Patent Publication Number: US-9906139-B2

Title: Power supply module, power supply device, and power controlling method

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present disclosure relates to a power supply module. More particularly, the present invention is related to a power controlling method and a power supply module applicable to power supply devices. 
     Description of Related Art 
     In general, the electronic products are operated when providing with a suitable and normal electric power, thereby the electronic products may be suffered when the electric power applies abnormally. A power converter is usually arranged between an alternative current (AC) electric power and the electronic product, and is configured to detecting the electric power required by the electronic product and convert the AC electric power to direct current (DC) electric power required by the electric power to power the electronic product. 
     Specifically, the electronic product can be operated under low power consumption mode (such as standby mode) or high power consumption mode (such as non-standby mode), and when the electronic product is operated under low power consumption mode, the electric power required by the electronic product reduces, thus the electric power provided by the power supply device for powering the electric product is then reduced to meet the requirement of the electronic product. However, the electric power required for the power supply device for powering its components is a constant no matter the electric product is operated under low power consumption mode or high power consumption mode. 
     SUMMARY OF THE INVENTION 
     According to one aspect of the present disclosure, a power supply module coupled with a primary winding of a power conversion module, the power supply module includes a plurality of power-controlling modules, a plurality of second switches, and a microprocessor. Each power-controlling module includes an auxiliary winding and a first switch electrically connected in series, and each auxiliary winding is magnetic coupled with the primary winding. Each second switch is electrically connected to one of the power-controlling units. The microprocessor is electrically connected to the first switches of the power-controlling modules and the second switches. The microprocessor places at least one first switch and one of the second switches in a conducting state to make the first switch in the conducting state and the second switch in the conducting state electrically connect in series and output an electric power to power the power conversion module. 
     According to another aspect of the present disclosure, the power supply device includes a power conversion module and a power supply module. The power conversion module includes a primary winding and a plurality of microcontrollers. The power supply module includes a plurality of power-controlling units, a plurality of second switches, and a microprocessor. Each power-controlling unit includes an auxiliary winding and a first switch electrically connected in series, wherein each auxiliary winding is coupled with the primary winding. Each second switch is electrically connected to one of the power-controlling units. The microprocessor is electrically connected to the first switches and the second switches. The microprocessor places at least one first switch and one of the second switches in a conducting state to make the first switch in the conducting state and the second switch in the conducting state electrically connect in series and output an electric power to power the microcontrollers of the power conversion module according to operation states of the microcontrollers. 
     According to still another aspect of the present disclosure, a power controlling method used for providing an electric power to power a power supply module of a power supply device comprising a primary winding includes following steps: providing a plurality of auxiliary windings, a plurality of first switches, and a plurality of second switches, the auxiliary windings coupled with the primary winding, each first switch electrically connected to one of the auxiliary windings to form a power-controlling unit, and each second switch electrically connected to one of the power-controlling unit; detecting the electric power for powering the power supply module; and placing at least one of the first switch and one of the second switches in a conducting state, wherein the second switch in the conducting state is electrically connected to the first switch in the conducting state in series. 
    
    
     
