FIELD OF THE INVENTION

This invention relates to a method of marking and coding various construction components, for example, lumber, plywood, drywall, piping, cables, cable ducts, and the like with a continuous coded scale or marking grid along at least one edge or surface thereof and the use thereof to assist in the construction of various structures including houses and buildings thereby reducing time and costs of construction.

Construction components are generally manufactured in standard sizes and lengths, and are delivered to construction sites bundled in the standard sizes and lengths. The various construction components must then be laid out to suit engineering requirements and are assembled according to a detailed plan or drawings prepared by an architect or engineer which drawings indicate the necessary specifications to achieve the architectural, structural and functional aspects of the design.

Skilled labour is normally responsible for sorting the various construction components and then manually measuring and marking the components for cutting to size in accordance with the detailed design drawings as specified by the architect. Further, skilled labour is also required to mark, using conventional marking instruments, the various components to locate and identify where the various components of the structure intersect or join in accordance with the detailed drawings.

For any project for the construction of a structure, building or house, skilled labour usually is required to spend several hours manually measuring and marking the various construction components in accordance with the detailed design drawings as described above adding time and costs to the project.

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SUMMARY OF THE INVENTION

According to the present invention there is provided a method of facilitating the construction of a structure comprising marking a construction component prior to the actual construction phase with a continuous coded scale or marking grid consisting of standard divisions commonly used in the construction trade, each identified by a different repeating symbol, the scale or grid being applied to at least one edge or surface of the construction component.

The coded scale or marking grid permits skilled labour to merely view the construction component and cut or join the components in accordance with a detailed design drawings, all without the use and assistance of measuring tools, squares and marking instruments thereby reducing time spent by skilled labour and ultimately resulting in substantial costs savings in the construction of the structure.

The coded scale or marking grid may also assist in correctly locating facilities on or in relation to marked components, for example in the location of electrical components at a desired height on marked wall boards. Also, a coded scale or marking grid may facilitate the correct location and spacing of fasteners or other components relative to a marked component, for example, a wall board may be marked across a surface with lines corresponding to the spacing of studs to which the board will be nailed, the lines including markings indicating the correct spacing of nails to be used to secure the board to the studs.

Such a continuous coded scale or marking grid can be applied to the various construction components without significant added costs to the construction components. Further, such continuous coded scale or marking grid may increase the accuracy of the cuts or joints of construction components as human error is reduced.

Preferably, the continuous coded scale or marking grid is marked by an easily distinguishable symbol, such as by a clearly identifiable shape, to allow easy and speedy reading of the scale or marking. Common shapes with different shading or colouring may be used to represent multiples of common units. The use of such symbols also permits marked components and similarly labelled drawings or plans to be used in locations irrespective of local language or units of measurement and thus may be useful to, for example, overcome reluctance of labour to change from imperial to metric units.

Preferably also, a plurality of continuous coded scales or marking grids is marked on the construction component, each scale or grid representing a standard division and being identified by a different repeating symbol. Scales or grids may be selected depending upon the intended use of the components, as particular applications may utilise a series of standard divisions.

The continuous coded scale or marking grid may be printed or marked directly on the construction component, or may be applied to a tape which is affixed to the component.

According to a further aspect of the present invention there is provided a method of marking or application of a continuous coded scale or marking grid along at least one edge or surface of a construction component using a printing or engraving apparatus having a complementary coded scale or marking grid and such continuous coded scale or marking grid being applied to the construction components prior to delivery to the construction site.

The printing or engraving apparatus may be in the form of an inked printing wheel which moves relative to the construction component. It is preferable for the wheel to register with an edge or end of the component such that the scale or grid can be used to, for example, measure distances from the edge or end. The use of a

coded scale or marking grid permits the use of printing wheels of relatively small diameter, as the scale or grid will repeat regularly, as opposed to, for example, a scale for a tape measure which requires the provision of progressing numerals and must therefore be printed using a very large print wheel.

According to a still further embodiment of the present invention there is provided a construction component having a continuous coded scale or marking grid applied to at least one edge or surface thereof.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the present invention will now be described, by way of example, with reference to the accompanying drawings in which: Figures la - lh show various continuous coded scales and marking grids in accordance with the present invention; and

Figure 2 shows various construction components provided with coded scales and marking grids forming part of a structure.

