Injection type LED lamp assembly

文档序号:5031 发布日期:2021-09-17 浏览:57次 中文

1. A lamp assembly, comprising:

a lamp layer, comprising:

a flexible substrate;

an electrical circuit printed on the flexible substrate to form a printed circuit thereon; and

a plurality of LEDs operatively attached to the printed circuit and extending outwardly from the flexible substrate;

a thermoplastic housing on a side of the light layer opposite the plurality of LEDs; and

an in-mold coating (IMC) layer opposite the thermoplastic housing relative to the lamp layer such that the IMC layer covers the LED.

2. The lamp assembly of claim 1, wherein the lamp assembly,

wherein the flexible substrate of the lamp layer is transparent, and

wherein the IMC layer is transparent such that the thermoplastic housing is viewable through the IMC layer and the flexible substrate.

3. The lamp assembly of claim 2, further comprising:

a plurality of attachment features formed in the thermoplastic housing.

4. The lamp assembly of claim 3, further comprising:

a plurality of fiducial features formed on the flexible substrate of the lamp layer, wherein the fiducial features orient the lamp layer relative to the attachment features of the thermoplastic housing.

5. The lamp assembly of claim 4,

wherein the IMC layer is formed from one of urethane, silicone, or PMMA and provides scratch protection and ultraviolet protection to the plurality of LEDs.

6. The lamp assembly of claim 1, wherein the printed circuit extends outwardly from the flexible substrate such that the printed circuit is three-dimensional.

7. The lamp assembly of claim 1, further comprising:

a plurality of attachment features formed in the thermoplastic housing; and

a plurality of fiducial features formed on the flexible substrate of the light layer such that the fiducial features align the light layer relative to the attachment features of the thermoplastic housing.

8. A method of forming a lamp assembly, the method comprising:

placing a flexible lamp layer within a mold cavity;

injecting a thermoplastic structure into the mold cavity on one side of the flexible lamp layer, wherein the flexible lamp layer conforms to a shape of a portion of the mold cavity; and

an in-mold coating (IMC) layer is injected onto a side of the flexible lamp layer opposite the thermoplastic structure.

9. The method of claim 8, wherein the flexible lamp layer comprises:

a flexible substrate;

a printed circuit formed on one side of the flexible substrate; and

a plurality of LEDs operatively attached to the printed circuit and extending from the flexible substrate opposite the thermoplastic structure and covered by the IMC layer.

10. The method of claim 9, further comprising:

aligning a plurality of fiducial features formed on the flexible lamp layer within the mold cavity such that portions of the thermoplastic structure are aligned relative to the fiducial features.

Disclosure of Invention

A lamp assembly and a method of forming a lamp assembly are provided. The lamp assembly comprises a flexible lamp layer, a thermoplastic housing and an in-mold coating (IMC) layer. The flexible lamp layer has: a flexible substrate; a circuit printed on the flexible substrate; and a plurality of LEDs operatively attached to the printed circuit and extending outwardly from the flexible substrate. A thermoplastic housing is formed on a side of the flexible light layer opposite the plurality of LEDs, and an IMC layer is formed opposite the thermoplastic housing relative to the flexible light layer. The IMC layer covers and protects the LED.

Forming the lamp assembly may include placing the flexible lamp layer within a mold cavity; and injecting a thermoplastic structure into the mold cavity on one side of the flexible lamp layer. The IMC layer is injected onto the side of the flexible lamp layer opposite the thermoplastic structure. The flexible lamp layer may have a first shape when placed into the mold cavity, such that injecting the thermoplastic structure into the mold cavity changes the shape of the flexible lamp layer to a second shape different from the first shape. The datum features of the flexible lamp layer may be aligned within the mold cavity such that portions of the thermoplastic structure are aligned relative to the datum features.

In some configurations, the mold cavity includes a movable wall. When the movable wall is in the first position, injecting the thermoplastic structure occurs such that the flexible lamp layer is adjacent to the movable wall, and when the movable wall is in the second position, injecting the IMC layer occurs such that both the thermoplastic structure and the IMC layer are injected into the same mold cavity.

