U.S. patent application number 13/444128 was filed with the patent office on 2012-10-11 for modular mounting apparatus.
Invention is credited to Reynold Hendrickson, Jon Karpovich, Rajul Patel.
Application Number | 20120255244 13/444128 |
Document ID | / |
Family ID | 46965006 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120255244 |
Kind Code |
A1 |
Hendrickson; Reynold ; et
al. |
October 11, 2012 |
Modular Mounting Apparatus
Abstract
A mounting apparatus, primarily for solar panels and other
renewable energy panels. The mounting apparatus has a base, sides,
a front, a back, and a top. It is generally wedge-shaped. It has a
depression designed to fit photovoltaic and solar thermal panels.
It has a number of mounting mechanisms, including ballast, tethers,
and fasteners, designed to minimize the number of roof-top holes
needed to anchor a system.
Inventors: |
Hendrickson; Reynold;
(US) ; Patel; Rajul; (US) ; Karpovich;
Jon; (US) |
Family ID: |
46965006 |
Appl. No.: |
13/444128 |
Filed: |
April 11, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61474263 |
Apr 11, 2011 |
|
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Current U.S.
Class: |
52/173.3 ;
52/698 |
Current CPC
Class: |
H01L 35/30 20130101;
F24S 25/11 20180501; Y02E 10/47 20130101; F24S 10/20 20180501; F24S
10/30 20180501; Y02B 10/20 20130101; Y02E 10/44 20130101; F24S
2025/6007 20180501; F24S 2025/02 20180501; F24S 25/16 20180501 |
Class at
Publication: |
52/173.3 ;
52/698 |
International
Class: |
E04D 13/18 20060101
E04D013/18; E04B 1/38 20060101 E04B001/38 |
Claims
1. A mounting apparatus comprising: a base member; a pair of side
walls extending vertically from the base; a rear wall that extends
upward from the base at an angle less than 90 degrees; a front wall
that extends from the base member; and a top surface that extends
from the front wall to the rear wall and is intersected by the two
side walls.
2. The invention as described in 1, in which the shape of the
mounting apparatus is wedge-shaped, with the front wall being the
narrow part and the rear wall being the tall part.
3. The invention as described in 2, in which the angle of the wedge
is selected to maximize the amount of sunlight incident on a panel
installed to the mounting apparatus.
4. The invention as described in 1, in which the mounting apparatus
has a cutout to facilitate the mounting of solar panels.
5. The invention as described in 4, in which the cutout is replaced
with a blank panel, so that the surface of the mounting apparatus
can be used for mounting.
6. The invention as described in 1, in which the top and/or side
have cutouts for mounting hardware.
7. The invention as described in 1, in which there are a plurality
of semi-circular other semi-round cutouts to route conduits for
water or electricity.
8. The invention as described in 1, in which the mounting apparatus
contains a ballast cavity.
9. The invention as described in 1, in which the mounting apparatus
contains lips on their front and back walls, so that multiple
mounting apparatus may be hooked together, front-to-back.
10. The invention as described in 1, in which the sides of the
mounting apparatus have tabs and sleeves, so that multiple mounting
apparatus may be hooked together, side-by-side.
11. The invention as described in 1, in which the mounting
apparatus contains tether holes.
12. The invention as described in 1, in which the mounting
apparatus contains drawers, capable of holding water, ballast, a
heat exchanger, etc.
13. The invention as described in 1, in which the mounting
apparatus has at lease one pipe containing holes, and plumbing
connecting the pipe to a liquid source, so that the liquid can be
pumped from the interior of the mounting apparatus onto its
surface.
14. The invention as described in 1, in which the mounting
apparatus is modular, with at least two sections.
15. The invention as described in 14, in which the modular mounting
apparatus has at least three sections.
16. The invention as described in 14, in which the modular sections
fit together through the use of male and female locking sleeves.
Description
CLAIM OF PRIORITY
[0001] The applicants claims priority under 35 USC 119, et. seq.,
to a prior filed provisional utility patent application No.
61/474,263, filed Apr. 11, 2011; entitled, "Modular Mounting
Apparatus;" by named inventors Rajul L. Patel, Reynold Hendrickson,
and Jon Karpovich.
