U.S. patent application number 13/765153 was filed with the patent office on 2013-06-13 for fabrication of welded wheels without filler material.
This patent application is currently assigned to LINCOLN GLOBAL, INC.. The applicant listed for this patent is Lincoln Global, Inc.. Invention is credited to Paul Edward Denney.
Application Number | 20130147256 13/765153 |
Document ID | / |
Family ID | 47116108 |
Filed Date | 2013-06-13 |
United States Patent
Application |
20130147256 |
Kind Code |
A1 |
Denney; Paul Edward |
June 13, 2013 |
FABRICATION OF WELDED WHEELS WITHOUT FILLER MATERIAL
Abstract
A hermetically sealed wheel assembly which has been welding
autogenously is provided, along with a method and system for
welding the wheel assembly. The wheel assembly is made up of at
least two components which are laser welded to each other without
the use of filler material to create a hermetically sealed wheel
assembly.
Inventors: |
Denney; Paul Edward; (Bay
Village, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Lincoln Global, Inc.; |
City of Industry |
CA |
US |
|
|
Assignee: |
LINCOLN GLOBAL, INC.
City of Industry
CA
|
Family ID: |
47116108 |
Appl. No.: |
13/765153 |
Filed: |
February 12, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13736777 |
Jan 8, 2013 |
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13765153 |
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13690569 |
Nov 30, 2012 |
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13736777 |
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13269319 |
Oct 7, 2011 |
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13690569 |
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Current U.S.
Class: |
301/64.303 ;
219/121.64 |
Current CPC
Class: |
B60B 2360/141 20130101;
B23K 26/28 20130101; B60B 2310/3026 20130101; B60B 3/08 20130101;
B60B 3/087 20130101; B60B 2900/5116 20130101; B23K 26/20
20130101 |
Class at
Publication: |
301/64.303 ;
219/121.64 |
International
Class: |
B23K 26/28 20060101
B23K026/28; B60B 3/08 20060101 B60B003/08 |
Claims
1. A method of welding a wheel structure, comprising: positioning a
first wheel section having a first web portion adjacent to a second
wheel section having a second web portion, such that each of said
first and second web portions are contacting each other; directing
a laser beam to said first web portion; and autogenously welding
said first web portion to said second web portion with a laser beam
such that said laser beam passes through an entire thickness of
said first web section and said laser beam penetrates 5 to 100% of
a thickness of said second web portion; wherein said autogenously
welding creates a continuous hermetically sealed weld joint around
a center of the welded first and second wheel sections, wherein
said first web portion has a web length between a hub portion
positioned radially inward from said first web portion and an
angled portion positioned radially outward from said first web
portion, and said weld joint is positioned on the first web portion
10 to 80% of the web length inward from said angled portion, and
wherein a width of said weld joint at the point at which said first
and second web portions contact each other is in the range of 5 to
50% of the thickness of said second web portion.
2. The method of claim 1, wherein said weld joint penetrates 20 to
75% of said thickness of said second web portion.
3. The method of claim 1, wherein said weld joint is welded in a
pattern having a nonconstant radial distance from said center.
4. The method of claim 1, wherein a depth of said weld joint in
said second web portion varies along a length of said weld
joint.
5. The method of claim 4, wherein said weld joint has a first
portion with a first depth of up to 100% of the thickness of said
second web portion and a second depth of 5 to 50% of the thickness
of said second web portion, where said second depth is less than
said first depth.
6. The method of claim 4, wherein said weld joint has a first
portion with a first depth of 20 to 50% of the thickness of said
second web portion and a second depth of 5 to 50% of the thickness
of said second web portion, where said second depth is less than
said first depth.
7. The method of claim 1, wherein said width of said weld joint at
said contact point varies along a length of said weld joint.
8. The method of claim 1, wherein at least one of said first and
second web portions has cavities through an entire thickness of
said first or second web portion and said weld joint is positioned
radially outward from said cavities.