In some configurations, the lamp assembly is formed in a rotary molding machine. Injecting a thermoplastic structure occurs at a first station (station) of a rotary molding machine; and the injection of the IMC layer occurs at the second station. Thus, the rotary molding machine moves the thermoplastic structure from the first station to the second station.

In some configurations, the flexible lamp layer is thermoformed prior to placing the flexible lamp layer within the mold cavity. The IMC layer may be formed of one of urethane, silicone, or PMMA, and the flexible substrate may be formed of one of polyamide, PEEK, or transparent polyester film.

The invention also comprises the following technical scheme:

scheme 1. a lamp assembly comprising:

a lamp layer, comprising:

a flexible substrate;

an electrical circuit printed on the flexible substrate to form a printed circuit thereon; and

a plurality of LEDs operatively attached to the printed circuit and extending outwardly from the flexible substrate;

a thermoplastic housing on a side of the light layer opposite the plurality of LEDs; and

an in-mold coating (IMC) layer opposite the thermoplastic housing relative to the lamp layer such that the IMC layer covers the LED.

Scheme 2. the lamp assembly according to scheme 1,

wherein the flexible substrate of the lamp layer is transparent, and

wherein the IMC layer is transparent such that the thermoplastic housing is viewable through the IMC layer and the flexible substrate.

Scheme 3. the lamp assembly of scheme 2, further comprising:

a plurality of attachment features formed in the thermoplastic housing.

Scheme 4. the lamp assembly of scheme 3, further comprising:

a plurality of fiducial features formed on the flexible substrate of the lamp layer, wherein the fiducial features orient the lamp layer relative to the attachment features of the thermoplastic housing.

Scheme 5. the lamp assembly according to scheme 4,

wherein the IMC layer is formed from one of urethane, silicone, or PMMA and provides scratch protection and ultraviolet protection to the plurality of LEDs.

Scheme 6. the lamp assembly of scheme 1, wherein the printed circuit extends outwardly from the flexible substrate such that the printed circuit is three-dimensional.

Scheme 7. the lamp assembly of scheme 1, further comprising:

a plurality of attachment features formed in the thermoplastic housing; and

a plurality of fiducial features formed on the flexible substrate of the light layer such that the fiducial features align the light layer relative to the attachment features of the thermoplastic housing.

Scheme 8. a method of forming a lamp assembly, the method comprising:

placing a flexible lamp layer within a mold cavity;

injecting a thermoplastic structure into the mold cavity on one side of the flexible lamp layer, wherein the flexible lamp layer conforms to a shape of a portion of the mold cavity; and

an in-mold coating (IMC) layer is injected onto a side of the flexible lamp layer opposite the thermoplastic structure.

Scheme 9. the method of scheme 8, wherein the flexible lamp layer comprises:

a flexible substrate;

a printed circuit formed on one side of the flexible substrate; and

a plurality of LEDs operatively attached to the printed circuit and extending from the flexible substrate opposite the thermoplastic structure and covered by the IMC layer.

Scheme 10. the method of scheme 9, further comprising:

aligning a plurality of fiducial features formed on the flexible lamp layer within the mold cavity such that portions of the thermoplastic structure are aligned relative to the fiducial features.

The method of claim 10, wherein the mold cavity includes a movable wall, and further comprising:

injecting the thermoplastic structure while the movable wall is in a first position such that the flexible light layer is adjacent to the movable wall; and

injecting the IMC layer when the movable wall is in a second position such that both the thermoplastic structure and the IMC layer are injected into the same mold cavity.

The method of scheme 10, wherein the lamp assembly is formed in a rotary molding machine, and further comprising:

injecting the thermoplastic structure at a first station of the rotary molding machine; and

injecting the IMC layer at a second station, wherein the rotary molding machine moves the thermoplastic structure from the first station to the second station.

Scheme 13. the method of scheme 10, further comprising:

thermoforming the flexible light layer prior to placing the flexible light layer within the mold cavity.

Scheme 14. according to the method of scheme 10,

wherein the IMC layer is formed from one of urethane, silicone, or PMMA; and is

Wherein the flexible substrate is formed from one of polyamide, PEEK, or a transparent polyester film.