       BRIEF DESCRIPTION OF DRAWING 
       The features of the invention believed to be novel are set forth with particularity in the appended claims. The invention itself, however, may be best understood by reference to the following detailed description of the invention, which describes an exemplary embodiment of the invention, taken in conjunction with the accompanying drawings, in which: 
         FIG. 1  is a circuit diagram of a power supply device according to the present disclosure; 
         FIG. 2  is a circuit diagram of a power supply module according to the present disclosure; and 
         FIG. 3  shows a graph of the relationship between the output voltage and time of the power supply module. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     A preferred embodiment of the present invention will be described with reference to the drawings. 
     Reference is made to  FIG. 1 , which is a circuit block diagram of a power supply device according to the present disclosure. The power supply device (its reference numeral is omitted) includes an input terminal for connecting to a power source Vin, an output terminal for connecting to the load RL, a power conversion module  10 , and a power supply module  20 . The power supply device receives an electric power (such as an alternative current electric power) provided by the power source Vin and then provides an direct current (DC) electric power to power the load RL. The power conversion module  10  is arranged between the power source Vin and the load RL and electrically connected thereto. The power conversion module  10  receives the AC electric power provided by the power source Vin and converts the AC electric power to the DC electric power that is used to power the load RL. The load RL is, for example, a server or a personal computer (PC). The power supply module  20  is electrically connected to the power conversion module  10  and is configured to provide electric powers to power microcontrollers  11  of the power conversion module  10 . 
     The power conversion module  10  includes a primary winding Wp and a secondary winding Ws coupled with the primary winding Wp, and the turn ratio of the primary winding Wp and the secondary ratio Ws is designated for determining how much electric power (such as voltage and/or current) can be produced at the output terminal. 
     The power conversion module  10  includes a primary side rectifier  100 , a power factor corrector  110 , a primary side filter  120 , a power converter  130 , a secondary side rectifier  140 , and a secondary side filter  150 . The primary side rectifier  100 , the power factor corrector  110 , the primary side filter  120 , and the power converter  130  are arranged between the power source Vin and the primary winding Wp. The primary side rectifier  100  is, for example, a bridge rectifier, and electrically connected to the power source Vin. The power factor corrector  110  is electrically connected to the primary side rectifier  100 . The primary side filter  120  is arranged between the power factor corrector  110  and the primary winding Wp of the power converter  130  and electrically connected thereto. The secondary side rectifier  140  and the secondary side filter  150  are arranged between the secondary winding Ws and the load RL, the secondary side rectifier  140  is connected to the secondary winding Ws, and the secondary side filter  150  is electrically connected to the secondary side rectifier  140  and the load RL. The primary side rectifier receives the AC electric power provided by the power source Vin and rectifies the AC electric power to a full-wave rectified power without power factor correction. The power factor corrector  110  received the full-wave rectified power without power factor correction and ensures that the input current of the rectified power without power factor correction follows voltage of the rectified power without power factor correction in time and amplitude proportionally (i.e. the input voltage and current of the rectified power are maintained in phase relative to each other). The primary side filter  120  filters the noise within the electric power outputted from the power factor corrector  110 , and the conducts the filtered electric power to the primary winding Wp. The secondary side rectifier  140  rectifies the electric power outputted from secondary winding Ws into a pulsating DC power, and the secondary side filter  150  filters the ripple of the pulsating DC electric power and then sent a stable DC electric power to the load RL to meet the requirements thereof. 
