
be shrink film, a plastic bag, or the like. In some embodiments, the adhesive
can be applied to the
top or to the bottom of the package. In some embodiments, the product is
placed into the
shipping case after the adhesive is applied.
[0031] Referring to Figs. 1-3, some embodiments of the present invention
include a
system for automating methods of the present invention. Some embodiments
include a primary
conveyor system, such as a conveyor belt or the like, for moving the package
(or components of
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the package) between two or more stations. Some embodiments include a stacking
station for
stacking one or more item on top of one or more other item, such as on top of
one or more good
and/or support member, such as a tray or the like. In some embodiments, a tray
or other support
member is stacked on top of one or more good. In some embodiments, items are
selected for
stacking based on delivery location, size of items, weight of items,
classification of items, or any
number of other factors associated with determining proper groupings of items.
[0032] Some embodiments of the present invention include a wrapping station,
such as a
shrink wrap station, a stretch wrap station, a paper wrapping station, or the
like, for wrapping
items together and/or for wrapping a single item, thereby creating a package
for shipping. In
some embodiments, wrapping a single item provides additional protection for
the item and/or
provides a sacrificial layer for adhesion. In some embodiments, the wrapping
station includes an
initial substation for initially wrapping the items and a finishing substation
for securing the
wrapping to the items. In some such embodiments, the initial substation
station includes rolls of
sacrificial film, such as shrink film, stretch film, paper, plastic, aluminum,
or the like. In some
embodiments, the finishing station includes a means for securing the film to
one or more item,
such as by heating shrink film, smoothing stretch film, taping paper, or the
like. In some
embodiments, the primary conveyor system moves the items relative to the rolls
of sacrificial
film, thereby causing the sacrificial film to wrap around the items as the
sacrificial film unrolls.
[0033] In some embodiments, the sacrificial film is paper, a paper product,
plastic,
aluminum, or the like. In some embodiments, the sacrificial film is wrapped at
least partially
around the one or more items of the package. In some embodiments, the
sacrificial film is
formed, at least partially, from a bag, such as a plastic bag, a paper bag, or
the like. In some
embodiments, the sacrificial film extends across an entire bottom surface of a
bottom item of the
package, such as by setting the item on an inner surface of the sacrificial
layer or otherwise. In
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some embodiments, the sacrificial layer is folded up (or is otherwise caused
to extend upward) so
as to cover side surfaces of each item in the package, thereby defining an
interior volume within
which the items are positioned. In some embodiments, the sacrificial layer
defines an open top
through which one or more item may be added or removed from the package prior
to the items
being secured together, the open top being defined by outer portions of the
sacrificial layer. In
some embodiments, the open top is closed, such as by folding the outer
portions over each other,
by twisting the outer portions together, by rolling the outer portions, or the
like. In this way, the
sacrificial film is secured tightly to the items, thereby creating a tight
barrier of the package. In
some embodiments, outer portions of the sacrificial film are secured so as to
prevent or inhibit
the same from unfolding, untwisting, unrolling, or the like.
[0034] In some embodiments, sacrificial film is a shrink film that is
configured to shrink
upon being heated. In some such embodiments, the primary conveyor system moves
the items
relative to a means for heating the shrink film such that the shrink film is
exposed to an
appropriate amount of heat for a sufficient amount of time for securing the
items together. In
some embodiments, the heating means is a heating tunnel and the primary
conveyor system is
configured to pass the goods through the heating tunnel at an appropriate
speed. As the product
travels through the heat tunnel, the shrink film begins to form around the
items, thereby forming
a package having a tight plastic barrier.
[0035] In some embodiments, the sacrificial film is formed at least partially
from a
plastic bag that is configured to shrink upon being heated. In some such
embodiments, the
primary conveyor system moves the items relative to a means for heating the
plastic bag such
that the plastic bag is exposed to an appropriate amount of heat for a
sufficient amount of time
for securing the items together. In some embodiments, the heating means is a
heating tunnel and
the primary conveyor system is configured to pass the goods through the
heating tunnel at an
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appropriate speed. As the product travels through the heat tunnel, the plastic
bag begins to form
around the items, thereby forming a package having a tight plastic barrier.
[0036] In some embodiments, a single bag is utilized with a single package or
item. In
some embodiments, a single bag is utilized with a plurality of packages or
items. In some
embodiments, a plurality of bags are utilized with a single package or item,
such as by placing
each item in a respective small bag and placing all items in a larger bag. In
some embodiments,
each bag is formed from the same or similar materials. In some embodiments,
one or more bag is
formed from a different material.
