Photovoltaic charging system
11139413 · 2021-10-05
Assignee
Inventors
- Ning Li (White Plains, NY, US)
- Devendra K. Sadana (Pleasantville, NY, US)
- Ghavam G. Shahidi (Pound Ridge, NY, US)
Cpc classification
H01L31/03046
ELECTRICITY
H01L31/0304
ELECTRICITY
Y02P70/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L31/167
ELECTRICITY
H01L31/0693
ELECTRICITY
Y02E10/544
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L31/022466
ELECTRICITY
International classification
H01L31/167
ELECTRICITY
H01L31/18
ELECTRICITY
H01L31/0304
ELECTRICITY
Abstract
A photovoltaic charging system having a narrow-spectrum light source attuned to an absorption band of a photovoltaic cell may achieve power delivery of at least 0.5 mW/10,000 μm.sup.2 upon stimulation of the photovoltaic cell with narrow-spectrum light.
Claims
1. A system, comprising: a narrow spectrum light source for generating a beam of light; a photovoltaic cell located at a receiving region of a wearable device and configured to receive the beam of light and generate a current therefrom, wherein the current generated by the photovoltaic cell is stored in a storage cell that is present in the wearable device and wherein the photovoltaic cell consists of a single junction cell having a single P-N junction having an absorption band that corresponds to an emission line of the beam of light, wherein the single P-N junction comprises an N-doped emitter region and a P-doped base region, and wherein a setback layer is sandwiched between the emitter region and the base region and the setback layer is composed of GaAs having 0.5 to 3% In dopant; and a lens to direct the beam of light into a light guide, the light guide selected from a fiber optic cable or a light tube, the light guide conveying the beam of light to the photovoltaic cell.
2. The system of claim 1, wherein the photovoltaic cell further comprises an N-doped optical window layer having a thickness of at least 400 nanometers (nm) and not more than 3500 nm.
3. The system of claim 2, wherein the optical window further comprises at least one of an N-doped indium gallium phosphide (InGaP) window layer and an N-doped aluminum gallium arsenide (AlGaAs) window layer.
4. The system of claim 2, further comprising a transparent conductive oxide layer.
5. The system of claim 4, wherein the transparent conductive oxide layer comprises one or more of indium tin oxide, fluorine-doped tin oxide, or aluminum doped zinc oxide.
6. The system of claim 4, wherein the transparent oxide layer has a thickness of not less than 200 nanometers (nm) to not more than 800 nm.
7. The system of claim 6, wherein a majority of the top side of the N-doped window layer forms an interface with the transparent oxide layer.
8. The system of claim 2, wherein the narrow-spectrum light source is configured to generate a beam of light having a wavelength distribution of not more than 10 nm from a band center of the beam of light.
9. The system of claim 8, wherein the beam of light generated by the light source has a wavelength of 550 nm ±5 nm.
10. The system of claim 8, wherein the beam of light generated by the light source has a wavelength of 850 nm ±5 nm.
11. The system of claim 8, wherein the light source further comprises a light emitting diode lamp.
12. A system, comprising: a narrow spectrum light source for generating a beam of light; a photovoltaic cell located at a receiving region of a wearable device and configured to receive the beam of light and generate a current therefrom, wherein the current generated by the photovoltaic cell is stored in a storage cell that is present in the wearable device and wherein the photovoltaic cell consists of a single junction cell having a single P-N junction having an absorption band that corresponds to an emission line of the beam of light comprising: an N-doped semiconductor film; a P-doped semiconductor film, the N-doped semiconductor film and the P-doped semiconductor film providing a P/N junction; a setback layer sandwiched between the N-doped semiconductor film and the P-doped semiconductor film and the setback layer is composed of GaAs having 0.5 to 3% In dopant; a first conductive layer; a second conductive layer, wherein the N-doped semiconductor film is between the first conductive layer and the P-doped semiconductor film, the P-doped semiconductor film is between the second conductive layer and the N-doped semiconductor film; and a lens to direct the beam of light into a light guide, the light guide selected from a fiber optic cable or a light tube, the light guide conveying the beam of light to the photovoltaic cell.