     The power conversion module  10  further includes a plurality of microcontrollers  11 , and the microprocessors  11  can be arranged within the power factor corrector  110 , the power converter  130 , and the secondary side rectifier  140 . The microprocessors  11  are configured to control operations (such as turn-on and turn-off) of power switches or active components within the power factor corrector  110 , the power converter  130 , and the secondary side rectifier  140  according to the DC electric power required for the load RL. For example, when the load RL is operated under a high power consumption mode, the power conversion module  10  provides the DC electric power with high power factor to power and drive the load RL, thus microcontroller  11  of the power factor corrector  110  drives the power factor corrector  110  to perform the power factor correcting procedure, and the electric power with high power factor is then provided to the load RL. On the contrary, when the load RL is operated under a low power consumption mode, the power conversion module  10  provides the DC electric power to the load RL to make sure that the load RL is activated or not (i.e. the DC electric power provided by the power supply device is used for detecting whether the load RL is entering from the high power consumption mode from the low power consumption mode or not). Thus the power factor corrector  110  may be inactivated to lower power consumption of the power supply device. 
     The power supply module  20  is electrically connected to the microcontrollers  11  of the power supply module  10 , and provides DC electric power according to the operations of the microcontroller  11 . 
     Reference is made to  FIG. 2 , which is a circuit diagram of the power supply module according to the present disclosure. The power supply module  20  includes a microprocessor  200 , a plurality of auxiliary windings Wa_ 1 ˜Wa_n, a plurality of first switches SW 1 _ 1 ˜SW 1 _ n , and a plurality of second switches SW 2 _ 1 ˜SW 2 _ n . The microprocessor  200  is electrically connected to the first switches SW 1 _ 1 ˜SW 1 _ n  and the second switches SW 2 _ 2 ˜SW 2 _ n , and respectively controls the operations (turn-on and turn-off) of the first switches SW 1 _ 1 ˜SW 1 _ n  and the second switch SW 2 _ 1 ˜SW 2 _ n  according to the operations of the microprocessors  11 , wherein the operations of the microcontroller  11  is in accordance with the operations of the load RL. 
     The auxiliary winding Wa_ 1 ˜Wa_n may be designated to have different turn numbers to meet the power requirements of microprocessors  11 ; however, the auxiliary winding Wa_ 1 ˜Wa_n may be designated to have the same turn number. 
     Each first switch SW 1 _ 1 ˜SW 1 _ n  is electrically connected to one of the auxiliary winding Wa_ 1 ˜Wa_n in series to form a power-controlling unit  210 _ 1 ˜ 210 _ n . The first switches SW 1 _ 1 ˜SW 1 _ n  electrically connected by the microprocessor  200  and driven thereby are, for example, metal-oxide-semiconductor field-effect transistors (MOSFETs). 
     Each second switch SW 2 _ 1 ˜SW 2 _ n  is arranged between one of the power-controlling unit  210 _ 1 ˜ 210 _ n  and one of the output terminal OUT_ 1 ˜OUT_n, and is placed in a conducting state (turn-on) or a non-conducting state (turn-off) by the microprocessor  200 . The second switches SW 2 _ 1 ˜SW 2 _ n  are, for example, MOSFETs. 
     The microprocessor  200  detects the operations of the microcontrollers  11  and places at least one first switch SW 1 _ 1 ˜SW 1 _ n  and one of the second switch SW 2 _ 1 ˜SW 2 _ n  in conducting state to provide electric powers to power the microcontrollers  11 . The electric powers (the output voltage) provided by the power supply module  20  and conducted to the microcontrollers  11  according to the operations of the microcontrollers  11  are shown in  FIG. 3 . More particularly, the output voltage provided by the power supply module  20  is direct proportional to the amount of the microcontrollers  11  placed in the conducting state. 
     Reference is made to  FIG. 2  and  FIG. 3 . In first operation state (as time points between t 1  and t 2  shown in  FIG. 3 ), a first output voltage Vcc_ 1  is provided by the power supply module  20 . Specifically, in first operation state, the microprocessor  200  places the first switch SW_ 1  and the second switch SW 2 _ 1  in the conducting state, thus the auxiliary winding Wa_ 1 , the first switch SW 1 _ 1 , and the second switch SW 2 _ 1  are electrically connected in series, the auxiliary winding Wa_ 1  is coupled with the primary winding Wp, and the first output voltage Vcc_ 1  is generated. The first output voltage Vcc_ 1  is conducted to the microcontrollers  11  of the power conversion module  10  by the output terminal OUT_ 1 . 
     When the voltage of the primary winding Wp is Vp, the turn number of the primary winding Wp is Np, and the turn number of the auxiliary winding Wa_ 1  is N Wa   _   1 , the first output voltage Vcc_ 1  can write as 
     