Figure 3 shows a marking apparatus according to the present invention;

Figure 4 shows a close up cross-sectional view of a component of the apparatus of Figure 3; Figure 5 shows an end view of the component of

Figure 4;

Figure 6 is a close up view of an element of Figure 5;

Figure 7 is a close up view of a section of Figure 3.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT

Reference is first made to Figures la - lh which illustrate various continuous scales and marking grids for marking on construction components such as lumber.

plywood, drywall, piping, cable ducts and the like. The scales and grids are selected to be easily recognizable and, where a number of scales are provided, to be clearly distinguishable from other scales. Each of the markings illustrated in Figures la -

If includes a grid, somewhat similar to a ruler, marking smaller increments, with various repeating symbols representing larger increments. The grids and symbols may be at any predetermined distance, but will normally coincide to a standard imperial or metric unit of distance. Each of the grids is two-sided, to assist in the visualisation or marking of a line on the component; the marking will normally be oriented parallel to a component edge or main axis such that a line across the grid will be perpendicular to the component edge or main axis.

The symbols may use differently shaded or coloured common shapes to indicate different distances in terms of multiples of common unit. Symbols of different shapes may be used to indicate, for example, larger units of length.

In each of Figures la - If differently shaded circles are used to indicate multiples of common units equal to frequently used measurements, while diamonds are used to indicate further units of commonly used reference points.

A "key" to the various symbols used in Figures la - If is set out below. It should be noted of course that the figures are not to scale. MARKING (REF.NO.) LENGTH DIVISION

FIGURE la

Grid (10,11,12) Circle (13) Concentric Circles (14) Solid Circle (15) Diamond (16)

FIGURE lb Grid (17, 18) Circle (19) Solid Circle (20) Diamond (21)

Figure lb illustrates an imperial marking and includes indications of each three inch division. For the metric equivalent the numbers would of course be omitted or replaced with an appropriate indicator of, for example, millimetres or centimetres.

FIGURES lc and Id Grid (22, 23, 24) 1/4, 1/2, 1" 6.25, 12.5, 25mm Circle (25) 3" 7.5cm Solid Circle (26) 1' (12") 30cm Diamond (27) 16" 40cm

FIGURES le and If Grid (37,38,39,40)

Circle (41) Concentric Circles (42) Solid Circle (43) Diamond (44)

Figure If illustrates a grid including triangular ^{^} symbols to identify the 1/8 and 1/4 inch divisions, or for the metric equivalent the 3.125 and 6.25 millimetre divisions.

The markings illustrated in Figure lg differ somewhat from those of Figures la - If in that the grid is marked along a single line and that the repeating symbol is a square. A key to the marking is set out below:

Figure lh illustrates a further marking in which there is no grid, but in which a series of steps are used to indicate units of distance, multiples of the units being signified by arranging the steps in "flights". Repeating symbols are also provided, as set out in the key below:

FIGURE lh

The marking of components may be carried out at any suitable step in processing, but most conveniently takes place during or following manufacture or bulk sizing of the construction components. For lumber components, the marking may be carried out following sorting of the cut lumber. The markings may conveniently be made using an inked print wheel which is registered with a reference point on the lumber, typically an end or corner, and the length of lumber then fed past the wheel. Equally, the print wheel could be moved relative to the lumber, and could be operated automatically without human intervention, or a hand held printer provided. An example of a preferred marking apparatus is described below.

As the patterns and symbol repeat every, for example, inch, foot and sixteen inches, a relatively small diameter (48 inches) print wheel may be utilised; to print existing measuring tapes it is normal to utilise a print wheel having a circumference corresponding to the length of the tape.

Marked components may be bundled and delivered to construction sites. As an illustration of some of the advantages available through marking components as described above, reference is now made to Figure 2 of the drawings which illustrates a part of a structure, in the form of a building wall, comprising various construction components provided with coded scales and marking grids. Due to the scale of the Figure, many of the markings are shown somewhat simplified. The wall 50 includes a horizontal bottom plate

54, a plurality of upright studs 56 and a number of wall boards 58. An electrical outlet 60 is also shown, together with an associated supply cable 62.