Description
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
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DETAILED DESCRIPTION
(8) The present application will now be described in greater detail by referring to the following discussion and drawings that accompany the present application. It is noted that the drawings of the present application are provided for illustrative purposes only and, as such, the drawings are not drawn to scale. It is also noted that like and corresponding elements may referred to by like reference numerals.
(9) In the following description, numerous specific details are set forth, such as particular structures, components, materials, dimensions, processing steps and techniques, in order to provide an understanding of the various embodiments of the present application. However, it will be appreciated by one of ordinary skill in the art that the various embodiments of the present application may be practiced without these specific details. In other instances, well-known structures or processing steps have not been described in detail in order to avoid obscuring the present application.
(10) It will be understood that when an element as a layer, region or substrate is referred to as being “on” or “over” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” or “directly over” another element, there are no intervening elements present. It will also be understood that when an element is referred to as being “beneath” or “under” another element, it can be directly beneath or under the other element, or intervening elements may be present. In contrast, when an element is referred to as being “directly beneath” or “directly under” another element, there are no intervening elements present.
(11) One aspect of the present application that improves photovoltaic charging with regard to wearable and portable devices is the use, in PV charging systems, of a light source that outputs a narrow spectrum light to charge devices with integral PV cells responsive to the light of the narrow spectrum light source. A larger fraction of the light or photons generated by a narrow spectrum light source is absorbed by a responsive PV cell than for the light or photons generated by a broad spectrum light source. Use of a narrow spectrum light source counters industry trends of improving light conversion efficiency by combining multiple P/N junctions in a single PV cell, or by reengineering a PV cell chemistry to make individual P/N junctions sensitive to a broader spectrum of incident light wavelengths.
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(13) Broad spectrum lighting sources may produce numerous photons that cannot be absorbed by a photovoltaic cell. Examples of broad spectrum lighting sources may include incandescent lighting, direct solar irradiation, compact fluorescent lighting. Photons that do not activate formation of charge carrier pairs in a photovoltaic cell may be absorbed by the photovoltaic cell to form heat, or may be reflected from the cell.
(14) In some embodiments, light source 102 is an excited vapor light source or a laser light source. Light source 102 may be a gas laser, dye laser, or solid state laser. In some embodiments, light source 102 has an emission band between 500 nanometers (nm) and 600 nm. In some embodiments, light source 102 has an emission band between 800 nm and 900 nm. In some embodiments, light source 102 is a helium neon (HeNe) laser, a gallium nitride (GaN) laser, a gallium aluminum arsenide (GaAlAs) laser, a Ti:sapphire laser, a Cr:fluoride laser, or another laser in the visible or infrared (including near-infrared) range. In some embodiments of the present application, a preferred type of laser may include semiconductor lasers using GaAs/AlGaAs, InP/InGaAsP/, or GaN/InGaN for compactness and portability. Power input into a laser is emitted as light with a narrow wavelength distribution. Single mode lasers may have individual laser emission line wavelength distributions that are up to 1 nm in width, while multi-mode lasers may have individual laser emission line wavelength distributions up to 5 nm in width. A wavelength distribution of a laser used as light source 102 may be selected according to a responsive range of a photovoltaic cell to convert the incident photons from light source 102 to electricity. The lasers and the PV cells may be selected in pairs wherein one or more laser emission lines of a selected laser type correspond to one or more absorption bands of a PV cell. In some embodiments of the present application, a GaAs PV cell may be paired with a GaAs QW laser, wherein the GaAs PV cell is configured to absorb light having a wavelength of 850 nm, and the GaAs QW laser may have an emission line centered at 850 nm.