       
         
           
             
               Vcc 
               1 
             
             = 
             
               
                 
                   V 
                   ⁢ 
                   
                       
                   
                   ⁢ 
                   p 
                   × 
                   
                     N 
                     
                       Wa 
                       ⁢ 
                       
                           
                       
                       ⁢ 
                       _ 
                       ⁢ 
                       
                           
                       
                       ⁢ 
                       1 
                       ⁢ 
                       
                           
                       
                       ⁢ 
                       _ 
                     
                   
                 
                 
                   N 
                   ⁢ 
                   
                       
                   
                   ⁢ 
                   p 
                 
               
               . 
             
           
         
       
     
     In second operation state (as time points between t 2  and t 3  shown in  FIG. 3 ), a second output voltage Vcc_ 2  is provided by the power supply module  20 . Specifically, in second state, the microprocessor  200  places the first switches SW_ 1  and SW_ 2  and the second switch SW 2 _ 2  in the conducting state, thus the auxiliary windings Wa_ 1  and Wa_ 2 , the first switches SW 1 _ 1  and SW 1 _ 2 , and the second switch SW 2 _ 2  are electrically connected in series, the auxiliary windings Wa_ 1  and Wa_ 2  are coupled with the primary winding Wp and then the second output voltage Vcc_ 2  is generated. The second output voltage Vcc_ 2  is conducted to the microcontrollers  11  of the power conversion module  10  by the output terminal OUT_ 2 . It should be noted that the turn number of the auxiliary number Wa_ 1 ˜Wa_n when the power supply module  20  operated in second operation state (that the auxiliary windings Wa_ 1  and Wa_ 2  are coupled with the primary winding Wp) is larger than that of operated in first operation state (that the auxiliary winding Wa_ 1  is coupled with the primary winding Wp), thus the second output voltage Vcc_ 2  is higher than the first output voltage Vcc_ 1 . 
     When the voltage of the primary winding Wp is Vp, the turn number of the primary winding Wp is Np, the turn number of the auxiliary winding Wa_ 1  is N wa   _   1 , and the turn number of the auxiliary winding Wa_ 2  is N Wa   _   2 , the second output voltage Vcc_ 2  can write as 
     
       
         
           
             
               Vcc_ 
               ⁢ 
               2 
             
             = 
             
               
                 
                   V 
                   ⁢ 
                   
                       
                   
                   ⁢ 
                   p 
                   × 
                   
                     ( 
                     
                       
                         N 
                         
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                           ⁢ 
                           
                               
                           
                           ⁢ 
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                           ⁢ 
                           
                               
                           
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                           _ 
                           ⁢ 
                           
                               
                           
                           ⁢ 
                           1 
                         
                       
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                           ⁢ 
                           
                               
                           
                           ⁢ 
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                           2 
                         
                       
                     
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                   N 
                   ⁢ 
                   
                       
                   
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                   p 
                 
               
               . 
             
           
         
       
     
     In third operation state (as time points between t 3  shown in  FIG. 3 ), a third output voltage Vcc_ 3  is provided by the power supply module  20 . Specifically, in third state, the microprocessor  200  places the first switches SW_ 1 ˜SW_ 3  and the second switch SW 2 _ 3  in the conducting state, thus the auxiliary windings Wa_ 1 ˜Wa_ 3 , the first switches SW 1 _ 1 ˜SW 1 _ 3 , and the second switch SW 2 _ 3  are electrically connected in series, the auxiliary windings Wa_ 1 ˜Wa_ 3  are coupled with the primary winding Wp and then the third output voltage Vcc_ 3  is generated. The third output voltage Vcc_ 3  is conducted to the microcontrollers  11  of the power conversion module  10  by the output terminal OUT_ 3 . It should be noted that the turn number of the auxiliary number Wa_ 1 ˜Wa_n when the power supply module  20  operated in third operation state (that the auxiliary windings Wa_ 1 ˜Wa_ 3  are coupled with the primary winding Wp) is larger than that of operated in second operation state (that the auxiliary windings Wa_ 1  and Wa_ 2  are coupled with the primary winding Wp), thus the third output voltage Vcc_ 3  is higher than the second output voltage Vcc_ 2 . 
     When the voltage of the primary winding Wp is Vp, the turn number of the primary winding Wp is Np, the turn number of the auxiliary winding Wa_ 1  is N Wa   _   1 , the turn number of the auxiliary winding Wa_ 2  is N Wa   _   2 , and the turn number of the auxiliary winding Wa_ 3  is N Wa   _   3 , the third output voltage Vcc_ 3  can write as 
     
       
         
           
             