Scheme 15. according to the method of scheme 8,

wherein the flexible lamp layer has a first shape when placed into the mold cavity, and

wherein injecting the thermoplastic structure into the mold cavity changes the shape of the flexible lamp layer to a second shape different from the first shape.

Scheme 16. the method of scheme 15, further comprising:

thermoforming the flexible light layer into the first shape prior to placing the flexible light layer within the mold cavity.

The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings.

Drawings

FIG. 1 is a schematic side diagrammatic view of an LED lamp assembly.

Fig. 2 is a schematic isometric view of a segment of a flexible LED lamp layer.

Fig. 3A is a schematic diagram illustrating a first portion, movement, or step (such as those shown in the figure) of forming an LED light assembly.

Fig. 3B is a schematic diagram illustrating a second portion, movement, or step (such as those shown in the figures) of forming an LED light assembly.

Fig. 3C is a schematic diagram illustrating a third portion, movement, or step (such as those shown in the figures) of forming an LED lamp assembly.

Detailed Description

Referring to the drawings, like reference numbers refer to like parts, where possible. Fig. 1 schematically illustrates a lamp assembly 10, the lamp assembly 10 being shown generally as a side view or a planar intersection view to illustrate its internal components.

As seen in fig. 1, the lamp assembly has a lamp layer 12, a thermoplastic housing 14 or thermoplastic structure on one side of the lamp layer 12, and an in-mold coating (IMC) layer 16 on the other side of the lamp layer 12. A thermoplastic housing 14 is formed on and attached to a first side of the lamp layer 12, and an IMC layer 16 is formed on and attached to a second side of the lamp layer 12, the IMC layer 16 being opposite the thermoplastic housing 14.

The lamp assembly 10 may be used in a vehicle or for display lighting on other structures. When used in a vehicle, the lamp assembly 10 may be used, for example, but not limited to, interior or exterior lighting, and may be used for display or communication lighting (such as scrolling text or pictures), or for primary lighting (such as headlamps, brake lights, or signal indicators). As described herein, the lamp layer 12 provides structural elements that produce or project light.

The thermoplastic housing 14 may be referred to as the B-side of the lamp assembly 10 and includes structural elements and features for aligning the lamp assembly 10 relative to the vehicle. The thermoplastic housing 14 is generally formed via injection molding. As shown in fig. 1, a plurality of attachment features 20 are formed in the thermoplastic housing 14. The thermoplastic shell 14 may be formed from, for example, but not limited to: numerous types of thermoplastics, other hard plastics, or combinations thereof.

Note that the thermoplastic housing 14 is illustrated highly schematically. In many configurations, the thermoplastic housing 14 will include structural ribs and other features that reduce the overall weight of the thermoplastic housing 14 while providing sufficient strength and structure to support the light assembly 10 relative to the attachment features 20 and the structure to which the light assembly 10 is attached.

The drawings and illustrations presented herein are not to scale and are provided for instructional purposes only. Any specific and relative dimensions shown in the drawings are not to be construed as limiting. For example, the IMC layer 16 shown in fig. 1 and other figures may be oversized for illustration.

The IMC layer 16 may be referred to as the a-side of the lamp assembly 10 and includes aesthetic features and functionality. The IMC layer 16 also protects the lamp layer 12 from light damage (such as from ultraviolet light damage), corrosion, and scratch damage. The IMC layer 16 may be formed from, for example, but not limited to: urethane, silicone, Polymethylmethacrylate (PMMA), or a combination thereof.

The combination of the flexible lamp layer 12, the injected thermoplastic shell 14, and the protective IMC layer 16 allows the lamp assembly 10 to have a complex a-side while still being able to be manufactured and attached to a vehicle via standard means. The manufacture of the lamp assembly 10 is discussed in more detail below with particular reference to fig. 3A-C. Note that the lamp assembly 10 can be formed with multiple bends (curves), including small radius bends (less than 10 millimeters) and multiple bends or elements in close proximity.

