U.S. patent application number 10/860401 was filed with the patent office on 2004-12-09 for yarn feeding system.
Invention is credited to Sheehy, James J. JR..
Application Number | 20040244430 10/860401 |
Document ID | / |
Family ID | 33493477 |
Filed Date | 2004-12-09 |
United States Patent
Application |
20040244430 |
Kind Code |
A1 |
Sheehy, James J. JR. |
December 9, 2004 |
YARN FEEDING SYSTEM
Abstract
An improved system and associated method is disclosed for
positive feeding of multiple strands of yarn from spools using a
single motor drive within a hose reinforcement knitting machine of
the type having a central knitter head with reciprocating needles
that stitch a reinforcement web pattern around flexible hose moving
through the central axis of the machine. The positive yarn feeding
system comprises a feeder head assembly attached to rotating
framework of the knitting machine coaxially with the knitter head.
The feeder head assembly includes a circular support plate having
an axial opening therethrough and a plurality of positive feeder
units, one for each of the yarn strands intended for knitting. The
feeder units are arranged in a radial pattern about the periphery
of the support plate and interconnected for concurrent rotation by
a coupling belt extended about upper wheels on the units. The
feeder head assembly further includes a central gear mounted in a
stationary position atop the support plate, a planetary gear
rotatably mounted upon the support plate in position to engage the
central gear, an adjustable control gear secured atop the planetary
gear, and a drive belt engaged about the control gear and a
proximate one of the feeder units to provide the rotational drive
for all. As the single motor drive rotates the framework of the
knitter machine and its mounted spools, the feeder head assembly
rotates in unison and by means of the combined arrangement of
interconnected gears assembled thereto, synchronizes the drawing of
the yarn strands through the feeder units and into the central
knitter head.
Inventors: |
Sheehy, James J. JR.;
(Bensalem, PA) |
Correspondence
Address: |
Armand M. Vozzo, Jr. , Esquire
19 Short Road
Doylestown
PA
18901
US
|
Family ID: |
33493477 |
Appl. No.: |
10/860401 |
Filed: |
June 3, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60475962 |
Jun 5, 2003 |
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Current U.S.
Class: |
66/125R |
Current CPC
Class: |
D04B 1/225 20130101;
D04B 15/48 20130101; D04B 9/44 20130101 |
Class at
Publication: |
066/125.00R |
International
Class: |
D04B 003/06 |
Claims
What is claimed:
1. A system for feeding yarn in a circular knitter machine of the
type used to reinforce a flexible hose by applying a knitted yarn
pattern upon the exterior of the hose moving axially through the
machine, the knitter machine being further of the type including a
cylindrical knitter head disposed along the central axis of the
machine and a deck rotatable about the axis, the knitter head
further containing a plurality of knitting needles disposed about
the knitter head, each needle operatively connected to a rotatable
cam member and thereupon made to reciprocate along the central axis
and thereby apply the knitted yarn pattern, comprising: a plurality
of wound supplies of yarn in continuous strands mounted upon the
deck for rotation about the central axis of the machine; feeder
head means assembled to rotate about the knitter head and connected
to receive respective strands from said plurality of wound supplies
of yarn for positively feeding the strands into the knitter head
and the reciprocating needles thereof at a controlled and
synchronized rate; and motor means connected to drive the rotation
of said feeder head means in unison with the deck and cam member of
the knitter machine.
2. A yarn feeding system according to claim 1, wherein said feeder
head means comprises: positive feeder means mounted for rotation
about the central axis of the knitter machine and operatively
connected to draw respective strands of yarn from the plurality of
wound supplies for positively feeding the yarn strands into the
knitter head and to the reciprocating knitting needles; and rate
control means operatively connected to said positive feeder means
for controlling the feed rate of the yarn strands to the knitting
needles.
3. A yarn feeding system according to claim 2, wherein said
positive feeder means comprises: a support plate having a central
opening axially therethrough and rotatably mounted about the
central axis of the knitting machine; a plurality of positive
feeder units rotatably mounted to said support plate about the
periphery thereof, each of said plurality of positive feeder units
being operatively connected to receive a yarn strand from a
respective one of said wound supplies of yarn; and a first belt
member interconnecting said plurality of positive feeder units for
concurrent rotation thereof.