FIELD OF INVENTION
[0002] This invention relates to the field of mounting apparatus.
Specifically, this invention relates to the mounting hardware and
methods for renewable energy panels, satellites, and other roof
mounted equipment.
BACKGROUND OF INVENTION
[0003] Mounting apparatus have been developed over the years to
anchor items such as signs, solar panels, satellite dishes, HVAC
units and the like to buildings and the ground. Many of these
apparatus are used on the roof. For many items the roof is the
ideal mounting location. For instance, the roof is an ideal
mounting location for a solar panel because it is not obstructed
from the sun. Additionally, the roof is the ideal mounting place
for billboards, because such a mounted billboard is easy to see.
Last, for items that people prefer to keep out of sight, like an
HVAC unit, the roof is also ideal. Rooftops, thus, increase the
usable space of a building.
[0004] Traditionally, building owners were reluctant to fasten
large items to their roof, for fear that the equipment would be
damaged by the elements. As land became more precious, and as the
desire to mount certain items out of site, the capabilities of
mounting apparatus have improved. Mounting apparatus for the roof
have advanced to a point that many components may be safely
anchored to the roof, while withstanding the elements of weather
such as wind, rain, snow and the like. Depending on the land and
the use, a land owner may decide to put solar panels, HVAC units,
signs, satellite dishes and the like on the ground, adjacent to the
building.
[0005] One drawback of current technology is that, when mounted to
a flat top roof, often found with commercial buildings, it requires
the use of many drill holes. Adding holes to sealed rooftops
provokes leakage by creating paths for water to find its way inside
the building, potentially damaging the structure and the interior
of the building. The more holes that are added to anchor a
component to a roof, the more potential for leak paths and water
entry into the building. For example, solar panels are typically
designed in 4.times.8 sizes. Generally, a large number of solar
panels are required to work in unison to generate enough
electricity to power a building. Often, these solar panels are
mounted to a roof top and typically require that each of the four
corners of a rectangular solar panel be anchored to a rooftop.
These panels are first secured to a mounting system or frame and
then the frame may be anchored to the roof of the building. Each of
the four corners of the mounting system must be anchored to the
rooftop, thus requiring the addition of four holes to the rooftop
for securement means.
[0006] Often, current mounting apparatus are manufactured of steel,
aluminum, or like metal, that are heavy, large and bulky to
transport and install. They may also add additional unnecessary
weight to any roof. These mounting systems may also be quite costly
to manufacture, transport and install.
[0007] Therefore, a need exists for a modular mounting apparatus
that may be anchored to buildings or the ground that is lightweight
and inexpensive to manufacture while at the same time reducing the
number of mounting holes that may be added to a rooftop of a
building or ground and may be used to mount signs, satellite
dishes, solar panels and the like.
SUMMARY OF THE INVENTION
[0008] A modular mounting apparatus for solar panels is disclosed.
The mounting apparatus has a number of embodiments designed to
reduce or eliminate the need for roof-top anchors. The mounting
apparatus has a cavity that can be loaded with a heavy substance,
to prevent the mounting apparatus from moving. The mounting
apparatus also includes a system to mate several mounts together,
creating a larger, more inert mass. The mounting apparatus comes
with a tethering system to reduce the number of roof-top
anchors.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of the present invention, a
modular mounting apparatus.
[0010] FIG. 2 is a side view of the present invention.
[0011] FIG. 3 is a front view of the present invention and
[0012] FIG. 4 is a rear view of the present invention.
[0013] FIG. 5 is an exploded perspective view of the present
invention, with a solar panel mount to it.
[0014] FIG. 6 is a perspective view of the present invention with a
solar panel mounted to it.
[0015] FIG. 7 is a perspective view of the present invention with a
blank panel mounted to it.
[0016] FIG. 8 is a cross-sectional view of the present
invention.
[0017] FIG. 9 is a perspective view of multiple modular mounting
apparatus with attached solar panels.
[0018] FIG. 10 is perspective view of two modular mounting
apparatus with attached solar panels.
[0019] FIG. 11 is a side view of multiple modular mounting
apparatus.
[0020] FIG. 12 is a side view of an alternative embodiment of the
present invention, in which the modular pieces of the unit are
highlighted.