The bottom plate 54 is marked with diamonds 64 at 16" spacing on at least one visible surface corresponding to the correct location for upright studs 56. The plate 54 may also be marked with other divisions 66 to facilitate cutting of the plate 54 from the original length of lumber supplied to the construction site. Similarly, the studs are marked along with a grid and solid circle 69 at 12" spacings to permit the studs 56 to be cut to a desired length without reference to any measuring tapes and the like. Once cut, the studs 56 may be correctly located relative to the plate 54 by reference to the diamonds 64 marked on the plate 54. The studs 56 are then fixed in place by conventional means.

The wall boards 58 include a number of markings along edges of the board and across the surface of the board. In this example, for simplicity, the wall boards 58 are supplied in a standard size ready for fastening to the studs 56. In the preferred embodiment, the markings provided are in two forms. The first form comprises a series of individual small diameter dots spaced closely together to appear as lines 70 marked on the wall boards 58 to form a 12" rectangular grid comprised of rows 74 and columns 75. That is, the spacing between successive rows 74 or columns 75 is 12". The second form of marking

comprises individual symbols 71 (such as dots or dashes, crosses, triangles, or other types of markings) marked on the 12" grid 70 at intervals of every 4". This form of marking facilitates the fastening of the wall board 58 to the studs 56, through the use of fasteners 72, when the studs 56 are spaced on centres which are multiples of 4", including 12", 16" and 24". By using the grid 70 and the symbols 71, the correct location and spacing of the fasteners 72 is easily accomplished. The grid 70 and the symbols 71 are also marked along the edges 73 of the wall board 58 in order to facilitate positioning of the wall board on the studs 56 and also to aid in cutting the wall board 58 into desired lengths.

In addition, the grid 70 and the symbols 71 may assist in the location of utilities in the wall board 58. Typically electrical and telephone outlets are positioned at a uniform height in a wall. The marking of the wall board 58 will therefore assist in the positioning of such items. In Figure 2 an electrical outlet 60 is shown by way of example.

It will be appreciated that the markings on the wall board 58 could be of different symbols or spacing and remain within the scope of the invention.

A further application of the marking system may be seen on the cable 62 connected to the socket 60. The cable 62 is marked with a grid and repeating circles to indicate, for example, inches and feet, to permit an electrician to easily and quickly "measure" and cut cable from a longer length. Constructing a structure using components marked as described above virtually eliminates the need for measuring equipment such as scales and tape measures and marking instruments such as pencils and scribes, and the elimination of the measuring and marking steps in, for example, the cutting of lengths of lumber results in a considerable saving in time and skilled labour costs. Further, as may be seen from the above description,

marking in this manner can be used to facilitate the correct location of construction components, fittings and utilities in the construction of a structure. This minimises errors made in construction, assures closer correspondence with building codes and standards, and leads to a more economical use of material. Further, the use of easily read symbols in place of, for example, numbers of centimetres or feet, obviates difficulties when labour is familiar with one system of units and is reluctant or has difficulty in converting to other systems. It is also possible that plans or drawings of proposed structures could also include markings corresponding to those used on the components used to form the structure. Figure 3 shows a preferred marking apparatus indicated generally at 100. The marking apparatus 100 is shown in a lumber mill line indicated generally as 102. It will be appreciated by those skilled in the art that marking apparatus is described in association with marking lumber components, but that other construction materials may also be marked in a similar fashion and that the present invention is not necessarily restricted to marking solely lumber.

The mill line 102 includes a support structure 104. Lumber enters at 106 coming from the planners and edgers and is transported in the direction of the arrows 108 by a chain 110. The lumber then falls down a chute 112 and is transported by a second chain up incline 114. As shown, a tippler 116 is movable between a raised position 117 and a lowered position 118. The purpose of the tippler 116 is to provide alternate routes for the lumber through the mill 102. The tippler 116 would be hydraulically or pneumatically actuated.

Describing first the route 118, this route is a by-pass route. This route would be employed when the marker apparatus 100 was not being used. The lumber would simply be moved along the direction of arrows 120 and 122

through the middle of structure 104 being carried by a chain 124 and out onto a lumber stacker at 126. A chute 128 would be in the raised position during the bypass of lumber past the marking apparatus 100. The chains are conventional and thus are not discussed in any detail.