4. A yarn feeding system according to claim 3, wherein said rate
control means comprises: a first gear member stationed within the
knitting machine in a coaxial position relative to said support
plate; a second gear member rotatably mounted to said support plate
and positioned to engage said first gear member so that said second
gear member rotates about said first gear member as said support
plate rotates; a third gear member having a selected size and
number of gear teeth, said third gear member being coaxially
positioned and mounted upon said second gear member so as to rotate
coaxially together with said second gear member; and a second belt
member engaged between said third gear member and a selected one of
said positive feeder units for rotation thereof at a controlled
rotational rate determined by the size and teeth of said third gear
member.
5. A yarn feeding system according to claim 4, wherein said
plurality of wound supplies of yarn are yarn spools.
6. A yarn feeding system according to claim 5, wherein said motor
means is a drive motor mounted within the knitting machine.
7. A yarn feeding system according to claim 1, wherein said feeder
head means comprises: positive feeder means mounted for rotation
about the central axis of the knitter machine and operatively
connected to draw respective strands of yarn from the plurality of
wound supplies for positively feeding the yarn strands into the
knitter head and to the reciprocating knitting needles; and
variable rate control means operatively connected to said positive
feeder means to provide a fine adjustment to the rate control of
said positive feeder means and thereby reduce the tensioning of the
yarn strands delivered to the knitting needles.
8. A yarn feeding system according to claim 7, wherein said
positive feeder means comprises: a support plate having a central
opening axially therethrough and rotatably mounted about the
central axis of the knitting machine; a plurality of positive
feeder units rotatably mounted to said support plate about the
periphery thereof, each of said plurality of positive feeder units
being operatively connected to receive a yarn strand from a
respective one of said wound supplies of yarn; and a first belt
member interconnecting said plurality of positive feeder units for
concurrent rotation thereof.
9. A yarn feeding system according to claim 8, wherein said
variable rate control means comprises: a first gear member
rotatably coupled to said support plate for independent rotation
about the central axis of the knitting machine; variable speed
drive means mounted within the knitter machine for rotating said
first gear member at an adjusted rate in either direction relative
to said support plate; a second gear member rotatably mounted upon
said support plate and positioned to engage said first gear member
so that the rate of rotation of said second gear member is
established by the adjusted rate of said first gear member; a third
gear member having a selected size and number of gear teeth, said
third gear member being coaxially positioned and mounted upon said
second gear member so as to rotate coaxially together with said
second gear member; and a second belt member engaged between said
third gear member and a selected one of said positive feeder units
for rotation thereof at variably controlled rotational rate
determined by the size and teeth of said third gear member.
10. A yarn feeding system according to claim 9, wherein said
variable speed drive means comprises: a variable speed motor
stationed to the knitting machine; and a fourth gear member
operatively coupled to said variable speed motor and disposed for
rotational engagement with said first gear member.
11. A yarn feeding system according to claim 10, wherein said
plurality of wound supplies of yarn are yarn spools.
12. A yarn feeding system according to claim 11, wherein said motor
means is a drive motor mounted within the knitting machine.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of Provisional
Application Ser. No. 60/475,962 filed Jun. 5, 2003 for Yarn Feeding
System.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the production of
reinforced flexible hose having a knitted pattern of yarn or other
fabric material secured upon the exterior hose surface, and more
particularly to an improved system and associated method for the
positive feeding of the yarn in multiple strands around the hose at
a controlled and synchronized rate using a single motor drive and
novel feeder head assembly that enhances the product quality and
efficiency of production of the reinforced hose.
[0003] Flexible hose made of rubber, synthetic plastics, and the
like have limited burst strength so that their use in industry for
the transmission of fluids at high pressure require a reinforcement
of their exterior surface. A longstanding and well known method for
reinforcing such flexible hose uses a circular knitting machine
that applies the yarn or like fabric material in a mesh like
pattern around and along the exterior of the hose as it is drawn
through the knitting machine. A common type of circular knitting
machine generally adapted for use in hose reinforcement comprises a
hollow cylindrical member, called a knitter head, containing a
plurality of latch needles that are symmetrically arranged about
the knitter head and made to reciprocate within equally spaced
guide slots axially formed along the head, the reciprocating action
of the needles being imparted typically by one or more cam members
that are mounted for rotation along with the knitter head.