[0021] FIG. 13A is a side view of the modular mounting apparatus,
showing a number of modular units.
[0022] FIG. 13B shows the modular mounting apparatus segments
stored in the large unit.
[0023] FIG. 14 is a side view of another embodiment of the present
invention.
[0024] FIG. 15 is a top view of a drawer, used in the embodiment
from FIG. 14.
[0025] FIG. 16 is a side view of a drawer, used in the embodiment
from FIG. 14.
[0026] FIG. 17 is a side view of another embodiment of the present
invention.
[0027] FIG. 18 is a side view of another embodiment of the modular
mounting apparatus.
[0028] FIG. 19 is a perspective view of another embodiment of the
present invention.
[0029] FIG. 20 is a side view of another embodiment of the present
invention.
[0030] FIG. 21 is a perspective view of another embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The detailed description is intended to illustrate the
present invention, without, in any way, limiting its scope. The
drawings are not scale models, and the drawings do not show all the
potential embodiments of the present invention. The drawings
represent the preferred embodiment, and important alternative
embodiments of the present invention, known to the inventors.
[0032] A mounting apparatus 10 is illustrated in FIGS. 1-4. The
mounting apparatus 10 is in the general shape of a wedge and is
comprised of a base surface 12, a pair of side walls 14 and 16, a
rear wall 18, a front wall 20 and a top surface 22. Side walls 14
and 16 extend upward and generally perpendicular from the base
surface 12. Side wall 14 and 16 are also generally parallel to one
another. Rear wall 18 extends upward from base surface 12 and at an
angle that is generally less than 90 degrees. Rear wall 18 also
intersects side wall 14 and 16. Front wall 20 extends upward from
base surface as well and intersects side walls 14 and 16. Top
surface 22 extends between rear wall 18 and front wall 20 and
intersects side walls 14 and 16. Collectively, base surface 12,
side walls 14, 16, rear wall 18, front wall 20 and top surface 22
form the wedge-shaped mounting apparatus 10.
[0033] Top surface 22 includes a depression 24. Depression 24 may
be sized to accept, secure, or facilitate the mounting of any type
of component desired. As seen in FIGS. 5 and 6, in this particular
embodiment of the present invention, the depression 24 is sized to
accept and secure a solar panel 26 to the mounting apparatus 10.
The depression 24 may be designed such that the upper surface of
the solar panel 26 may be either flush to top surface 22, proud of
top surface 22 or slightly below the top surface 22.
[0034] Top surface 22 further includes a first set of cutouts 30
that are generally positioned at an edge of top surface 22 at side
walls 14 and 16. Cutouts 30 may extend from depression 24 through
top surface 22 and into side walls 14 and 16. Cutouts 30 may be
generally rectangular in shape and are generally sized to accept
any type of anchor system to adequately secure panel 26 to mounting
apparatus 10. Looking at FIG. 1, this embodiment of the present
invention has six cutouts 30. Looking at FIGS. 5 and 6, in this
particular embodiment, the anchor system is comprised of a bracket
32 and fastener 34 such as a screw or bolt to secure the bracket 32
to mounting apparatus 10. Although six cutouts 30 are illustrated
in the drawings, any number of cutouts 30 may be used to mount and
anchor the panel 26 to the mounting apparatus 10.
[0035] As shown in FIGS. 1 and 7, the depression 24 may also be
sized to accept and secure a blank 62. Blank 62 may be added to the
depression 24 in order that the top surface 22 is continuous across
the mounting apparatus 10. The mounting apparatus 10 may then be
used for mounting panels of various sizes that may be larger than
depression 24, yet still require some mounting or anchoring
means.
[0036] Typically, solar panels, whether photovoltaic or thermal in
nature, are mounted in arrays. Manufacturing and transportation
considerations restrict the effective size of a single panel. While
an array of panels is convenient for manufacturing and
installation, the panels must be positioned in such a manner that
the flow of water and electricity is efficient. Typically, this
means that the panels must interface with one or more conduit for
routing electricity or water.