9. A welded wheel structure, comprising: a first wheel section
having a first web portion; a second wheel section having a second
web portion, where each of said first and second web portions are
contacting each other; and a continuous hermetically sealed weld
joint which welds said first web portion to said second web
portion, such that said weld joint passes through an entire
thickness of said first web portion and 5 to 100% of a thickness of
said second web portion; wherein said weld joint is positioned
radially around a center of said welded first and second sections,
wherein said weld joint is an autogenous weld joint, wherein said
first web portion has a web length between a hub portion positioned
radially inward from said first web portion and an angled portion
positioned radially outward from said first web portion, and said
weld joint is positioned on the first web portion 10 to 80% of the
web length inward from said angled portion, and wherein a width of
said weld joint at the point at which said first and second web
portions contact each is in the range of 5 to 50% of the thickness
of said second web portion.
10. The welded wheel structure of claim 9, wherein said weld joint
penetrates 20 to 75% of said thickness of said second web
portion.
11. The welded wheel structure of claim 9, wherein said weld joint
is welded in a pattern having a nonconstant radial distance from
said center.
12. The welded wheel structure of claim 9, wherein a depth of said
weld joint in said second web portion varies along a length of said
weld joint.
13. The welded wheel structure of claim 12, wherein said weld joint
has a first portion with a first depth of up to 100% of the
thickness of said second web portion and a second depth of 5 to 50%
of the thickness of said second web portion, wherein said second
depth is less than said first depth.
14. The welded wheel structure of claim 12, wherein said weld joint
has a first portion with a first depth of 20 to 50% of the
thickness of said second web portion and a second depth of 5 to 50%
of the thickness of said second web portion, wherein said second
depth is less than said first depth.
15. The welded wheel structure of claim 9, wherein said width of
said weld joint at said contact point varies along a length of said
weld joint.
16. The welded wheel structure of claim 9, wherein at least one of
said first and second web portions has cavities through an entire
thickness of said first or second web portion and said weld joint
is positioned radially outward from said cavities.
17. A welded wheel structure, comprising: a first wheel section
having a first web portion; a second wheel section having a second
web portion, where each of said first and second web portions are
contacting each other and have the same length; and a continuous
hermetically sealed weld joint which welds said first web portion
to said second web portion, such that said weld joint passes
through an entire thickness of said first web portion and 5 to 100%
of a thickness of said second web portion; wherein said weld joint
is positioned radially around a center of said welded first and
second sections, wherein said weld joint is an autogenous weld
joint, and wherein a width of said weld joint at the point at which
said first and second web portions contact each is in the range of
5 to 50% of the thickness of said second web portion, and wherein
said second width is less than said first width.
Description
[0001] PRIORITY
[0002] The present application is a continuation of U.S. patent
application Ser. No. 13/736,777 filed Jan. 8, 2013 which is a
continuation of U.S. patent application Ser. No. 13/690,569 filed
Nov. 30, 2012 which is a continuation of U.S. patent application
Ser. No. 13/269,319 filed Oct. 7, 2011, each of which applications
have been incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0003] The present invention relates to the art of welding and more
particularly to the fabrication of welded wheels without filler
materials.
BACKGROUND OF INVENTION
[0004] As the art of arc welding has grown, it has found its
application in many different structures and uses. It is known that
although arc welding can provide a strong bond between metallic
components, depending on the process used, it can also result in a
weld joint that has porosity. Although in some welding applications
an amount of porosity is acceptable, there are other applications
where porosity can be problematic. For example, when welding wheel
structures that are used for pressurized tires the presence of
porosity can result in a welded wheel structure which fails to
maintain pressure. To prevent this loss of pressure from occurring
it is common to over-weld wheel structures to ensure that the
welded wheel structure is capable of maintaining pressure. However,
this over-welding increases overall cost of the welded wheel
structure by increasing the amount of time needed to weld the wheel
and increases the material cost of the wheel, by requiring
increases amounts of filler metals used in the welding process.
Therefore, it is desirable to provide a welding process which
improves the efficiency and quality of welding wheel
structures.