If the lumber is directed towards the marking apparatus 100, then it follows the route indicated when the tippler apparatus 116 is in the raised position 117. Arrow 130 indicates that the lumber is carried up incline 132 which may be referred to as a singulator over the top 134 and onto a further chain 136 on an accumulation table 137. Chain 136 directs the lumber in the direction as is shown by arrow 138 where it passes through a staging area 139 into the marking apparatus 100. The marking apparatus 100 is contained within a housing indicated generally at 141. The marking apparatus 100 comprises a feed means 140, a rotatable carrousel 142, and a marking means comprising a print wheel and an ink wheel marked 144 and 146 respectively. In a further embodiment, the marking means may comprise a laser adapted to burn or engrave the markings onto the component.

As shown by arrow 148, the construction components, after being marked, are deposited on a chain 150 transported in the direction of arrow 152 down the chute 128 which is in its lowered position indicated by 128, and then onto the lumber stacker 126 as previously described. A stack of lumber is shown at 154. It will be appreciated from the foregoing that the marking apparatus of the present invention is ideally suited to be used in line in a mill and can accommodate the normal through-put of the mill. This reduces the expense and difficulty of marking the construction components since they are already being transported in an individual fashion through the mill. Turning to Figure 4, a cross-sectional view through the marking apparatus 100 depicted in Figure 3. is shown. Beginning at the right hand entrance side, a

construction component 158 is shown. It is transported by the chain 136, which in a conventional manner is thread around a gear having a central axis at 160 in a bearing 162 in the direction of arrow 164. Shown in ghost outline at 166 are a further number of construction components in the staging area 139. An overhead T-beam 168 is positioned with a plurality of rollers 170 to ensure that the construction components shown at 166 are not stacked one upon the other which would interfere with the smooth operation of the equipment. The overhead T-beam 168 is vertically adjustable by means of a slot 171 to allow for different thicknesses of construction components which may be passed through staging area 139 and into the marking apparatus 100. Also shown is a lateral positioner 172, which roughly or generally positions the lateral edges of the construction components prior to being loaded into the rotating carrousel 142. In a preferred embodiment, the lateral positioner 172 may be an endless belt which gently urges the construction components into a proper alignment. Beneath the construction components 166 is shown the feed means 140, which comprises an axle 174 to which is attached a kick wheel 176. An end plate 178 secures the kick wheel 176 to the axle. The kick wheel 176 is comprised of a pair of outwardly extending portions 180 on opposite sides of the axle. At the end of sections 180 are located a pair of elastomeric sections 182 which contact and urge the individual components into the rotating carrousel 142 in a manner described hereafter. The rotating carrousel 142 includes a plurality of gripping slots, which are indicated at 184. In the carrousel 142 shown in Figure 4, there are ten gripping slots 184 although fewer or more gripping slots 184 could be used. Each gripping slot 184 is formed by a series of plates 186 mounted on a central axle 188. The preferred spacing of the plates is two feet, with sufficient plates to span the full length of .the construction elements 166

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in order that they may be gripped along their full length. Each gripping slot 184 incorporates a back stop 190 which is substantially continuous and spans all of the plates 186. The preferred back stop 190 is in the form of an angle. As shown at 192 the back stop 190 is movable between various positions to adjust the depth of the gripping slot 184. Also shown associated with each gripping slot are gripping clamps 194 which operate in a manner described hereafter. Also shown in Figure 3 is an outer alignment device indicated generally at 200 which includes a alignment guide 202 which is pivotally mounted at 204 to a support 206 and is partially free at the opposite end 208. A limit stop 210 is fixed to a mount 212 and has a curved end 214 which fits in a slot 216 in the member 202. A flexible extender 220 is mounted between the mount 212 and the member 202. A guide surface 222 is located on the outer surface of the member 202. In the preferred embodiment the flexible extender 220 is pneumatic. For example, a Firestone #16 Airstroke Actuator ¹ may be used. By controlling the amount of the inflation in the extendable mount 202 the degree of distance between the guiding surface 222 and the carrousel 142 can be controlled. Also shown is a lateral edge rub bar 226 which is curved inwardly towards the carrousel 142 and which insures that the ends of the construction components 166 are exactly aligned as they are carried by the carrousel 142. This exact side edge alignment may be referred to as establishing a zero point, as discussed below.