[0037] Looking at FIGS. 5-6, mounting apparatus 10 may be designed
such that the angle of top surface 22 with respect to bottom
surface 12 is optimized to maximize exposure to the sun. The angle
may be determined such that any solar panel 26 that is positioned
on top surface 22 will receive maximum exposure to the sun for
optimal power generation or the heating of water. Furthermore, this
angle between top surface 22 and bottom surface 12 may also be
optimized for the shedding of any snow and the rapid runoff of any
rainwater to ensure the panel has maximum exposure to the sun.
[0038] Looking at FIG. 8, top surface 22 may include a second set
of cutouts 36 that are generally positioned at the edge of top
surface 22 at side walls 14 and 16. Cutouts 36 may extend from
depression 24 through top surface 22 and into side walls 14 and 16.
Cutouts 36 may be generally shaped as a semi-circle, forming the
contour for a conduit. FIG. 6 shows the present invention, with
panel 26 and conduit in place in the semi-circular cutout 36.
[0039] In FIG. 8, the base 12, side walls 14 and 16, rear wall 18,
front wall 20 and top surface 22 collectively create a cavity 38.
The cavity 38 is provided to allow for a ballast to be added in
cavity 38 of the mounting apparatus 10. Material such as water,
sand, gravel, rock, lead, ground tires, steel and the like may be
added to cavity 38 to provide added weight or ballast so that
mounting apparatus 10 may maintain its position once optimally
located.
[0040] Side walls 14 and 16 include holes 40 and 42. Hole 40 is
generally located near front wall 20 of mounting apparatus 10 and
typically runs the width of mounting apparatus 10 from side wall 14
to side wall 16. Similarly, hole 42 is generally located near rear
wall 18 and typically runs the width of mounting apparatus 10 from
side wall 14 to side wall 16. A rope, cable or other tether may be
passed through each of holes 40 and 42, to help secure the mounting
apparatus 10, in situ. Each end of the tether may be anchored to
the roof, ground or other surface in order to fix the mounting
apparatus 10.
[0041] The tether system will allow several of the mounting
apparatus 10 to be positioned side by side as illustrated by FIG.
9. Once an array of mounting apparatus 10 has been positioned, the
tether may be strung through holes 40 and 42 of each separate
mounting apparatus 10. Rather than having to permanently secure
each individual mounting apparatus 10 to the roof, the present
invention allows the user to minimize roof holes by anchoring only
the tether, and not the individual mounting apparatus 10. The
cavity ballast and the tether system work combine to fix the
mounting apparatus 10 in its optimal location.
[0042] FIG. 10 shows another embodiment. The side wall 14 may
include at least one tab 114 that extends the height of side wall
14. Side wall 16 may include at least one locking sleeve 116 that
is sized to accept and secure tab 114. This tab 114 and sleeve 116
configuration will allow multiple mounting apparatus 10 to be
anchored together in close proximity to one another as shown in
FIG. 10.
[0043] Looking at FIG. 11, front wall 20 and rear wall 18 may
include interlocking mounting lips 118 and 120, respectively, such
that two mounting apparatus 10 may be connected from front to back.
Front wall 20 may include upward facing lip 118 and rear wall 18
may include downward facing lip 120 such that lip 120 may capture
lip 118 to further anchor mounting apparatus 10.
[0044] FIG. 12 shows an alternative embodiment, in which the
mounting apparatus 10 may be manufactured in multiple pieces that
may be easily transported and assembled, to create a full mounting
apparatus. In this particular embodiment of the present invention,
two separate pieces may be designed, that, when assembled, will
produce mounting apparatus 10. Mounting apparatus 10 may be
assembled from a front section 142 and a rear section 146 as
illustrated in FIG. 12. Front section 142 may be designed to
include a female locking sleeve 48 that may be sized to accept a
male locking tab 50 of rear section 146. Tab 50 may be designed
such that when seated in the sleeve 48, the front section 142 is
secured to rear section 146 to create a mounting apparatus 10.
[0045] As described above, a two piece mounting apparatus 10 design
may work well to provide for easy transportation and installation.
However, the present invention is not limited to two-piece
construction of the mounting apparatus 10. For example, FIGS. 13A
and 13B illustrate a three component mounting apparatus 10 that
includes a front section 135, a middle section 133 and a rear
section 131. In this particular embodiment of the present
invention, the rear section 131 may be sized such that middle
section 133 may fit within a cavity 132 of rear section 131.