(15) A PV charging system may use one or more narrow spectrum light sources in conjunction with other charging system elements such as light collectors, focusers, or directors in order to brighten the intensity of incident light on a PV cell. In
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(17) Light is converted into electricity when photons travel through one layer of the semiconductor material stack and creates pairs of charge carriers by exciting electrons (negative charge carriers) in the depletion layer to higher energy levels in the N-doped semiconductor, and by leaving holes (positive charge carriers) in the P-doped semiconductor. Because the P/N junction poses a barrier to immediate recombination of the charge carriers, the excited electron and accompanying “hole” seek to recombine by traveling through an electrical circuit that circumvents the P/N junction barrier and connects the N-doped and the P-doped semiconductor materials. Recombining charge carriers may be used to perform electrical work or to store energy in capacitors, in chemical batteries, or other energy storage devices.
(18) In some embodiments, contact layer 202, window layer 204, and emitter layer 206 are N-doped layers of PV cell 200. Contact layer 202 may be doped with a larger concentration of N-type dopant than window layer or emitter layer 206, according to some embodiments. The term “n-type dopant” refers to the addition of impurities that contributes free electrons to an intrinsic semiconductor. In a silicon containing semiconductor material, examples of n-type dopants, i.e., impurities, include, but are not limited to, antimony, arsenic and phosphorous. Base 210 and substrate layer 216 may be P-doped layers. The term “p-type dopant” refers to the addition of impurities to an intrinsic semiconductor that creates deficiencies of valence electrons. In a silicon-containing semiconductor material, examples of p-type dopants, i.e., impurities, include, but are not limited to, boron, aluminum, gallium and indium. Base 210 may be doped less heavily than substrate 216. In some embodiments of PV cell 200, a back surface field (BSF) layer 212 (more strongly P-doped than the base layer) may be deposited between base layer and substrate 216 in order to prevent carrier recombination at the back of the base layer 210. In some embodiments, one or more buffer layers 214 may be present in order to regulate a crystal lattice constant of PV cell 200 at the bottom side of base layer 210 and a top side of substrate 216 to promote good layer adhesion and good electrical characteristics of the PV cell. In some embodiments, a setback layer 208 may be present between base layer 210 and emitter 206 to offset dopant diffusion and increase current gain. Other layers may be present in PV cell 200 according to manufacturing flows, device designs, and other aspects of developing and producing photovoltaic cells for photovoltaic charging. A substrate and a contact layer may be connected to circuit 220 by a first electrode 218A and a second electrode 218B according to some embodiments. Electrodes may be metallic layers deposited onto a top and bottom surface of a PV cell in order to promote good electrical connection between the PV cell stack and the external load 222 connected thereto.
(19) Layers in PV cell may be based on silicon semiconductor material, binary (e.g. III-V) semiconductors, or other types of semiconductor materials that can be incorporated into a PV cell manufacturing flow. In some embodiments, contact layer 202 may comprise a silicon layer, a gallium arsenide layer, an aluminum gallium arsenide layer, an indium gallium arsenide layer, or some other low bandgap semiconductor material. Contact layer 202 may be N-doped with dopants such as phosphorous (P) or tellurium (Te). An N-type dopant concentration in contact layer 202 may at least 3×10.sup.18 atoms/cm.sup.3 according to some embodiments. Contact layer 202 may have a thickness ranging from 400 nm to 1200 nm, although other thickness are also envisioned.
(20) Window layer 204 may comprise a silicon layer, a gallium arsenide layer, an indium gallium phosphide (InGaP) layer, an aluminum gallium arsenide (AlGaAs) layer, or some other wide bandgap semiconductor material lattice matched to the substrate, according to embodiments. Window layer 204 may be N-doped to a degree less than the dopant concentration in contact layer 202. Window layer 204 may have an N-type dopant concentration ranging from 1×10.sup.18 atoms/cm.sup.3 to 5×10.sup.18 atoms/cm.sup.3. Window layer 204 may have a window layer thickness ranging from 400 nm to 3500 nm, according to some embodiments, in order to manage power output of not less than 1 mW/10,000 μm.sup.2 for a silicon based photovoltaic cell and 2 mW/10,000 μm.sup.2 for a III-V semiconductor based photovoltaic cell. Current (i.e., charge carriers) from the P/N junction may travel up through the stack of layers in PV cell 200 and travel through window layer 204 toward contact 202 and an electrode.
