U.S. patent application number 13/072991 was filed with the patent office on 2011-07-14 for apparatus and methods for connecting multiple photovoltaic modules.
This patent application is currently assigned to SOLYNDRA, INC.. Invention is credited to Benyamin Buller, Tim Leong.
Application Number | 20110168230 13/072991 |
Document ID | / |
Family ID | 39369725 |
Filed Date | 2011-07-14 |
United States Patent
Application |
20110168230 |
Kind Code |
A1 |
Buller; Benyamin ; et
al. |
July 14, 2011 |
APPARATUS AND METHODS FOR CONNECTING MULTIPLE PHOTOVOLTAIC
MODULES
Abstract
In some embodiments, an apparatus for electrically connecting a
plurality of photovoltaic modules in a solar panel includes a first
electrically conductive line engageable with and capable of
electrically connecting a plurality of first output contacts of the
photovoltaic modules along a common axis.
Inventors: |
Buller; Benyamin;
(Cupertino, CA) ; Leong; Tim; (Danville,
CA) |
Assignee: |
SOLYNDRA, INC.
Fremont
CA
|
Family ID: |
39369725 |
Appl. No.: |
13/072991 |
Filed: |
March 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11982612 |
Nov 2, 2007 |
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13072991 |
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60859213 |
Nov 15, 2006 |
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60859212 |
Nov 15, 2006 |
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60859188 |
Nov 15, 2006 |
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60859033 |
Nov 15, 2006 |
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60859215 |
Nov 15, 2006 |
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60861162 |
Nov 27, 2006 |
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60901517 |
Feb 14, 2007 |
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Current U.S.
Class: |
136/244 |
Current CPC
Class: |
H01R 4/4818 20130101;
H01R 33/02 20130101; H01L 31/0508 20130101; H01R 13/22 20130101;
H01L 31/035281 20130101; H01L 31/02008 20130101; Y02E 10/50
20130101; H01L 31/0504 20130101; H01R 13/10 20130101; H02S 30/10
20141201; H01L 31/0201 20130101 |
Class at
Publication: |
136/244 |
International
Class: |
H01L 31/05 20060101
H01L031/05 |
Claims
1. An apparatus for electrically connecting a plurality of
photovoltaic modules disposed within a solar panel, the solar panel
including a frame that includes first and second opposing side
rails and first and second opposing end rails, the apparatus
comprising: at least one of the photovoltaic modules including a
plurality of solar cells that share a common substrate; and a first
electrically conductive line extending at least partially through,
and electrically connecting together the plurality of photovoltaic
modules within, at least one among the first and second opposing
side rails and the first and second opposing end rails of the
frame.
2. An apparatus for electrically connecting a plurality of
photovoltaic modules disposed within a solar panel, the solar panel
including a frame that includes first and second opposing side
rails and first and second opposing end rails, the apparatus
comprising: the plurality of photovoltaic modules being disposed
within the solar panel in a manner that prohibits rotational
movement of the plurality of photovoltaic modules relative to the
solar panel; at least one of the photovoltaic modules including a
plurality of solar cells that share a common substrate; and a first
electrically conductive line extending at least partially through,
and electrically connecting together the plurality of photovoltaic
modules within, at least one among the first and second opposing
side rails and the first and second opposing end rails of the
frame.
3. An apparatus for electrically connecting a plurality of
photovoltaic modules disposed within a solar panel, the solar panel
including a frame that includes first and second opposing side
rails and first and second opposing end rails, the apparatus
comprising: at least one of the photovoltaic modules including a
plurality of solar cells that share a common substrate; the
plurality of photovoltaic modules being configured to accept light
from more than one planar direction and produce electric power from
light received from more than one planar direction; and a first
electrically conductive line extending at least partially through,
and electrically connecting together the plurality of photovoltaic
modules within, at least one among the first and second opposing
side rails and the first and second opposing end rails of the
frame.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 11/982,612, filed Nov. 2, 2007, entitled
"Apparatus and Methods for Connection Multiple Photovoltaic
Modules", which claims the benefit of U.S. provisional application
Ser. Nos. 60/859,213, 60/859,212, 60/859,188, 60/859,033,
601859,215, 60/861,162, 60/901,517, and incorporates all the
preceding applications by reference herein in their entireties.