SUMMARY OF THE INVENTION
[0005] An exemplary embodiment of the present invention is a wheel
structure and a method of welding a wheel stricture, where the
method of welding the wheel structure includes positioning a first
wheel section having a first web portion adjacent to a second wheel
section having a second web portion, such that each of the first
and second web portions are contacting each other. The method
includes directing a laser beam to the first web portion, and
autogenously welding the first web portion to the second web
portion with a laser beam such that the laser beam passes through
an entire thickness of the first web section and the laser beam
penetrates at least a portion of a thickness of the second web
portion. The autogenously welding creates a hermetically sealed
weld joint around a center the welded first and second wheel
sections.
BRIEF DESCRIPTION OF DRAWINGS
[0006] The above and/or other aspects of the invention will be more
apparent by describing in detail exemplary embodiments of the
invention with reference to the accompanying drawings, in
which:
[0007] FIG. 1 is a diagrammatical representation of a welded wheel
in accordance with an exemplary embodiment of the present
invention;
[0008] FIG. 2 is a diagrammatical representation of another view of
the exemplary wheel of FIG. 1;
[0009] FIG. 3 is a diagrammatical representation of an exemplary
embodiment of a welding system of the present invention; and
[0010] FIG. 4 is a diagrammatical representation of another view of
the exemplary wheel of FIG. 1.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0011] Referring now to the drawings wherein the showings are for
the purpose of illustrating exemplary embodiments of the invention
only and not for the purpose of limiting the same, an apparatus and
system used in practicing the invention is shown in detail in FIGS.
1-4.
[0012] FIGS. 1 and 2 depict a wheel assembly 100 in accordance with
an exemplary embodiment of the present invention. The wheel
assembly 100 contains a hub 101 and two wheel sections 103 and 105
which are to be welded to each other. The hub 101 may or may not be
a part of the completed wheel assembly 100 depending on the
applications. As shown in FIG. 1, the wheel assembly 100 can have a
tire 117 mounted to it. The tire 117 and the sections 103/105
create a void or cavity 119 which can be filled with air or gas
under pressure and it is desirable for the sections 103 and 105 to
be able to form an air tight and secure assembly for use. The shape
and construction of the sections 103 and 105 shown in FIGS. 1 to 4
are intended to be exemplary and other embodiments of the present
invention can utilize wheel sections having different shapes as
different applications require.
[0013] As shown in the Figures, each of the sections 103 and 105
contain a hub portion 108/110 which make contact with the hub 101
or other otherwise adjacent to the centerline of the wheel assembly
100. The hub portions 108/110 can have a flange extension, as
shown, which extends along a length of the hub 101 or wheel
centerline, or can have other shapes as needed. Extending radially
outward from the hub portions 108/110 are web portions 107/109
which are oriented perpendicular to the radial centerline of the
assembly 100. In the embodiment shown, the web portions 107/109 are
of the same length, but in other embodiments this may not be the
case. Also, in the embodiment shown the web portions are shown as
solid. However, in other exemplary embodiments it is contemplated
that holes can be made web portions 107/109 to reduce the overall
weight of the wheel assembly 100. The holes can be of any shape but
are usually made as circles, ovals or ellipses so as to avoid
creating locations of stress concentrations. The sizing and number
of holes should be determined to ensure that the structural
integrity of the webs 107/109 are sufficient for their expected
loading. The holes should also be positioned radially inward from
the weld bead 115--which will be discussed in more detail
below.
[0014] Extending from the radially outward edges of the web
portions 107/109 are angled portions 111/113. The angled portions
111/113 diverge from each other respectively to define at least a
portion of the pressure void 119. As shown in FIG. 1 the angled
portions are angled between 0 and 90 degrees from the
cross-sectional centerline of the assembly 100. The angle to be
chosen is based on the design and application of the wheel assembly
100. In some exemplary embodiments the angle can be 90 degrees from
the cross-sectional centerline. Extending from the radially outward
edge of the angled portions 111/113 are flange portions 112/114.
The flange portions 112/114 can be utilized to hold a tire 117 or
other similar component as needed. In the embodiment shown the
flange portions 112/114 are oriented parallel to the
cross-sectional centerline of the assembly 100 as shown. However,
in other embodiments this is not required as other angles can be
utilized based on the application and design needs. In some
exemplary embodiments, the flange portions 112/114 are not needed
as the angled portions 111/113 can themselves be utilized to hold
any structure or tire 117.