[0037] In some embodiments, one or more item is placed into one or more bag
prior to
the bag being secured to a container. In some such embodiments, one or more
bag is sealed or
otherwise moved to a secure configuration, such as by heat shrinking,
twisting, tying, gluing,
taping, or the like, prior to a respective package being placed into a
respective container. In some
embodiments, air is evacuated from one or more bag. In some such embodiments,
the evacuation
of the air creates a tight seal, such as a vacuum seal, around the good or
goods. In some
embodiments, evacuation of air from one or more bag reduces the overall volume
of a package
or otherwise facilitates more compact packaging within a container.
[0038] In some embodiments, one or more sacrificial film, such as paper,
plastic, or the
like, whether in the form of a bag or not, positioned in a container prior to
securing the same
relative to one or more item or package. In some such embodiments, a portion
of the sacrificial
film is secured to one or more inner surface of the container, such as via
tape, glue dots, hot melt,
cold set, or other adhesives or retentions means, thereby creating a retention
mechanism. In some
embodiments, one or more item or package is positioned relative to one or more
retention
mechanism, thereby enabling a user to retain such items or packages within the
container, such
as by wrapping one or more retention mechanism around one or more item or
package and
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moving the same to a secure configuration, such as by heat shrinking,
twisting, tying, gluing,
taping, or the like.
[0039] In some embodiments, the system includes a secondary conveyor system
for
moving a shipping case into position for receiving one or more package from
the primary
conveyor system, such as at a loading station. In some embodiments, the
loading station includes
a means for moving one or more package into contact with one or more inner
surface of the
shipping case and/or for otherwise securing one or more package within the
shipping case, such
as by securing the one or more package to one or more other package within the
case. In some
embodiments, the loading station includes and/or is associated with a means of
moving the
shipping case from an open configuration for receiving packages to a closed
configuration for
concealing packages within the shipping case. In some embodiments, the loading
station further
includes and/or is further associated with a means of securing the shipping
case in the closed
configuration, such as with tape, glue, banding, or the like.
[0040] In some embodiments, the system includes one or more adhesive
application
station. In some embodiments, the adhesive application station applies
adhesive to one or more
inner surface of a shipping case, such as by spraying adhesive into the
shipping case as the
shipping case is moved towards the loading station. In some embodiments, the
adhesive
application station applies adhesive to one or more surface of the package,
such as a top or
bottom surface of the package. In some embodiments, the loading station is
configured to flip the
package over so as to facilitate bonding a top surface of the package to an
inner surface of a
bottom panel of the shipping case using adhesive dots applied to a top surface
of the package. In
some embodiments, the adhesive is configured to secure a sacrificial film
(such as shrink film,
stretch film, paper, or the like) to corrugated paper board. In some
embodiments, the system
includes two adhesive application stations, a first for applying a first
adhesive to a package and
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the second for applying a second adhesive to the shipping case. In some
embodiments, the first
and second adhesives are configured to bond to each other.
[0041] In some embodiments, the system is configured to automatically select a
shipping
case based on sizing and weight requirements. In some embodiments, the system
includes a
selection station for selecting a shipping case based on size and/or weight
requirements and/or
the like. In some embodiments, the sacrificial film is formed at least
partially from a recyclable
material. In some embodiments, the sacrificial film is produced at least
partially from a
renewable resource.
[0042] In the foregoing description, certain terms have been used for brevity,
clearness
and understanding; but no unnecessary limitations are to be implied therefrom
beyond the
requirements of the prior art, because such terms are used for descriptive
purposes and are
intended to be broadly construed. Moreover, the description and illustration
of the inventions is
by way of example, and the scope of the inventions is not limited to the exact
details shown or
described.
[0043] Although the foregoing detailed description of the present invention
has been
described by reference to an exemplary embodiment, and the best mode
contemplated for
carrying out the present invention has been shown and described, it will be
understood that
certain changes, modification or variations may be made in embodying the above
invention, and
in the construction thereof, other than those specifically set forth herein,
may be achieved by
those skilled in the art without departing from the spirit and scope of the
invention, and that such
changes, modification or variations are to be considered as being within the
overall scope of the
present invention. Therefore, it is contemplated to cover the present
invention and any and all
changes, modifications, variations, or equivalents that fall with in the true
spirit and scope of the
underlying principles disclosed and claimed herein. Consequently, the scope of
the present
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invention is intended to be limited only by the attached claims, all matter
contained in the above
description and shown in the accompanying drawings shall be interpreted as
illustrative and not
in a limiting sense.
[0044] Having now described the features, discoveries and principles of the
invention,
the manner in which the invention is constructed and used, the characteristics
of the construction,
and advantageous, new and useful results obtained; the new and useful
structures, devices,
elements, arrangements, parts and combinations, are set forth in the appended
claims.
[0045] It is also to be understood that the following claims are intended to
cover all of the
generic and specific features of the invention herein described, and all
statements of the scope of
the invention which, as a matter of language, might be said to fall
therebetween.
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