BACKGROUND
[0002] This disclosure relates to photovoltaic energy
absorption/collection technology. In some embodiments, this
disclosure relates to apparatus and methods for electrically
connecting two or more photovoltaic modules in a solar panel.
[0003] Various known photovoltaic energy absorption/collection
devices, such as solar panels, include an array of essentially flat
photovoltaic modules arranged side-by-side and placed in a box-like
housing. Typically, the modules are coated with a clear, thermoset
elastomer and the housing is sealed with a clear faceplate. The
modules are thus typically rendered immobile within a "sandwich" of
materials in large flat panels.
[0004] The photovoltaic modules are often electrically connected
together by a series connection that weaves amongst the modules
lying in the housing. In some instances, such arrangement may have
disadvantages. For example, every turn and span of the connection
configuration could be subject to breakage or separation. For
another example, due to the sandwich-like configuration, when a
module or connection fails, it is difficult or impossible to
replace the module or repair the connection buried in the
panel.
[0005] It should be understood, however, that the above-described
examples, features and/or disadvantages are provided for
illustrative purposes only and are not intended to limit the scope
or subject matter of this patent, any other patent claiming
priority hereto or any claim thereof. Thus, none of the appended
claims, or claims of any related patent application or patent,
should be limited by the above discussion or construed to address,
include or exclude the above-cited examples, features and/or
disadvantages, except and only to the extent as may be expressly
stated in a particular claim. Further, the above exemplary
disadvantages should be evaluated on a case-by-case basis to
determine if they may exist.
BRIEF SUMMARY
[0006] In some embodiments, the present disclosure involves an
apparatus for electrically connecting a plurality of photovoltaic
modules located within a solar panel. Each photovoltaic module
includes a first output contact that extends at least partially on
a first common axis. A first electrically conductive line is
engageable with and capable of electrically connecting the first
output contacts of the photovoltaic modules along the first common
axis.
[0007] Various embodiments of the present disclosure involve an
apparatus for electrically connecting a plurality of photovoltaic
modules disposed within a solar panel. The solar panel includes a
frame having first and second opposing side rails and first and
second opposing end rails. A first electrically conductive line
extends at least partially through, and electrically connects
together the plurality of photovoltaic modules within, at least one
among the first and second opposing side rails and the first and
second opposing end rails of the frame.
[0008] There are embodiments of the present disclosure that involve
an apparatus capable of electrically connecting a plurality of
elongated photovoltaic modules disposed in generally spaced
parallel relationship with one another within a solar energy
absorption device. Each of the elongated photovoltaic modules
includes an anode output contact that extends at least partially on
a first common axis and a cathode output contact that extends at
least partially on a second common axis. A first electrically
conductive line is engageable with and capable of electrically
connecting together the cathode output contacts along the first
common axis. A second electrically conductive line is engageable
with and capable of electrically connecting together the anode
output contacts along the second common axis.
[0009] Accordingly, the present disclosure includes features and
advantages which are believed to enable it to advance solar energy
absorption or collection technology. Characteristics and advantages
of the present disclosure described above and additional features
and benefits will be readily apparent to those skilled in the art
upon consideration of the following detailed description and
referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following figures are part of the present specification,
included to demonstrate certain aspects of embodiments of the
present disclosure and referenced in the detailed description
herein.
[0011] FIG. 1 is a perspective view of an example solar panel that
includes a plurality of photovoltaic modules mounted in a
frame;
[0012] FIG. 2 is a plan view of the example solar panel of FIG.
1;
[0013] FIG. 3 is a partial top view of multiple example
photovoltaic modules being electrically connected by first and
second electrically conductive lines in accordance with an
embodiment of the present disclosure;
[0014] FIG. 4A is a perspective view with partial cutaway of a
socket strip with connectors in accordance with an embodiment of
the present disclosure;
[0015] FIG. 4B is an exploded view of the embodiment of the
connector shown in FIG. 4A;
[0016] FIG. 4C is a partial sectional view of the connector of FIG.