[0015] In the embodiments shown the wheel sections 103/105 are
shown as an integral component such that the hub, web, angled and
flange portions are all made of a single piece of material (usually
metal). This can be formed in many different ways including
pressing a flat material into the desired shape. However, other
exemplary embodiments are not limited to the use of integral
sections 103/105 as the sections 103/105 can be made up of welded
components.
[0016] The two wheel sections 103/105 are secured to each other by
welding their respective web portions 107/109, which make contact
with each other when the assembly 100 is assembled. As such, each
of the web portions 107/109 have surfaces 116/118 which are
parallel to each other and made such that the surfaces 116/118 are
flush with each other when the portions 103/105 are positioned
adjacent to each other for assembly. It is not required that the
surfaces 116/118 be flush with each other for the entire length of
the web portions 107/108. However, these surfaces 116/118 should be
flush with each other at least at the weld joint 115.
[0017] In the shown exemplary embodiment, the weld joint 115 is a
continuous weld joint 115 which forms a circular pattern around the
assembly 100. The weld joint 115 is made by welding through one of
the wheel sections 103/105 and into the other of the wheel sections
103/105. In the embodiment shown in FIG. 1, the weld joint is
welded through the section 103 and into the section 105. However,
as shown the weld joint 115 does not fully penetrate the thickness
of the second of the sections (section 105 in FIG. 1). In some
embodiments, as discussed further below, the joint 115 can fully
penetrate the thickness of both sections 103/105 at the weld.
[0018] Unlike prior welded wheel assemblies this weld joint 115 is
not made via the use of arc welding or with the use of filler
metals. Rather the weld joint 115 is made using a laser welding
system in which no filler metal is used--this is commonly referred
to as an autogenous weld. Filler metal is typically used to fill
gaps during welding and/or to provide additional material to a
joint to form a fillet, or the like. However, because the surfaces
116/118 are flush with each other at the weld joint 115 there is no
gap to fill and therefore the weld joint 115 is made entirely of
the material of the web portions 107/109 and no filler metal is
needed.
[0019] Furthermore, because the weld joint 115 is made to penetrate
through the entire thickness of one section 103 and into at least
some of the second section 105, the joint 115 creates a continuous
seal around the entire wheel assembly 100. Because of this seal any
pressure in the pressure zone 119 (like air pressure) will be
unable to pass between the portions 103/105 and escape at the hub
101--which is a problem with arc welded wheels. Thus, this weld
joint 115 creates a hermetic weld joint. Therefore, embodiments of
the present invention can create a welded wheel assembly 100 having
a weld made with no filler material which provides the needed
structural integrity and the needed air tight seal for pressurized
wheel applications. With embodiments of the present invention, a
significant amount of filler material and welding is avoided, as it
is often needed to weld the sections 103/105 to the hub 101--with
filler metal.about.to provide the required air tight seal.
[0020] As shown in FIG. 2, the weld joint 115 has a circular
pattern along a radius from the center of the assembly 100.
However, embodiments of the present invention are not limited in
this regard. For example, it is contemplated that the weld joint
115 can have a zig-zag or undulating pattern along a radius from
the center of the assembly 100. Such a pattern would increase the
overall length of the weld joint 115 to provide added structural
integrity. However, the weld joint 115 should be continuous so as
to provide the requisite hermetic seal between the sections
103/105, if the wheel is to be used in a pressurized application.
It is noted that to the extent holes are placed in the webs 107/109
to reduce the weight of the assembly (as discussed above) the weld
joint 115 should be placed radially outward from the holes to
provide the needed air tight seal--in pressurized applications. Of
course, many different types of patterns can be used for the
welding operation.
[0021] It is further noted that although a single weld joint 115 is
shown in the figures, the present invention is not limited in this
regard. Specifically, additional weld joints can be used to
increase the strength of the wheel assembly 100. For example,
another weld joint can be positioned radially inward or outward
from the weld joint 115. Further, any additional joint does not
have to be continuous but can be an intermittent or spot weld
joint. As long as one weld joint (115) is continuous, any
additional weld joint will not have to be continuous to provide the
requisite air tight seal. Of course, it can be continuous as
well--if needed.