(21) The power delivered by a PV cell to a wearable device may depend on both the size/active/absorption area of the PV cell and on the spot size of the beam of light received by the PV cell. Electricity generation from photovoltaic cells may be improved, from an efficiency and cost perspective, when an incident beam of light has a spot size that corresponds to a PV cell active/absorption area, with no light falling outside the absorption area of the PV cell, and no PV cell absorption area sitting idle (e.g., not receiving light from the incident beam). However, in some embodiments of the present application, a beam of light may overlay multiple PV cells and/or PV cell active/absorption areas, with some incident light not being converted into electricity. The light intensity of a wavelength absorbed by one or more PV cells in a wearable device may generate sufficient electrical current that an excess of light may be generated at little additional cost (e.g., acceptable planned inefficiency) relative to the benefit of photovoltaic charging of the device.
(22) P/N junction 201 may comprise at least emitter 206 and base layer 210. In some embodiments, a setback layer 208 may also be located within P/N junction 201 to reduce carrier recombination at the P/N junction interface between the emitter and base layers. Emitter 206 may comprise an N-doped semiconductor material such as silicon, gallium arsenide (GaAs), or some other III-V semiconductor material compatible with window layer 204 or base layer 210. In some embodiments of the present application, an emitter layer may include AlGaAs or InGaP for photovoltaic cells formed on a GaAs substrate. In some embodiments of the present application, the emitter layer may be InP for photovoltaic cells formed on an InP substrate. Emitter 206 may be N-doped to a concentration less than the dopant concentration in contact layer 202, the emitter layer N-dopant concentration generally ranging from 5×10.sup.19 atoms/cm.sup.3 to 5×10.sup.18 atoms/cm.sup.3, although other concentrations are also envisioned. Emitter 206 may have an emitter layer thickness ranging from 70 nm to 200 nm, according to embodiments. In some embodiments, emitter 206 has a thickness that is approximately 100 nm.
(23) Base layer 210 in P/N junction 201 may comprise a same type of semiconductor as can be found in emitter 206, with an opposite dopant type (i.e., the emitter is N-doped silicon, and the base is P-doped silicon, or the emitter is N-doped GaAs, and the base is P-doped GaAs). In some embodiments of the present application, the base layer may be AlGaAs or InGaP for photovoltaic cells on GaAs substrate. Some embodiments may include an InP base layer for photovoltaic cells on an InP substrate. Use of two different types of semiconductor material (e.g., Si emitter and GaAs base) may create an additional barrier to the creation of charge carrier pairs upon absorption of a photon, reducing PV cell conversion efficiency. Base layer 210 may be doped with a P-type dopant such as P, Te, or Al, although other P-type dopants are also envisioned. P-type dopant in the base layer 210 may have a concentration ranging from 5×10.sup.17 to 1×10.sup.18 atoms/cm.sup.3, according to some embodiments.
(24) Setback layer 208 may be a layer that prevents dopant diffusion from p type layers into n type layers. In some embodiments, the setback layer 208 may be a doped silicon layer, or a doped III-V semiconductor layer. In some embodiments, the setback layer 208 may be an GaAs layer having 1% In dopant and 99% Ga (e.g., In.sub.0.01Ga.sub.0.99As). In some embodiments, the fraction of indium in a doped GaAs semiconductor may be as low as 0.5% and as much as 3%.
(25) Base layer 210, BSF layer 212, and substrate 216 may all be P-doped semiconductor materials such as silicon, gallium arsenide, or some other type III-V semiconductor material. The back surface field layer (BSF) layer prevents the charges to diffuse to the wrong direction and helps to increase PV efficiency. In some embodiments, base layer 210 has a thickness ranging from 2000 nm to 4000 nm. In some embodiments, a protector used for the base layer 210, BSF layer 212, and substrate 216 may be zinc or some other acceptable form of P-type dopant. In some embodiments, protective concentration and base layer 210 may range from 1×10.sup.16 to 5×10.sup.17 atoms/cm.sup.3. In some embodiments, a concentration of pre-type dopant is approximately 1×10.sup.17 atoms/cm.sup.3.