4A shown engaged with an example photovoltaic module in accordance
with an embodiment of the present disclosure;
[0017] FIG. 5 is a partial sectional view of another embodiment of
a connector in accordance with the present disclosure;
[0018] FIG. 6 is a partial sectional view of yet another embodiment
of a connector in accordance with the present disclosure; and
[0019] FIG. 7 is an isolated view of still a further embodiment of
a connector in accordance with the present disclosure.
DETAILED DESCRIPTION
[0020] Characteristics and advantages of the present disclosure and
additional features and benefits will be readily apparent to those
skilled in the art upon consideration of the following detailed
description and referring to the accompanying figures. It should be
understood that the description herein and appended drawings are of
various exemplary embodiments and are not intended to limit the
appended claims or the claims of any patent or patent application
claiming priority to this application. On the contrary, the
intention is to cover all modifications, equivalents and
alternatives falling within the spirit and scope of the claims.
Many changes may be made to the particular embodiments and details
disclosed herein without departing from such spirit and scope.
[0021] In the description below and appended figures, common or
similar features are indicated by like or identical reference
numerals or, in the absence of a reference numeral, are evident
based upon the appended figures and/or description herein. The
figures are not necessarily to scale and certain features and
certain views of the figures may be shown exaggerated in scale or
in schematic in the interest of clarity and conciseness. It should
also be noted that reference herein and in the appended claims to
components and aspects in a singular tense does not necessarily
limit the present disclosure to only one such component or aspect,
but should be interpreted generally to mean one or more, as may be
suitable and desirable in each particular instance.
[0022] Referring initially to FIGS. 1 and 2, an example solar
energy collection or absorption device 10, such as a solar panel
12, is shown having an array, or plurality, of photovoltaic cells,
or modules, 16. If desired, the solar panel 12 may be used as part
of a larger system of solar panels (not shown), as is and becomes
further know. The photovoltaic modules 16 may have any suitable
form, shape and construction. In the particular example shown, each
module 16 is "elongated" because its length L (FIG. 2) is equal to
or greater than three times its width, or diameter, W. However, the
photovoltaic modules 16 may not be elongated and different types
and configurations of photovoltaic modules 16 may be included in
the same solar panel 12.
[0023] In this example, the modules 16 have a generally cylindrical
overall shape with a generally circular cross-sectional shape to
capture light from any direction. However, the modules 16 may have
any suitable cross-sectional shape, such as square, rectangular,
elliptical, polygonal, or have a varying cross-sectional shape, as
well as desired overall shape and configuration. For example, the
modules 16 may have a cylindric-like shape, bifacial or omnifacial
configuration or be otherwise designed to capture light on planes
both facing and not facing the initial light source. An example
omnifacial topology of a module 16 may include a bifacial
configuration where both its top and bottom planes accept light and
produce electric power in response to that light. Another example
omnifacial topology may collect reflected light on the back and/or
sides of the module 16 and light striking the module 16 from any
direction other than the planar orientation of the frame 20.
[0024] The modules 16 may have any suitable construction. Each
module 16 of this example includes a monolithic substrate having a
plurality of solar cells (not shown) disposed or manufactured on
it. In other embodiments, the module 16 may include a monolithic
substrate having one solar cell disposed on it. In yet other
embodiments, the module 16 may include a plurality of solar cells
each made on their own individual substrates and linked together
electrically.
[0025] The solar panel 12 may have any other desired components and
configuration. In the example shown, the solar panel 12 includes a
frame 20 having a pair of opposing first and second side rails 24,
26 interconnected with a pair of opposing first and second end
rails 32, 34. The illustrated rails 24, 26, 32, 34 are each
substantially straight, but, if desired, may not be straight. In
this example, the rails are connected together with corner brackets
30 and the end rails 32, 34 each have a concave portion, or groove,
33. The illustrated frame 20 may employ one or more reflective or
increased-albedo surface or capability, such as a backplate 37
having a reflective surface 38 located behind the modules 16, to
reflect and thus redirect light back to the modules 16.