[0022] FIG. 3 depicts an exemplary welding system 300 for welding
the assembly 100 described above. As discussed above, the weld
joint 115 is created using a laser welding system with no filler
metal. The system 300 includes a laser power supply 301 which
supplies power to a laser 305. The laser 305 can be any known type
of laser which is capable of laser welding, including but not
limited to carbon dioxide, Nd:YAG, Yb-disk, YB-fiber, fiber
delivered or direct diode laser systems. Further, white light or
quartz laser type systems can be used if they have sufficient
energy. Other embodiments of the system may employ electron beam
energy. Exemplary lasers should have power capabilities in the
range of 1 to 20 kW. Higher power lasers can be utilized, but can
become very costly. In the embodiment shown, the laser 305 is
emitting a single beam 307 to weld the joint 115. However, a
multiple beam configuration can also be employed if desired. A
multiple beam configuration can use multiple lasers 305 and/or beam
splitters with a single laser 305 as desired. In such an embodiment
the separate beams can be used to make separate portions of the
same continuous weld, or can be positioned adjacent to each other
to make a wider weld joint.
[0023] The laser 305 emits a beam 307 having a sufficient energy
and shape to fully penetrate or keyhole the entire thickness of the
web portion 107/109 of one of the wheel sections 103/105 and at
least some of the thickness of the web portion 107/109 of the other
of the wheel sections 103/105. This will be discussed further
below.
[0024] The system 300 also includes a system controller 303 which
monitors and/or controls the power supply 301 and/or the laser 307
to produce a sufficient weld. Additionally, in the embodiment shown
the controller 303 also controls a motor 311 which is coupled to a
platen 309 which rotates during welding. In the embodiment shown,
the platen 309 is rotated while the laser 305 and beam 307 remain
stationary to complete the weld. Of course, in other exemplary
embodiments the laser 305 can be moved to create the joint 115. In
further embodiments, both the wheel 100 and the laser 305 can be
moved to create the weld, or the laser 305 can remain stationary
while the beam 307 is moved using optics of the laser 305.
Embodiments of the present invention are not limited in this
regard, as other means of creating the weld can be used. For
example, other configurations can use mirrors or optics external to
the laser optics which move and translate to create the desired
weld pattern.
[0025] It is noted that although the controller 303, power supply
301, laser 305, motor 311 and platen 309 are shown as separate
components in FIG. 3, this is done for clarity. It is contemplated
that at least some or all of these components can be made into an
integral unit or assembly to perform the welding operation. It is
not required that these components are separate physical
structures.
[0026] Turning now to FIG. 4, a more detailed view of the joint 115
is shown. As shown, the web 107 has a length W and the center of
the weld joint 115 is positioned a distance L from the outer radial
edge of the web 107. In most embodiments this distance should be
relatively small so that the joint 115 is close to the angled
portions 111/113. This will aid in minimizing the moment forces on
the webs 107/109 when the assembly 100 is in use. In exemplary
embodiments of the present invention, the distance L should be
based on the thickness of the web material and the design loads on
the wheel in the area of the weld 115. If the web is of sufficient
thickness and stiffness the distance L can approach 0% of the
length W. However, in other embodiments the distance L is in the
range of 10 to 80% of the web length W.
[0027] Furthermore, the web 109 has a thickness T and the weld
joint 115 penetrates the web 109 by a distance D. In exemplary
embodiments the distance D is less than the thickness T. In some
exemplary embodiments, the distance D is in the range of 5 to 100%
of the thickness T, as long as the distance L results in a
structurally sound weld. In other embodiments the distance is in
the range of 20 to 75%. Of course, other depths can be employed as
needed. In fact, in some exemplary embodiments the joint 115 will
keyhole through both web portions 107/109. These welds will
penetrate 100% of the thickness T and provide a "witness mark" on
the back of the web to allow for inspection of the weld joint--to
ensure sufficient penetration. However, to the extent that both web
portions 107/109 are fully keyholed the back bead of the joint 115
should be controlled carefully so that no significant amount of
weld metal sags below the bottom web portion 109 as this could
create a cavity in the upper surface of the weld joint (as no
filler metal is employed).