(26) In some embodiments, BSF layer 212 has a P-type dopant concentration greater than the P-dopant concentration in base layer 210. Buffer layer 214 may include one or more sub-layers deposited in order to modify a lattice constant in the stack of photovoltaic cell layers. For example, a substrate such as substrate 216 may have a different lattice constant than BSF layer 212. In order to promote good adhesion between the layers, and, in order to promote good electrical conductivity between the layers, one or more buffer layers may be deposited between a substrate and a BSF layer in order to provide a smooth transition between a substrate having one first lattice constant and a BSF layer having a different lattice constant. A sub-layer of a buffer may have different dopant concentrations from an adjacent buffer sub-layer, or may be a different semiconductor material, in order to resolve a lattice mismatch through the photovoltaic cell film stack.
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(28) In an operation 340, a first region of the photovoltaic film stack may be protected by a mask and a portion of the photovoltaic film stack in a second region may be removed in order to expose a substrate layer in the photovoltaic film stack. The first region of the photovoltaic film stack may substantially correspond to a light absorbing region of the photovoltaic cell being manufactured, and a region for an electrical contact or electrode to be formed on a photovoltaic cell surface. The second region may correspond to a region for an electrode or electrical contact against a substrate layer of the photovoltaic cell to be positioned in the photovoltaic cell.
(29) In an operation 350, the portion of photovoltaic film stack within/below the second region may be removed by a plasma or an aqueous etching process to expose a region of the substrate layer approximately corresponding to the second region of the semiconductor film stack within a perimeter of a photovoltaic cell of the film stack.
(30) In an operation 360, electrical contacts and/or metal electrodes may be formed on a top surface of the photovoltaic cell, and on the exposed region of the photovoltaic cell substrate layer within the second region that was exposed during operation 350. Electrode and/or electrical contact formation may occur by a variety of processing steps known to practitioners of the art. During an optional operation 370, individual photocells may be removed from the handler base or adhesive layer. According to some embodiments of operation 370, individual photocells may be separated from each other by cleaving, by etching a separation space between adjacent photocells, or by other methods known to practitioners in the art. In some embodiments, individual photocells may be incorporated into a circuit or a wearable device upon removal from the handler base or adhesive. In some embodiments of operation 370, individual photocells may be stored before inclusion in an electrical circuit or wearable device.
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(35) Window layer 508 may be situated between contact layer 506 and emitter 510. Window layer 508 may comprise a gallium phosphide (GaP) layer, an indium gallium phosphide (InGaP), a gallium arsenide (GaAs) layer, an aluminum gallium arsenide (AlGaAs) layer, or some other semiconductor configured to conduct current. The window layer may have a window thickness ranging from 300 nm to 3500 nm, although preferred embodiments may have window thickness ranging from 400 nm to 3000 nm.
(36) Emitter 510 is situated between window layer 508 and base layer 512. Emitter layer may be an n-doped semiconductor such as silicon or gallium arsenide (GaAs), among other III-V semiconductor. Emitter 510 may be N-doped in order to form a P/N junction with base layer 512. An emitter may have a thickness ranging from 70 nm to 130 nm, with a preferred thickness of 100 nm. Dopant concentration in an emitter layer may range from 9×10.sup.19 atoms/cm.sup.3 to 3×10.sup.18 atoms/cm.sup.3.
(37) Base layer 512 may comprise a second part of a photovoltaic cell P/N junction, being a P-doped semiconductor material such as silicon, gallium arsenide (GaAs), or some other III-V semiconductor. Base layer 512, back surface field (BSF) 514, and setback layer 516 may all be P-doped layers, with a P-type dopant concentration in base layer 512 being smaller than a P-type dopant concentration in either BSF layer 514 or setback layer 516. A P-type dopant concentration in base layer 512 may range from 1×10.sup.18 to 5×10.sup.17 atoms/cm.sup.3. Back surface field layer 514 may be a gallium phosphide (GaP) or indium gallium phosphide (InGaP) layer, or a gallium arsenide (GaAs) or indium gallium arsenide (InGaAs) layer configured to prevent carrier recombination within the film stack. Buffer layer 516 may be a P-doped gallium arsenide layer configured to adjust a lattice constant between substrate 518 and back surface field layer 514. Buffer layer 516 may be P-doped. In some embodiments, buffer layer 516 may undoped (i.e., an intrinsic semiconductor material). Electrical contact may, in some embodiments, be a P-doped semiconductor material, while contact 520 may be a metallic layer above contact layer 522.