[0026] The photovoltaic modules 16 may be arranged in any desired
manner and configuration. In the example shown, over three dozen
photovoltaic modules 16 are secured in generally spaced parallel
relationship with one another within the frame 20. However, any
number of modules 16 may be contained within the exemplary solar
panel 20. The illustrated modules 16 generally run perpendicular
to, and extend between, the end rails 32, 34. The modules 16 are
engaged in, or affixed to, the rails 32, 34 so that they are not
movable relative to the frame 20 or one another. Alternately, one
or more modules 16 may be movable. For example, the modules 16 may
be engaged in, or affixed to, the rails 32, 34 so that they may be
individually or collectively swiveled or tilted at angles relative
to the frame 20, such as to track the movement of the sun.
[0027] The exemplary modules 16 are spaced apart and positioned
depth-wise in the frame 20 so that light is capable of passing
through spaces formed between the modules 16 and the modules 16 can
absorb light from the direction the light emanates or reflects. For
example, the modules 16 may be capable of absorbing light passing
through spaces between the modules 16 and reflected back from the
backplate 37. Modules 16 having a cylindrical or cylindric-like
shape, or bifacial or omnifacial configuration or otherwise enabled
to capture the light on a plane not facing the initial light
source, may absorb light emanating or reflecting from any direction
and use it to generate electrical energy.
[0028] Referring specifically to FIG. 2, each illustrated
photovoltaic module 16 includes first and second electrical output
contacts 42, 44 at its first and second ends 43, 45, respectively.
The output contacts 42, 44 provide the electricity that is
generated by the corresponding photovoltaic module 16. In this
example, the first output contacts 42 are anodes and the second
output contacts 44 are cathodes, but the opposite arrangement may
instead be employed. As shown in FIGS. 3 and 4, all of the
exemplary first output contacts 42 extend at least partially on a
first common axis 50, while all of the second illustrated output
contacts 44 extend at least partially on a second common axis 54.
As used herein and in the appended claims, the term "axis" means a
line or an area having a width that is no greater than
approximately one-half its length. Further information about the
components and operation of the example solar panel 12,
photovoltaic modules 16 and their construction and operation are
know and may be found in publicly available documents.
[0029] It should be understood that the present disclosure is not
limited to any of the above details. For one example, each
photovoltaic module 16 may include a single output contact or more
than two output contacts at any desired location (e.g. intermediate
to its ends). For another example, as previously mentioned, the
photovoltaic modules 16 need not be mounted in a frame, nor be
capable of having an omnifacial topology (e.g. capable of absorbing
light from more than one direction). Moreover, all of the
above-referenced components are not required for the present
disclosure, the appended claims or the claims of any patent
application or patent claiming priority hereto.
[0030] Now in accordance with the present disclosure, referring to
the example of FIG. 2, at least one electrically conductive line 60
is capable of electrically connecting at least some of the
photovoltaic modules 16 along a single axis (e.g. axes 50, 54,
FIGS. 3, 4). As used herein and in the appended claims, the term
"electrically conductive line" and variations thereof means any
material(s) or component(s) capable of electrically joining at
least two photovoltaic modules.
[0031] The electrically conductive line (ECL) 60 may have any
suitable construction, and may electrically connect at least two
photovoltaic modules 16 in any desired manner. For example, the ECL
60 may be a flexible or rigid metal wire or strip, or a series
thereof, soldered to at least two output contacts 42. In the
embodiment of FIGS. 2 and 3, a first ECL 64 extends on the first
common axis 50 along the length of and within the first end rail 32
of the frame 20. The first ECL 64 electrically couples each of the
first output contacts 42. A second ECL 68 is similarly situated
with respect to the second common axis 54, second end rail 34 and
second output contacts 44. It should be understood that the first
and second ECLs 64, 68 need not necessarily each be a single wire
or strip, but may instead each include a series of electrically
conducting wires, strips or other members.
[0032] Referring now to FIG. 4A, the first ECL 64 of this
embodiment is a bus-type connection line 66 that includes a
metallic ribbon 67 extending through the length of the end rail 32.