Individual strands of yarn, usually drawn from separate cones or
spools mounted on the knitter machine, are directed in a path to
each latch needle in the knitter head so that the reciprocating
needle will engage the strand in the one direction and pull the
yarn through the knitter head and onto. the hose exterior in the
opposite direction as the hose travels therethrough. This process
is repeated with all the reciprocating needles acting together
around the knitter head to produce a stitched pattern of the
knitted yarn surrounding the hose that can be varied in size and
disposition of the stitches to provide it with the required
reinforcement strength.
[0004] In the past, such circular knitting machines would rely on
the tension adjustment of the yarn as it was drawn through the
knitter head, typically using a spring-loaded washer device, to
regulate the flow rates of the yarn strands and thereby control the
stitching pattern of the reinforcement. This process of tension
adjustment, however, was often inconsistent and generally proved
unreliable, with resulting variations in yarn tension that caused
uneven patterns of reinforcement along the hose product, the uneven
removal of yarn from the individual spools, and a damaging stress
on the knitting needles that would in turn result in needle failure
and machine breakdown. Supplemental positive feeding devices, such
as that described in U.S. Pat. No. 5,309,738, have been devised to
overcome the problems of strand tensioning and the detrimental
effects that result when knitter needles alone are used to draw the
yarn strands from their respective supply packages and through the
knitter head. These and other positive yarn feeding devices have
been satisfactory and effective in equalizing the feed rates of the
individual yarn strands onto the knitter head and in coordinating
those feed rates with the rate at which the knitter head with its
reciprocating needles acts upon the respective strands to knit the
desired reinforcement pattern about the hose. Although existing
positive yarn feeding devices have been effective in their
operational performance, they have generally required the use of
multiple drive motors with associated mechanical and electrical
means to maintain them in unison so that the final reinforced hose
product is made to the desired specifications. Thus, while
generally found to be effective, the multi-drive positive feeding
systems of the prior art have been relatively expensive to assemble
and run and, because of the essential coordination required between
the separate drives, they are inherently at risk to a possible
system failure or disorientation between drives that can result in
costly downtime of the hose reinforcement system as well as the
production of defective quantities of hose product having
inadequate or improper reinforcement. A need therefore exists for
an improved system and associated method for positive yarn feeding
to be incorporated within a circular knitting machine used to
produce reinforced flexible hose.
SUMMARY OF THE INVENTION
[0005] Accordingly, it is a general purpose and object of the
present invention to provide an improved positive yarn feeding
device and associated method for use in the production of
reinforced flexible hose.
[0006] A more particular object of the present invention is to
provide a positive yarn feeding system that delivers multiple
strands of yarn to the knitter head of a conventional circular
knitting machine at a controlled and synchronized rate and in a
manner more economical and efficient than heretofore devised.
[0007] Another object of the present invention is to provide an
improved positive yarn feeding system for use in the production of
reinforced flexible hose that is reliable in its operation so as to
reduce downtimes and defects in the production process.
[0008] Still another object of the present invention is to provide
an improved positive yarn feeding system for knitted reinforcement
of flexible hose that enhances the quality of the reinforced hose
product and affords greater control of the knitted pattern applied
during production.
[0009] A still further object of the present invention is to
provide a positive yarn feeding system that is easily assembled and
readily adapted to the knitter heads of conventional circular
knitting machines used for flexible hose reinforcement.
[0010] Briefly, these and other objects of the present invention
are accomplished by an improved system and associated method for
the positive feeding of multiple strands of yarn from spools using
a single motor drive within a hose reinforcement knitting machine
of the type having a central knitter head with reciprocating
needles that stitch a reinforcement web pattern around flexible
hose moving through the central axis of the machine. The positive
yarn feeding system comprises a feeder head assembly attached to
rotating framework of the knitting machine coaxially with the
knitter head. The feeder head assembly includes a circular support
plate having an axial opening and a plurality of positive feeder
units, one for each of the yarn strands intended for knitting. The
feeder units are arranged in a radial pattern about the periphery
of the support plate and interconnected for concurrent rotation by
a coupling belt extended about upper wheels on the units. The
feeder head assembly further includes a central gear mounted in a
stationary position atop the support plate, a planetary gear
rotatably mounted upon the support plate in position to engage the
central gear, an adjustable control gear secured atop the planetary
gear, and a drive belt engaged about the control gear and a
proximate one of the feeder units to provide the rotational drive
for all. As the single motor drive rotates the framework of the
knitter machine and its mounted spools, the feeder head assembly
rotates in unison and by means of the combined arrangement of
interconnected gears assembled thereto, synchronizes the drawing of
the yarn strands through the feeder units and into the central
knitter head.