Figure 5 shows a enlarged view of a portion of the carrousel 142. As can be seen, construction elements are loaded in the position shown at 228. The carrousel turns in the direction of arrow 230. At the station 228 it can been seen that a construction element 229 is being

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loaded into the slot 184 and up against the end stop 190. The carrousel then rotates and the next construction element to be loaded, element 231 slides on outer surface 232 until it is free to go into slot 233. This will occur when the carrousel 142 has rotated far enough that the opening of the slot is adjacent to where construction element 231 is located. Just at that moment, one elastomeric section 182 of kick wheel 176 will contact the construction element driving it or "kicking" it into slot 233. The kick wheel 176 will be rotating in the direction of arrow 177 (see Fig. 3) at a predetermined speed, so as to provide the "kick" at exactly the appropriate instant.

Returning now to construction element 229, as the carrousel 142 rotates in the direction of arrow 230 the gripping clamp 194 begins to close. With each increase in rotation, the gripping clamp 194 closes more and more onto the construction element. For example, at 234 the gripping clamp 194 is shown closely adjacent to the construction element. At 235 the construction element is shown being loosely gripped by gripping clamp 194 and at 236, the gripping clamp 194 is firmly gripping the construction element. The firm grip continues through stations 236, 237, and 238, however, at 239 the gripping is eased and the construction component is released. At this point carrousel 142 has rotated so that the gripping slot opens down, and thus the marked construction component is dropped out of the carrousel 142.

It can now be appreciated how the gripping clamp 194 is caused to move between its open position as exemplified at 228, its loosely gripped position at 235 and its firmly gripped position at 236. Each gripping clamp 194 is attached to an actuator arm 250. The actuator arm in turn extends to a rigid member 252 which is rotatable mounted a cam follower 254. Around at least one end of the carrousel 142 is located a cam ring 256. By reason of the attachment between the actuator arm 250 and the gripping clamp 194, movement of the cam

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follower 254 in a radial direction causes rotation of the gripping clamp 194 about the axle 250. Thus, if the cam follower 254 is urged towards the centre of axle 188, the gripping clamps 194 are urged onto the construction 5 elements.

As shown in Figure 5, between the locations 228 and 234, the cam ring 256 is gradually curved inwardly causing the gripping clamp 194 to begin gripping the construction c nponent. At 235 the cam ring 256 becomes 0 circular, meaning the construction component gripped at the same gripping pressure, which is a secure gripping pressure, for the pass by the printer or marker 144. Shown at 260 in ghost outline is an extension spring which would be attached to each gripping clamp 194. A suitable 5 spring 260 would be Associated Spring ² E0750-075-4500. Between 238 and 239 it can be seen that the cam ring 256 gradually curves outwardly allowing the gripping clamps 194 to disengage from the construction components and allowing them to fall out. The cam ring 256 then 0 continues on in a circular fashion keeping the slots 184 open. In this manner, the gripping clamps 194 can selectively apply a gripping force to the construction components as the carrousel 142 carries the construction components from the feed end, past the printer or marker 5 144, and to the outlet at 239. It will be appreciated in those skilled in the art that in Figure 5. the top is generally towards the left, whereas the bottom is generally towards the right.

It can now be appreciated how the positioning 0 members 202 and 226 can be placed in an appropriate location having regard to the gripping action of gri ^p ping clamps 194. During the period when the constru tion elements are passing by 226, the gripping clamp 194 is gradually being applied. Thus, at the time that the

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construction component passes beyond rub bar 226, it is fairly firmly gripped by the gripping clamp so that desired movement by the action of passing by rub bar 226, is allowed but undesired movement will be prevented. Then, the construction component passes beneath the guide surface 222 which forces the construction component fully within the slot fully along its length. Again the gripping force is light enough to allow desired movement but tight enough to prevent unwanted movement. After the construction component has passed by the end of surface 222 the gripping clamp 194 is applied with full gripping pressure _ preventing any subsequent movement of the construction component.