Additionally, the front section 135 may fit within a cavity 134 of
middle section 133. The three sections 131, 133 and 135 may be
assembled to one another with the sleeve and tab system described
above for the two piece system. The mounting apparatus 10 may be
manufactured in this manner to minimize shipping and installation
weight and size.
[0046] An alternative embodiment of the present invention provides
a draw 64 for the mounting apparatus 10 as shown in FIGS. 4, 14 and
15. Rear wall 18, as well as rear sections 46 and 131, may include
an aperture 82 that is sized to accommodate drawer 64. Drawer 64
may include a pair of side walls 66 and 68, a rear wall 70 that
intersects side walls 66 and 68, a front wall 72 that also
intersects side walls 66 and 68 and a bottom plate 74 that
intersects side wall 66 and 68, rear wall 70 and front wall 74 to
form a generally rectangular compartment 76 of drawer 64. Front
wall 72 may be angled slightly with respect to rear wall 70 such
that the contour of front wall will follow the contour of rear wall
18 of mounting apparatus 10. Front wall 72 may also include a lip
78 that surrounds the perimeter of front wall 72 such that lip 78
may engage a depressed edge 80 of aperture 82 such that front wall
72 will be flush to rear wall 18 when drawer 64 is in a closed
position, meaning drawer 64 is fully pushed into cavity 38.
[0047] Drawer 64 may be used to add ballast to mounting apparatus
10. As stated above, material such as water, sand, gravel, rock,
lead, ground tires, steel and the like may be added to drawer 64 to
provide added weight or ballast so that mounting apparatus 10 may
maintain its position once optimally located.
[0048] Drawer 64 may also be used to house a typical heat
exchanger. Water or other types of fluids such as glycol and the
like may be heated in the solar panel that is secured to mounting
apparatus 10. The fluid passing through the panel and heated by the
sun's solar heat may be directed into compartment 76 of drawer 64.
Looking at FIG. 16, coils of pipe 84 having an inlet 86 and an
outlet 88 may be placed in compartment 76 and submersed in the
fluid. A second fluid, may be introduced into inlet 86, travel
though the coils of pipe 84 and through outlet 88. Generally, the
second fluid entering pipe 84 is at a lesser temperature than the
fluid that is circulating in compartment 76. As with any heat
exchanger, the fluid flowing through pipe 84 will increase in
temperature until it is about equal to the temperature of the fluid
filling compartment 76 through a heat transfer process from the
fluid in compartment 76 to the fluid in pipe 84 that is well known
in the art. A pump may be added to compartment 76, and associated
electronics stored in another drawer, to maintain the flow of fluid
from panel 26 through drawer 64. The fluids will continue to
circulate through pipe 84 and compartment 76 and the heat exchange
will continue as long as the fluid entering the compartment remains
at a higher temperature than the fluid entering pipe 84. The fluid
exiting pipe 84 through outlet 88 may be used for heating pool
water, heating water for showers, and the like. Multiple drawers 64
may be added to mounting apparatus 10. Although the drawer 64 has
been described, above, as being located in the rear wall 18, a
drawer 64 may be added to side walls 16 and 14 for further storage
of materials such as electrical wiring or electrical controls that
may be used with other features of structure 10.
[0049] In another embodiment of the present invention illustrated
by FIG. 17, an end cap 90 may be to mounting apparatus 10. End cap
90 may be added to rear wall 18 and extend along a ridge 108 that
intersects rear wall 18 and top surface 22. The end cap may include
at least one pipe 92 that extends the width of end cap 90 and rear
wall 18. The pipe 92 may be plumbed into the any conventional
plumbing system of a building to allow fluid to flow from the
building through pipe 92 of mounting apparatus 10 and back to
building. End cap 90 may include a plurality of holes 94 that will
allow air to enter end cap 90, circulate around pipe 92 and exit
end cap 90. When used in this manner, end cap 90 may be an
air-to-fluid heat exchanger.