The illustrated bus-type connection line 66 electrically connects a
plurality of leaves, or output contact connectors, 70. Each
exemplary connector 70 is capable of engaging at least one output
contact 42 (FIG. 3) of at least one photovoltaic module 16. The
illustrated bus-type connection line 66 and connectors 70 connect
all the anode contacts 42 of the modules 16 in a common line.
[0033] When included, the connectors 70 may have any suitable form
and construction, and may electrically engage the ECL 60 and
photovoltaic module(s) 16 in any suitable manner. For example, the
ECL 60 and connectors 70 may be formed integrally in a single unit
or connected by weld, solder or snapping engagement. In the
embodiment shown, the illustrated row of connectors 70 are leaf
members 74 having leaves 76 (e.g. FIG. 4B) that crimp or deform
into engagement with an output contact 42 of a photovoltaic module
16 (e.g. FIG. 4C). In another embodiment, referring to FIG. 5, the
connector 70 includes a receptacle 78 engageable with at least one
output contact 42. In this embodiment, the receptacle 78 includes a
curved member 80 engageable with a rounded portion 82 of the output
contact 42. For example, the output contact 42 may have at least
one solder point 84 that engages an at least partially C-shaped
portion 86 of the curved member 80. In yet another embodiment,
referring to FIG. 6, the connector 70 includes a button contact 85
engageable with a tip, or button contact, 87 of the contact 42. In
still another example, referring to FIG. 7, each connector 70 may
include a socket 88 (e.g. akin to the type of socket commonly used
in overhead fluorescent light fixtures) that engages at least one
prong 90 of at least one output contact 42.
[0034] The connectors 70 may be disposed within the solar panel 12
in any desired manner. For example, a row of connectors 70 may be
integrally formed with the corresponding end rail 32, 34 as a
single unitary body (not shown). For another example, a row of
connectors 70 may be integrally formed in a unitary body (not
shown) that is engaged with or embedded into the end rail 32, 34.
In the embodiment of FIG. 4A, the connectors 70 and the bus-type
connection line 66 are located within an insert, or socket strip,
92 that is positioned within the concave portion 33 of the first
end rail 32. The illustrated socket strip 92 is designed to secure
the connectors 70 in the frame 20 at predetermined spacing
intervals to correspond with the orientation of the contacts 42
(e.g. FIG. 3). The socket strip 92 and connectors 70 of this
example serve to both electrically connect and mechanically hold
the modules 16 in position in the frame 20.
[0035] The socket strip 92 may have any suitable form, construction
and configuration. In the embodiment of FIG. 4A, the socket strip
92 includes cavities 94 within which the connectors 70 are seated.
Additional spaces (not shown) may be necessary for placement of the
electrically conductive line(s) 60. In some embodiments, the socket
strip 92 may be constructed of flexible material, such as rubber,
to facilitate engagement with the corresponding end rail 32, 34,
electrically insulate the ECL 60, assist in reducing stress applied
to the modules 16, facilitate seating of the connectors 70 and/or
their engagement with the modules 16, or any other desired purpose.
In other embodiments, the socket strip 92 may be constructed of a
rigid material, such as to provide rigidity to the end rails 32,
34, assist in maintaining the desired positioning of the modules
16, or other purpose. Likewise, the socket strip 92 may be
constructed of a semi-rigid material, such as foam, or have
portions of differing rigidity and flexibility.
[0036] The socket strip 92, when included, may be engaged with the
solar panel 12 in any desired manner. For example, a socket strip
92 constructed at least partially of rubber or foam may be glued
inside the associated end rail 32, 34. For other examples, the
socket strip 92 may be press-fit, snapped or slid into the
associated end rail 32, 34.
[0037] If desired, one or more mechanism may be associated with the
socket strip 92, connectors 70, modules 16, rails 24, 26, 32, 34,
or any combination thereof to allow the modules 16 to be moveable.
For example, components may be included to automatically swivel or
tilt the modules 16 to vary their angular orientation, such as to
track the movement of the sun. However, the modules 16 may be
configured in any position or angular relationship relative to the
rails 24, 26, 32, 42, as long as they are electrically connected
within, or to, at least one rail.