[0011] For a better understanding of these and other aspects of the
present invention, reference should be made to the following
detailed description taken in conjunction with the accompanying
drawings in which like reference numerals and characters designate
like parts throughout the figures thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a fuller understanding of the nature and object of the
present invention, references in the detailed description of the
preferred embodiment set forth below shall be made to the
accompanying drawings in which:
[0013] FIG. 1 is a vertical elevation of a circular knitting
machine used for hose reinforcement and equipped with a yarn
feeding system made in accordance with the present invention;
[0014] FIG. 2 is a partial elevation of the knitting machine of
FIG. 1 with an enlarged view of the yarn feeding system of the
present invention;
[0015] FIG. 3 is an isometric from the top of the yarn feeding
system shown in FIG. 2;
[0016] FIG. 4 is a top plan view of the yarn feeding system shown
in FIG. 3; and
[0017] FIG. 5 is a schematic illustration of a modified version of
the yarn feeding system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following is a detailed description of a preferred
embodiment of the present invention and the best presently
contemplated mode of its production and practice. This description
is further made for the purpose of illustrating the general
principles of the invention but should not be taken in a limiting
sense, the scope of the invention being best determined by
reference to appended claims.
[0019] Referring now to FIG. 1, a circular knitting machine,
adapted for hose reinforcement and generally designated 10, is
vertically oriented and disposed about a central axis through which
a flexible hose 12 is drawn upward at a controlled rate for
application of a knitted yarn pattern P around the exterior surface
and along the length of the hose. The hose 12 is drawn from a
stored supply (not shown) apart from the knitting machine 10 and
routed typically through a base section 11 of the machine. Upon
application of the knitted yarn pattern P, the resultant reinforced
hose 14 is further drawn and routed through an upper portion of the
knitter machine 10, typically through an arrangement of pulleys 13,
for delivery to a remote station for further processing.
[0020] The middle portion of the knitting machine 10, contains a
rotatable deck 15 upon which a plurality of yarn spools 16 or like
supply packages are supported in a radial arrangement relative to
the central axis of the machine. A mounting support member 17
secured to the deck 15 at the corresponding radial positions of the
yarn spools 16 is used to engage the core of the spools, holding
each spool substantially upright and maintaining them in proper
position during rotation of the deck. Individual yarn strands 18
are drawn from the top of each spool 16 during rotation of the deck
15 and, as described in greater detail below, positively fed in
accordance with the present invention to a knitter head 20 of
conventional design disposed along the central axis of knitting
machine 10.
[0021] Knitter head 20 is a cylindrical device generally well known
in the prior art that contains a plurality of knitting needles 22
radially separated and guided for reciprocating action along the
cylindrical axis of the knitter head, the needles being moved in
such fashion by a multi-lobe cam ring 24 coupled to the needles. As
the cam ring 24 is rotated, the reciprocating action is imparted to
the respective knitting needles in succession so that as the
needles are delivered yarn, they apply the knitted yarn pattern P
in a circular manner upon the exterior of the hose 12 as it passes
through the knitter head 20. Reference in this regard to the
structure and operation of such a knitter head 20 may be made to
U.S. Pat. Nos. 3,462,976 and 5,520,018 and the patents cited
therein.