               Vcc_ 
               ⁢ 
               3 
             
             = 
             
               
                 
                   V 
                   ⁢ 
                   
                       
                   
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                   × 
                   
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     In fourth operation state, an output voltage Vcc_n is provided by the power supply module  20 . Specifically, in fourth state, the microprocessor  200  places the first switches SW_ 1 ˜SW_n and the second switch SW 2 _ n  in the conducting state, thus the auxiliary windings Wa_ 1 ˜Wa_n, the first switches SW 1 _ 1 ˜SW 1 _ n , and the second switch SW 2 _ n  are electrically connected in series, the auxiliary windings Wa_ 1 ˜Wa_n are coupled with the primary winding Wp, and then the output voltage Vcc_n is generated. The output voltage Vcc_n is conducted to the microcontrollers  11  of the power conversion module  10  by the output terminal OUT_n. 
     When the voltage of the primary winding Wp is Vp, the turn number of the primary winding Wp is Np, the turn number of the auxiliary winding Wa_ 1  is N Wa   _   1 , the turn number of the auxiliary winding Wa_ 2  is N Wa   _   2 , the turn number of the auxiliary winding Wa_ 3  is N Wa   _   3 , and the turn number of the auxiliary winding Wa_n is N Wa   _   n , the output voltage Vcc_n can write as 
     
       
         
           
             Vcc_n 
             = 
             
               Vp 
               × 
               
                 
                   
                     ( 
                     
                       
                         N 
                         
                           W 
                           ⁢ 
                           
                               
                           
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                             ⁢ 
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                         … 
                       
                       + 
                       
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                 . 
               
             
           
         
       
     
     According to first to fourth operation states mentioned above, the output voltage of the power supply module  20  is progressively increased when the electric power for powering the power conversion module  10  is gradually increased, and the amount of the switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state is increased when the output voltage is increased for electrically connecting the auxiliary winding Wa_ 1 ˜Wa_n connected to the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state in series. The microprocessor  200  of the power supply module  20  is then placed one of the second switches SW 2 _ 2 ˜SW 2 _ n  in the conducting state to make sure the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state, the second switch SW 2 _ 1 ˜SW 2 _ n  in the conducting state, and the auxiliary winding Wa_ 1 ˜Wa_n connected to the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state are electrically connected in series. The auxiliary winding Wa_ 1 ˜Wa_n connected to the first switches SW_ 1 ˜SW_n in the conducting state are respectively coupled with the primary winding Wp and then the output voltage is generated and outputted form the one of the output terminals OUT_ 1 ˜OUT_n to at least one of the microcontrollers  11 . 
     Thus, when the voltage outputted from the power supply module to the power conversion module  10  are Vcc_ 1 ˜Vcc_n, the voltage of the primary winding Wp is Vp, the turn number of the primary winding Wp is Np, the turn numbers of the auxiliary windings Wa_ 1 ˜Wa_n are N Wa   _   1 ˜N Wa   _   2 , and the signal sent from the microprocessor  200  to the second switches SW 2 _ 1 ˜SW 2 _ n  are A 1 ˜An, the following conditions are satisfied: 
     
       
         
           
             
               [ 
               
                 
                   
                     
                       Vcc_ 
                       ⁢ 
                       1 
                     
                   
                 
                 
                   
                     
                       Vcc_ 
                       ⁢ 
                       2 
                     
                   
                 
                 
                   
                     
                       Vcc_ 
                       ⁢ 
                       3 
                     
                   
                 
                 
                   
                     ⋮ 
                   
                 
                 
                   
                     Vcc_n 
                   
                 
               
               ] 
             
             = 
             
               
                 
                   
                     
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                       ⁢ 
                       
                           
                       
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                               ⁢ 
                               
                                   
                               
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               . 
             