[0050] In this particular embodiment, mounting apparatus 10 may be
used to take advantage the night air, which may typically be at a
lower temperature than the air during the day and sunlight. Water
or other fluids that may be passed through pipe 92 of end cap 90
will encounter air that is at a lower temperature then the fluids
passing though pipe 92. As with any type of heat exchange, the
fluids passing through pipe 92 that are at a higher temperature
than the air will begin to lower in temperature and approach the
temperature of the air as the temperature of the air increases to
that of the fluid temperature. A constant supply of cool air into
cap 90 and around pipe 92 will continue to lower the temperature of
the fluid passing though pipe 92. As stated previously, a number of
mounting apparatus 10 may be assembled in an array such that the
length of pipe 92 may be increased in length to maximize exposure
to the air.
[0051] In yet another embodiment of the present invention shown in
FIG. 18, end cap 90 may be designed to package electrical hardware
98 and plumbing such that the fluids passing though mounting
apparatus 10 may be used to generate electricity. In this
particular embodiment, the end cap 90 may include a second pipe 96
as well as electrical hardware to generate electricity from the
temperature differential between two fluids that will pass through
pipes 92 and 96. Electrical hardware may include plates 100 and 102
that contact pipes 92 and 96, respectively, and extend the width of
rear wall 18. Generally, plates 100 and 102 and pipes 92 and 96
will be manufactured of a metal such as copper, steel, aluminum and
the like to maximize the heat transfer between the components. As
stated previously, pipe 92 may be plumbed into a supply of building
fluids such as city supplied water while pipe 96 may be connected
to solar panel 26 for a supply of fluids such as water that may be
at higher temperature than the fluids supplied though pipe 92
during daylight hours. As pipe 92 contacts plate 100 and pipe 96
contacts plate 102, a transfer of heat will occur between pipes and
plates. Plate 100 will lower in temperature and plate 102 will rise
in temperature causing a temperature differential between the
plates thus leading to a generation of electricity. Generation of
electricity in this manner is well known in the art. Alternatively,
during times of no sunlight, such as during evening hours, the
fluids flowing though pipe 96 may be at a lower temperature than
the fluids flowing through pipe 92 thus reversing the temperature
differential and creating electricity during hours of no sun light.
The electricity generated may be used to generate any of the number
of pumps used to circulate the fluids throughout the building and
array of mounting apparatus 10 or for other electrical accessories
requiring power throughout the building such as lighting,
televisions and the like.
[0052] In another embodiment of the present invention, a plurality
of holes 104 may be added to top surface 22 near ridge 108 as
illustrated by FIGS. 19 and 20. Holes 104 may extend in a
relatively straight line about the width of top surface 22. On the
underside of top surface 22, a tube 110 having a plurality of holes
112 may extend the width of top surface and align with holes 104.
The tube 110 may be aligned and configured such that the holes 112
and 104 allow the flow of fluid through tube 110, out of holes 112
and 104 and onto top surfaces 22 and solar panel 26 that has been
secured to mounting apparatus 10. Alternatively, holes 104 may be
omitted and tube 110 may be configured to extend the width of top
surface 22. Tube 110 positioned in this manner will also allow the
flow of fluid through tube 110, out of holes 112 onto top surface
22 and solar panel 26.
[0053] In another embodiment of the present invention, mounting
apparatus 10 may be used to cool water. Mounting apparatus 10 may
be configured to accept the water that has been heated. When
thermodynamically efficient, water may be pumped to mounting
apparatus 10 and though the solar panel 26, in order to cool the
water.
[0054] In another embodiment of the present invention, the multiple
drawers 64 and compartments 76 included in mounting apparatus 10
may be used to collect rainwater and run-off.
[0055] In another embodiment of the present invention, as
illustrated in FIG. 20, the side walls 16 and 18 of mounting
apparatus 10 may each include an aperture 122, to allow for the
flow of air.
[0056] The mounting apparatus 10 may be manufactured of any
material including plastics, metal, wood and the like. The mounting
apparatus 10 may also include a roof friendly pad (not shown) for
fitting underneath mounting apparatus 10 during installation to
help prevent wear and damage to the roof as mounting apparatus 10
is positioned and secured on the roof.
[0057] Although the mounting apparatus 10 is illustrated as having
a general wedge shape, it is important to note, however, that
mounting apparatus 10 may be manufactured in any particular
geometric shape, such as rectangular, trapezoidal, triangular and
the like, while still maintaining the inventive concepts outlined
above.
* * * * *