Any reference to a vehicle may represent any rolling platform, including but not limited to: motorcycles, tractors, buses, mobile homes, campers, and tanks. Further, the components described herein may also be used in a variety of other industries and applications, including but not limited to: aerospace applications, consumer products, industrial and construction equipment, agricultural equipment, heavy machinery, or display lighting.

Although the present disclosure may be described with respect to a particular application or industry, those skilled in the art will recognize the broader applicability of the present disclosure. Those of ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," etc., are used to describe the figures and are not meant to limit the scope of the disclosure or the appended claims. Any numerical designation such as "first" or "second" is merely illustrative and is not intended to limit the scope of the disclosure in any way.

Features shown in one figure may be combined with, substituted for, or modified by features shown in any figure. No feature, element, or limitation is mutually exclusive of any other feature, element, or limitation, unless expressly stated otherwise. Furthermore, no feature, element, or limitation is essential to the operation. Any particular configuration shown in the figures is merely illustrative, and the particular configuration shown is not limiting of the claims or the specification.

As used herein, the term "substantially" refers to a perfect or complete relationship, but manufacturing reality hinders the absolute perfect situation. Therefore, a typical difference from perfect is roughly represented. For example, if height a is approximately equal to height B, it may be preferable that the two heights be 100.0% equal, but manufacturing reality is likely to result in distances that deviate from such perfect. The skilled artisan will recognize the amount of difference that is acceptable. For example and without limitation, for substantial equivalence, the coverage, area, or distance may be generally within 10% of perfect. Similarly, relative alignment (such as parallel or perpendicular) may generally be considered to be within 5-10%.

Referring to fig. 2, and with continued reference to fig. 1, a schematic isometric view of a portion of a lamp layer 12 is shown, which lamp layer 12 may form a portion of the lamp assembly 10. The lamp layer 12 is generally formed from a flexible substrate 22, a printed circuit 24, and a plurality of Light Emitting Diodes (LEDs) 26.

The flexible substrate 22 may be formed from, for example, but not limited to: polyamide, PEEK or transparent polyester film. A printed circuit 24 is printed on the flexible substrate 22 and the LEDs 26 are operatively attached to the printed circuit 24 such that the printed circuit 24 provides power to the LEDs 26 and thus control of the LEDs 26. For example, the LEDs 26 may be attached to the printed circuit 24 using, for example, but not limited to, a conductive adhesive or solder. Note that the printed circuit 24 is not shown in detail, and that there may be additional conductive lines formed of conductive or dielectric ink traces printed on the flexible substrate 22 in addition to masking or non-conductive traces.

In many configurations, the LEDs 26 will extend outwardly from the flexible substrate 22, as best illustrated in fig. 1, although the drawings are not drawn to scale. In the configuration shown, the LEDs 26 extend opposite the thermoplastic housing 14 such that the thermoplastic housing 14 is injected on and attached to the side of the lamp layer 12 opposite the LEDs 26.

The skilled person will recognize numerous techniques for forming the flexible lamp layer 12. For example, but not limited to, the printed circuit 24 may be applied to the flexible substrate 22 via direct printing or 3D printing techniques. Although not shown in the drawings, the printed circuit 24 may extend outwardly from the flexible substrate 22.

The conductive ink or paste may be applied to the flexible substrate 22 using an additive manufacturing process. For example, and without limitation, alternating layers of conductive and non-conductive (masking or via) material may be printed onto the flexible substrate 22 such that a three-dimensional circuit layout is formed for the printed circuit 24.

The LEDs 26 may be attached to the printed circuit 24 using, for example, but not limited to, an adhesive or a conductive paste. Further, the printed circuit 24 may be formed on the flexible substrate 22 via a removal process (such as etching) or other micromachining process. The IMC layer 16 is injected opposite the thermoplastic housing 14 relative to the lamp layer 12 such that the IMC layer 16 covers the LEDs 26 extending away from the flexible substrate 22 and the printed circuit 24.

Connections for control and operation of the lamp assembly 10 are not shown in the drawings. However, the lamp layer 12 may have, for example, but not limited to, a wiring harness or connector extending therefrom. A suitable control system or controller structure may be operatively attached to the lamp layer 12 for operation of the lamp assembly 10. In some configurations, a connector or plug that interfaces with the lamp layer 12 may be incorporated into the thermoplastic housing 14 either during formation or via post-processing.