It will be appreciated by those skilled in the art that in order for the marking according to the present invention to be accurate, each construction component to be marked must begin relative to the print roller 144 at exactly the same position. This is accomplished by means of the member 226 which in combination with the variable gripping action of the gripping clamp 194 insures such zero ending and good tolerance positioning of the construction components within each gripping slot.

Turning now to Figure 6, an alternate embodiment can be seen of the attachment of the gripping clamp 194 to the axle 250. In this case the axle 250 is shown as a solid square bar 250 which is housed within a rectangular tube 310. Rectangular tube 310 is diagonally housed within an outer square tube 312. Located between the outer tube 312 and the rectangular tube 310 are 4 elastomeric cushioners 314. These elastomeric cushioners provide some resilience in the gripping action of the gripping clamp 194. A suitable unit would be a ROSTA- RUBBER ³ suspension unit DR-5 50x120. Finally, a made up housing is used to secure the gripping clamp 194 in place around the tube 312. It is comprised of an angle 316 which

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is attached to plates 318 and 320 which are wielded together at 324. Bolts 326 secure the angle 316 to the wielded section.

Figure 7, shows the cross-sectional view of the print roller 144. The print roller 144 is comprised of a tubular element 350 which has flattened faces 352 and 354. For the purpose of illustrations a die 356 is shown attached to only one face although in the preferred embodiment there would be dies 356 at both faces. Also shown on the die 356 is a die printing surface 358 which would preferably include a raised knife edged pattern on its outer surface. The die 356 is housed between opposed clamping elements 359 and 360. These include angled surfaces 362 which retain the die 356 in place. The die at 356 is located on an elastomeric pad shown as 364 and on a pin 366. Thus, the die 356 is permitted a limited degree of axial motion on pin 366 by reason of the pad 364. Also shown are fastening screws 370 to attach the die clamps 359 and 360 to the print wheel 350. Referring back to Figure 1, an ink trough 147 is shown around the ink roller 146.

It can now be appreciated how the instant print roller 144 operates. Construction components, such as for example eight foot two by fours, will be carried up the feed end of the marking apparatus 100. They will be selectively loaded into the carrousel 142, and then positioned within the gripping slots 184, and firmly gripped. The carrousel will be driven by a motor, and will rotate at a predetermined speed. In turn, the print roller 144 will be rotated at a matching speed, which will cause the die to intersect with each construction component as it passes by. With each revolution of the print roller 144, the die will be re-inked by the ink roller, which comprises an open celled foam for carrying ink, in the normal manner. If there is only one die on the print roller 144, it must rotate one full revolution during the time it takes for the carrousel to rotate

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enough to bring a second construction component past the print roller. If there are dies on opposite faces of the print roller, then it may rotate at one half the speed of the first example. Good results can be achieved for lumber, when the interference between the outer edge of the die and the surface of the lumber to be printed is 1/32". Further, the die is preferred to have raised printing edges of 1/16". This ensures that the lumber is penetrated to expose the ink to virgin wood. Some interference is important, because often lumber may be treated with anti- fungal agents which interfere with clean printing. Also, lumber mills may not be heated, so snow or frost may build upon on the face to be printed, which, without penetration makes good printing difficult.

Further, good results are achieved when the die is segmented into small segments, such as two to four inch widths. Such segmentation, in conjunction with the flexible backing pad 364, permits good contact printing across the whole length to be printed, since local anomalies can be accommodated. Such anomalies would include changes in surface hardness, such as knots in lumber, or, changes in surface height, such as a lumber piece that may be slightly warped. It will be appreciated that the kick wheel 176, the rotating carrousel 142 and the print and ink rollers 144 and 146 will all need to be driven by a drive means, for example by a motor. In some instances separate motors may be used, but the preferred method would be to use one motor, with three separate drive belts, to ensure the proper alignment of the co-operating rotating elements, as described above. Such a motor is shown in ghost outline in Figure 3 at 143.

It will be appreciated by those skilled in the art that the foregoing description relates to preferred embodiments of the invention, and are intended to be by way of example only. Various alterations on modifications

can be made, some of which have been discussed above, and others which will be apparent to those skilled in the art, without departing from the broad scope of the appended claims.