[0038] It should be noted that the details of construction and
operation of the first ECL 64 of this embodiment as described above
and shown in FIG. 4A apply equally, as appropriate, to the second
ECL 68 of this embodiment.
[0039] The electrical energy, or voltage, from the modules 16 may
be communicated by the electrically conductive line(s) 60 from the
solar panel 12 in any desired manner. In the embodiment of FIG. 3,
for example, the first ECL 64 connects all the (anode) output
contacts 42 of the modules 16 to a common anode terminal 96, such
as a commercially available male or female electrical plug or
socket (not shown). Similarly, the second ECL 68 connects all the
(cathode) output contacts 44 to a common cathode terminal 98. The
illustrated modules 16 are thus connected in parallel. In this
manner, the electrical connection between the modules 16 of this
example is defined by two bus-like connections embedded within the
framework. However, the present disclosure includes embodiments
having one or more electrically conductive lines 60 engageable in
any suitable manner with any desired number of electrical output
contacts of photovoltaic modules 16. For example, one ECL 60 may
electrically connect some of the output contacts 42 in the first
end rail 32, while another ECL 60 electrically connects other of
the output contacts 42 in the same rail 32.
[0040] Accordingly, apparatuses and methods useful for electrically
connecting two or more photovoltaic modules in a solar panel are
described. These apparatuses and methods have one or more of the
following attributes, capabilities or features: an electrical
connection of at least two elongated photovoltaic modules of a
solar panel along a common axis; an electrical connection of at
least two elongated photovoltaic modules of a solar panel in a
generally straight path; a bus-type connection that connects all
the anode contacts of elongated photovoltaic modules in a common
line; a bus-type connection that connects all the cathode contacts
of elongated photovoltaic modules in a common line; a first
bus-type connection that connects all the anode contacts of the
photovoltaic modules in a common line and a second bus-type
connection that connects all the cathode contacts of the
photovoltaic modules in a common line; electrically connects
photovoltaic modules within one or more structural member of the
solar panel; electrically connects photovoltaic modules within one
or more rail of the solar panel; electrically connects the
photovoltaic modules in parallel within the end rails of the solar
panel; electrically connects elongated photovoltaic modules;
electrically connects photovoltaic modules capable of absorbing
solar energy from any direction; electrically connects photovoltaic
modules capable of absorbing solar energy from more than one planar
direction; electrically connects all photovoltaic modules of a
solar panel with one or more electrically conductive line of
minimal length; is reliable and easy to manufacture and
utilize.
[0041] Embodiments of the present disclosure thus offer advantages
over the prior art and are well adapted to carry out one or more of
the objects of the disclosure. However, each of the appended claims
do not require each of the components and acts described above and
is in no way limited to the above-described embodiments and methods
of assembly and operation. Any one or more of the above components,
features and processes may be employed in any suitable
configuration without inclusion of other such components, features
and processes. Moreover, the present disclosure includes additional
features, capabilities, functions, methods, uses and applications
that have not been specifically addressed herein but are, or will
become, apparent from the description herein, the appended drawings
and claims.
[0042] The methods described above and which may be claimed herein
and any other methods which may fall within the scope of the
appended claims can be performed in any desired suitable order and
are not necessarily limited to the sequence described herein or as
may be listed in any appended claims. Further, the methods of the
present disclosure do not necessarily require use of the particular
embodiments shown and described in the present application, but are
equally applicable with any other suitable structure, form and
configuration of components.
[0043] While embodiments have been shown and described, many
variations, modifications and/or changes of the system, apparatus
and methods herein, such as in the components, details of
construction and operation, arrangement of parts and/or methods of
use, are possible, contemplated by the patent applicant(s), within
the scope of the appended claims, and may be made and used by one
of ordinary skill in the art without departing from the spirit or
teachings of this disclosure and scope of appended claims. Thus,
all matter herein set forth or shown in the accompanying drawings
should be interpreted as illustrative, and the scope of this
disclosure and the appended claims should not be limited to the
embodiments described and shown herein.
* * * * *