[0028] In some exemplary embodiments the depth of the weld joint
115 in the lower portion 109 can vary along the length of the weld.
For example, it may not be structurally necessary for the weld
joint to have a constant depth in the lower web portion 109.
Therefore, in some exemplary embodiments portions of the weld joint
115 can be at a first depth and other portions of the joint 115 can
have a second depth, which is shallower than the first depth. For
example, the first depth D can be go up to 100% of the thickness T
of the web 109 and the second depth can be in the range of 5 to 50%
of the thickness T, where the second depth is less than the first
depth. Any change or depth differential can be made as long as at
least one weld results in a hermetic seal and the weld joint(s)
meet the desired mechanical strengths. The length of the different
depth sections can vary as well depending on the strength
requirements of the weld joint 115. For example, the first depth
can be welded for 2 inches while the shallower depth can then be
welded for 5 inches and then return to the first depth for 2
inches, etc. This allows for the optimization of the weld joint 115
in the wheel. This oscillating depth can be created by changing the
energy density of the beam 307 during the welding operation. Such
an embodiment can speed the welding operation and conserve welding
energy. This variation in weld depth can also be achieved by
changing the shape of the beam 307, the energy density of the beam,
and/or the speed of the welding process.
[0029] The cross-sectional width of the weld joint 115 at the
meeting of the surfaces 116/118 should be sufficient to provide the
needed structural integrity for the weld. Embodiments of the
present invention are not limited by the overall cross-sectional
shape of the weld joint, except that the point 115 should have the
required structural integrity. To increase the width of the joint
115 (if needed) a multi-beam laser welding process can be used. In
exemplary embodiments, the weld joint 115 at the meeting of the web
portions 107/109 has a width Z. The width Z should be sufficient to
hermetically seal the wheel 100 as well as provide whatever
strength is needed. In some exemplary embodiments of the present
invention the width Z is in the range of 10 to 100% of the
thickness T. In some exemplary embodiments, the weld joint 115 may
not be needed to provide strength to the wheel. As such, a thinner
weld joint 115 can be employed which is used to primarily
hermetically seal the wheel. For example, in such embodiments the
weld joint can have a width Z in the range of 5 to 50% of T. In
some exemplary embodiments, the width Z is not constant for the
entire weld. For example, it may not be necessary to have the
entire length of the weld joint 115 at a constant thickness because
of strength requirements. In such embodiments, some portions of the
joint 115 can have a first thickness Z, while other portions have a
second thickness Z which is less then the first section. In such
embodiments the first sections can provide the bulk of the strength
of the joint 115 while the thinner sections provide less strength
but continue the hermetic seal. Such embodiments allow for the
conservation of energy during the welding process. In some
exemplary embodiments, multiple beams can be used to vary the width
of the weld joint 115 during welding.
[0030] Embodiments of the present invention allow for the creation
of hermetically sealed wheel assemblies 100 which have been welded
autogenously in less than half of the time as prior art wheels,
with significantly less cost and less product scrapping due to
porosity from arc welding.
[0031] Of course, it should be noted that the sections 103/105 can
have other weld joints than those described herein as needed or
desired. For example, in some other exemplary embodiments the hub
portions 108/110 can be welded to the hub 101 for added strength.
Alternatively the hub portions 108/110 can be autogenously welded
to the hub in lieu of welding through the web portions 107/109.
Depending on the construction of the wheel 100 the autogenous weld
joint can be placed anywhere as needed so that the desired strength
and hermetic seal is achieved. Further, the sections 103/105 can be
welded to each other at the contact point between the sections (the
seam where they contact each other) inside the void 119. These
welds can be laser welds as described herein. Of course, there can
be multiple welds on the wheel assembly 100 as desired, where at
least one weld is autogenous. Depending on the fit of the sections
103/105, it may be necessary in some parts of the wheel to use a
weld with filler material to fill in gaps. This can be done with
any known welding method which uses filler material.
[0032] While the invention has been particularly shown and
described with reference to exemplary embodiments thereof, the
invention is not limited to these embodiments. It will be
understood by those of ordinary skill in the art that various
changes in form and details may be made therein without departing
from the spirit and scope of the invention as defined by the
following claims.
* * * * *