[0022] In accordance with the yarn feeding system of the present
invention, a feeder head assembly 30 is erected about and coaxially
disposed above the knitter head 20. A plurality of frame posts 32,
preferably four in number arranged in a square configuration, are
set about the knitter head 20 and connected at their respective
base ends to the deck 15 to permit concurrent coaxial rotation of
the frame posts with the deck. At the top of the frame posts 32 and
across their respective ends, the feeder head assembly 30 is
attached so that it may rotate about the knitter head 20
substantially in its entirety and in unison with the deck 15. A
single drive motor 26 is mounted within the knitter machine 10 and
operatively coupled to the deck 15 via a drive shaft 27 and
associated gear box 28 to rotate both the deck with its yarn spools
16 thereon and the feeder head assembly 30 upon frame posts 32
coaxially about the knitter head 20 and the central axis of the
knitter machine 10.
[0023] Referring now to FIG. 2 in conjunction with FIG. 1, the
feeder head assembly 30 includes a circular support plate 34 having
an annular opening centrally therethrough to permit passage of the
reinforced hose 14 upon upwardly exiting the knitter head 20.
Support plate 34 is mounted directly upon frame posts 32 and is
secured thereto by conventional means of attachment. A plurality of
yarn feeder units 36, one for each of the corresponding number of
yarn spools 16, are mounted to the support plate 34 about the
periphery thereof in separate radial positions that are equally
spaced apart, as better seen in FIGS. 3 and 4. The yarn feeder
units 36 employed in the feeder head assembly 30 are those
characterized in the industry as "positive feeders" that
incorporate yarn tensioning controls that even the tension of the
yarn fed through the unit regardless of the feed rate. A yarn
feeder unit 36 suitable in structure and operational features for
use in the yarn feeder assembly 30 is Model MPF-K1 currently
manufactured by MEMMINGER-IRO GMBH of Dornstetten, Germany. All of
the yarn feeder units 36 disposed about the periphery of the
support plate 34 are interconnected for rotation in unison by a
toothed belt 38 that stretches about and engages respective wheel
drives 36a on each of the feeder units.
[0024] The feeder head assembly 30 further includes a central gear
40 stationed just atop the support plate 34 in a coaxial position
relative thereto, a center opening in the gear being maintained in
axial alignment with the annular opening in the support plate to
permit and ensure passage of the reinforced hose product 14. The
central gear 40 is mounted and maintained in stationary position
above the support plate 34 by means of a bracket member 42 that is
attached to the upper frame of the knitter machine 10. A planetary
gear 44 is rotatably mounted to the top of the support plate 34 and
positioned thereon so that it engages the perimeter teeth of the
stationary central gear 40 as the support plate is made to rotate.
A separate control gear 46 generally having a reduced diameter,
which may be altered in its size and number of its teeth, is
coaxially positioned upon the planetary gear 44 and releasably
secured thereto. When secured in place, the control gear 46 is made
to rotate coaxially together with the planetary gear 44 about the
central gear 40 but at a rotational rate generally faster than the
planetary gear due to its reduced diameter. A drive belt 48,
preferably toothed in its form, is engaged about the control gear
46 and a proximate one of the yarn feeder units 36 upon an extended
upper wheel 36a provided thereon in order to transmit rotational
motion from the planetary gear 44, at an adjustable rate, to all of
the yarn feeder units 36. The adjustable rate of rotation
transmitted to the yarn feeder units 36 is controlled and
determined by the relative size and number of teeth of the control
gear 46. It should be noted and understood that by changing the
size and number of teeth of the control gear 46, the rate and
amount of yarn fed into the knitter head 20 by the present yarn
feeding system can be varied so that with a predetermined number of
knitting needles 22 reciprocating within the knitter head and a
known exterior diameter and feed rate of the flexible hose 12 being
processed, the quality measure of the knitted yarn pattern P
applied to the hose, typically specified in courses-per-inch (CPI),
can be controlled with considerable precision.
[0025] Referring now to FIGS. 3 and 4 in conjunction with FIGS. 1
and 2, the feeder head assembly 30 of the present yarn feeding
system combines the plurality of yarn feeder units 36 in radial
arrangement about the rotatable support plate 34 and, utilizing the
single rotational drive of motor unit 26, serves to provide
synchronized rate control of the positive feeding of yarn strands
18 through the feeder units and into the knitter head 20. By means
of the rotational engagement and cooperation of stationary central
gear 40, planetary gear 44 and its associated control gear 46, all
linked to the yarn feeder units 36 via drive belt 38, a controlled
and even flow of yarn strands is positively fed into the chamber of
the knitting head with reduced stress on the reciprocating needles.