(38) Substrate 518 may be a silicon substrate or a III-V semiconductor material configured to provide electrical conductivity between the base layer 512 and electrical contacts 520 and 522. Electrical contacts 520 and 522 may be semiconductor and/or metallic layers configured to connect to an external circuit having an external load to receive and/or perform work upon formation of charge carrier pairs by light absorbed at the photovoltaic cell P/N junction. In some embodiments, a photovoltaic film stack may have two or more P/N junctions within the stack. Each P/N junction in a film stack may be configured to respond to a different wavelength of light, in some embodiments, or to a same wavelength of light when light flux is quite high and a single P/N junction cannot process all incident photons from a light source.
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(40) A transparent oxide, or transparent conductive oxide (TCO) may be used as a front conductive electrode material for photovoltaic cells. A transparent oxide may be an indium tin oxide (InSnO), a fluorine-doped tin oxide (FTO), or an aluminum-doped zinc oxide (AZO), according to embodiments, although other transparent oxides are also envisioned. A thickness of transparent oxide may be selected to balance transparency of the transparent oxide layer with current-carrying capacity. In some embodiments, a thickness of the transparent oxide layer may range from 150 nm to 800 nm. A thickness of transparent oxide may also be selected according to an anticipated incident light flux from a light source, in order to meet a desired photoconversion rate for a range of light intensities without light loss due to absorption or scattering by either the transparent oxide or the window layer.
(41) One aspect of traditional photovoltaic cell designs is that the conversion of light to electrical current scales with the area of the photovoltaic cell, light intensity of wavelengths to which the photovoltaic cell is sensitive/responsive (e.g., from which current may be generated), and a distribution of wavelengths in the light source shining on a photovoltaic cell. A photovoltaic cell may have an active, or light absorbing, area of 10,000 μm.sup.2 (e.g., 100 μm×100 μm). An amount of output power anticipated from a III-V photovoltaic cell having 10,000 μm.sup.2 of light absorbing area may vary according to a type of light source, as follows: one sun's worth of solar radiation (i.e., direct sunlight) may produce approximately 1 μW of power; internal artificial lighting may produce approximately 0.005 μW, focused light emitting diodes may produce 0.5 μW of power, light from a commercially available laser pointer (e.g., a HeNe laser pointer or an argon (green light) laser pointer) may generate greater than 10 μW of power, and a well focused laser diode may generate approximately 1000 μW of power.
(42) Wearable devices may begin to be sufficiently charged for normal modes of operation (e.g., daily charging/wearing cycles) when photovoltaic charging can meet or exceed a current of 1 μW per 1 MHz of device clock speed. In an embodiment of a III-V semiconductor photovoltaic cell has been demonstrated to generate 400 μW/cm.sup.2 of light absorbing area under ambient internal artificial lighting, 50 milliWatts (mW)/cm.sup.2 under a red laser pointer (e.g., a HeNe laser) of light absorbing area, and over 1.3 mW/10 μm.sup.2 of light absorbing area under a 830 nm laser when the emitted light was gathered and directed onto the photovoltaic cell using a lensed fiber optic cable. Reductions in backside shadowing (e.g., illumination of the back side of the photovoltaic cell, not just the ‘top’ side), increased laser power, and reduced resistance may all contribute to increases in measured power output from the photovoltaic charging systems described above.
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(44) While the present application has been particularly shown and described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in forms and details may be made without departing from the spirit and scope of the present application. It is therefore intended that the present application not be limited to the exact forms and details described and illustrated, but fall within the scope of the appended claims.