           
         
       
     
     The switch signal sent from the microprocessor  200  to the second switches SW 2 _ 1 ˜SW 2 _ n  can be logic high signal ( 1 ) or logic low signal ( 0 ). For example, when A 1  gives as 1 and A 2 ˜An give as 0, the signal sent from the microprocessor  200  to the second switch SW 2 _ 1  is logic high signal and the signals sent form the microprocessor  200  to the second switches SW 2 _ 2 ˜SW 2 _ n  are logic low signals. Therefore the second switch SW 2 _ 1  is placed in the conducting state and the second switch SW 2 _ 2 ˜SW 2 _ n  are placed in the non-conducting state. When A 2  gives as 1, and A 1  and A 3 ˜An give as 0, the signal sent from the microprocessor  200  to the second switch SW 2 _ 2  is logic high signal and the signals sent form the microprocessor  200  to the second switches SW 2 _ 1  and SW 2 _ 3 ˜SW 2 _ n  are logic low signals. Therefore the second switch SW 2 _ 2  is placed in the conducting state and the second switch SW 1  and SW 3 _ 2 ˜SW 2 _ n  are placed in the non-conducting state. 
     To sum up, the power supply module  20  of the present disclosure places at least one first switches SW 1 _ 1 ˜SW 1 _ n  and one of the second switches SW 2 _ 1 ˜SW 2 _ n  in the conducting state for providing electric power to power at least one of the microcontroller  11 . The second switch SW 2 _ 1 ˜SW 2 _ n  in the conducting state is electrically connected to the auxiliary winding Wa_ 1 ˜Wa_n connected to the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state in series. The amount of the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state is direct proportional to the potential level of the electric power generated by the power supply module  20 . In the other words, the potential level of the electric power provided by the power supply module  20  is increased when the amount of the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state is increased, and the potential level of the electric power provided by the power supply module  20  is decreased when the amount of the first switches SW 1 _ 1 ˜SW 1 _ n  in the conducting state is decreased. 
     The power controlling method of the present disclosure used for providing an electric power to power the power supply device including a primary winding Wp includes the following steps. 
     At first, a power supply module  20  including a microprocessor  200 , a plurality of auxiliary windings Wa_ 1 ˜Wa_n, a plurality of first switch SW 1 _ 1 ˜SW 1 _ n , and a plurality of second switch SW 2 _ 1 ˜SW 2 _ n  is provided. The auxiliary windings Wa_ 1 ˜Wa_n are coupled with the primary winding Wp, each first switch SW 1 _ 1 ˜SW 1 _ n  is electrically connected to one of the auxiliary winding W_ 1 ˜Wa_n in series to from the power-controlling unit  210 _ 1 ˜ 210 _ n , and each second switch SW 2 _ 1 ˜SW 2 _ n  is electrically connected to one of the power-controlling unit  210 _ 1 ˜ 210 _ n . Thereafter, the microprocessor  200  of the power supply module  20  detects the operation state of the microcontrollers  11  with in the power supply device, and places at least one of the first switch SW 1 _ 1 ˜SW 1 _ n  and one of the second switch SW 2 _ 1 ˜SW 2 _ n  in a conducting state (i.e. turn on at least one of the first switch SW 1 _ 1 ˜SW 1 _ n  and one of the second switch SW 2 _ 1 ˜SW 2 _ n ) to provide an electric power to power the microcontrollers  11  according to the detected result. More particularly, the second switch SW 2 _ 1 ˜SW 2 _ n  in the conducting state is electrically connected to the first switch(es) SW 1 _ 1 ˜SW 1 _ n  in the conducting state and the auxiliary winding(s) Wa_ 1 ˜Wa_n connected to the first switch(es) SW 1 _ 1 ˜SW 1 _ n  in the conducting state in series, and the auxiliary winding(s) Wa_ 1 ˜Wa_n are coupled with the primary winding Wp and the electric power for power the power supply device is then generated. 
     Although the present invention has been described with reference to the foregoing preferred embodiment, it will be understood that the invention is not limited to the details thereof. Various equivalent variations and modifications can still occur to those skilled in this art in view of the teachings of the present invention. Thus, all such variations and equivalent modifications are also embraced within the scope of the invention as defined in the appended claims.