The feeder units 36 are coupled together via belt 38 and driven in
unison by the rotating action of the planetary gear 44 as it spins
with and upon the support plate 24 about the central gear 40.
Adjustment of the rate of the feeder units 36 is effected by
changing the size and number of radial teeth of the control gear 46
and provides the improved capability of controlling the CPI of the
knitted yarn pattern P applied to the hose 12 drawn through the
knitting machine 10. By this adjustable rate control feature, the
present yarn feeding system simplifies and ensures compliance with
the required strength specifications placed upon the reinforced
hose and while maintaining a positive and even flow of yarn strands
18 to the knitter head 20.
[0026] Referring now to FIG. 5, a modified version of the present
yarn feeding system, particularly intended to supplement the
aforedescribed feeder head assembly 30, is presented. In this
modified version of the feeder head assembly, generally designated
50, a variable speed motor unit 52 is further provided and mounted
within the knitter machine 10 atop the support plate 34 in
juxtaposition to the support bracket 42. An associated gear member
54 operatively coupled to the motor unit 52 via a drive shaft 53 is
sized in its diameter and perimeter teeth and positioned at a level
to engage the central gear 40, which, in this version of feeder
head assembly 50, is preferably increased in thickness to
accommodate engagement with motor gear 54 about the top of the
central gear structure while maintaining engagement with the
planetary gear 44 about the bottom of the central gear structure.
The central gear 40 in this version is further modified in its
mounting relative to the support plate 34 so that it is rotatable
therein and not stationary as in the aforedescribed feeder head
assembly 30. In this regard, a spindle 56 is axially mounted
through the central gear 40 and rotatably coupled thereto via a
central bearing fitted within the gear. The spindle 56 is further
disposed axially through the support plate 34 and adapted to rotate
therein via a similar bearing member fitted within the support
plate. The top of spindle 56 is secured to the support bracket 42
so that the spindle is made stationary within the knitting machine
10 along the central axis thereof and the support plate 34 and
central gear 40 may rotate relative to the spindle. As a result,
the central gear 40 in the modified feeder head assembly 50 may be
rotated in either direction driven by the variable speed motor unit
52 acting through gear member 54 and thereby vary the rotational
speed of the central gear in either a positive or negative fashion.
This added feature of rotational adjustment of the central gear 40
serves to provide a fine adjustment to the rate control of the yarn
feeder units 36 imparted through the respective planetary and
control gears, 44 and 46, and would be used to increase or decrease
the yarn fed into the knitter head 20 and its reciprocating
knitting needles 22 for greater control of the tensioning of the
yarn and the knitted pattern P applied to the reinforced hose
product 14.
[0027] Therefore, it is apparent that the described invention
provides an improved positive yarn feeding device and associated
method for use in the production of reinforced flexible hose. More
particularly, the present invention provides a positive yarn
feeding system that delivers multiple strands of yarn to the
knitter head of a conventional circular knitting machine at a
controlled and synchronized rate and in a manner more economical
and efficient than heretofore devised. Furthermore, the described
invention provides an improvement to positive yarn feeding for the
industrial production of reinforced flexible hose that is reliable
in its operation so as to reduce downtimes and defects in the
production process. In addition, the present yarn feeding system
for knitted reinforcement of flexible hose serves to enhance the
quality of the final reinforced hose product and afford greater
control of the knitted pattern applied during production. The
described positive yarn feeding system is also easily assembled and
readily adapted to the knitter heads of conventional circular
knitting machines that are used in industry for flexible hose
reinforcement.
[0028] Obviously, other embodiments and modifications of the
present invention will readily come to those of ordinary skill in
the art having the benefit of the teachings presented in the
foregoing description and drawings. Alternate embodiments of
different shapes and sizes, as well as substitution of known
materials or those materials which may be developed at a future
time to perform the same function as the present described
embodiment are therefore considered to be part of the present
invention. Accordingly, it is understood that this invention is not
limited to the particular embodiment described, but rather is
intended to cover modifications within the spirit and scope of the
present invention as expressed in the appended claims.
* * * * *