In many configurations of the lamp assembly 10 of claim 1, the flexible substrate 22 of the lamp layer 12 may be transparent. Thus, if the IMC layer 16 is also transparent, the thermoplastic housing 14 may be viewed through the IMC layer 16 and the flexible substrate 22. Thus, the thermoplastic shell 14 may provide aesthetics to the overall lamp assembly 10 by having its coloring (coloration) or features penetrate the a side of the lamp assembly 10. Further, note that where the LEDs 26 extend generally outwardly from the flexible substrate 22, the extended LEDs 26 will be viewable through the IMC layer 16, which may provide interesting aesthetic features to the lamp assembly 10.

As discussed herein, the lamp assembly 10 may be formed by insert molding the thermoplastic housing 14 around the lamp layer 12. Accordingly, a plurality of fiducial features 28 may be formed on the flexible substrate 22 of the lamp layer 12, as illustrated in fig. 2. These datum features 28 may orient the lamp layer 12 relative to the attachment features 20 of the thermoplastic shell 14 within the injection molding apparatus. The reference features 28 are illustrated in fig. 2 as holes or slots, but the skilled person will recognize several types of reference features 28 that may be used to align the lamp layers 12.

Referring also to fig. 3A, 3B, and 3C, and with continued reference to fig. 1-2, there is illustrated structure, mechanism, and method for manufacturing a lamp assembly, such as the lamp assembly 10 schematically shown in fig. 1. Each of fig. 3A, 3B, and 3C schematically illustrates different movements, portions, configurations, or variations of the injection molding apparatus 50. For example, but not limiting of, the injection molding apparatus 50 may be: a rotary injection system, a movable cavity system, or a pick and place molding system.

As illustrated in fig. 3A, forming the lamp assembly 10 may include placing the flexible lamp layer 12 within a mold cavity 52, the mold cavity 52 generally defined by a first platen (tension) 54 and a second platen 56. Either of first and second platens 54, 56 may be movable or fixed relative to each other and mold cavity 52.

In fig. 3A, the flexible lamp layer 12 is shown as having a shape that is partially similar to the shape of one of the walls of the mold cavity 52, which may be referred to as a lamp sidewall 58. However, in some configurations, the flexible lamp layer 12 may be substantially flat or unformed when placed into the mold cavity 52. Alternatively, the flexible lamp layer 12 may be pre-formed or pre-shaped (such as by thermoforming) to substantially its final shape prior to placement within the mold cavity 52.

If included, datum features 28 (not shown in FIGS. 3A-C) may be used to align flexible lamp layer 12 within mold cavity 52. The printed circuit 24 may also be formed to accommodate space for the fiducial features 28.

As schematically illustrated in fig. 3B, the thermoplastic shell 14 is injected into the mold cavity 52 through a plurality of injection ports 60. Thus, the thermoplastic housing 14 is formed on and attached to one side of the flexible lamp layer 12. During the injection process, the flexible lamp layer 12 conforms to the shape of a portion of the mold cavity 52, such as the lamp sidewall 58. The flexible lamp layer 12 is aligned relative to the thermoplastic housing 14 via either the datum feature 28 or the internal shape of the mold cavity 52.

The injection molded thermoplastic housing 14 generally forms the B-side construction of the lamp assembly 10. The thermoplastic housing 14 is shown in phantom in fig. 3B to schematically illustrate the injected portion. Note that the injection molding apparatus 50 may control the pressure of the injected material in order to prevent damage to the lamp layer 12. The attachment features 20 (not shown in fig. 3A-C) may also be formed during injection of the thermoplastic housing 14, or may be formed during a post-injection process. The injection process forces the flexible lamp layer 12 against the mold cavity 52.

Note that since the printed circuit 24 is printed on the flexible substrate 22, some modification to the layout of the printed circuit 24 (as opposed to the lateral grid illustrated in fig. 2) may be beneficial if the flexible lamp layer 12 is to be substantially deformed. Although the shape illustrated in the figures is generally a larger radius bend, the flexible lamp layer 12 may be flexed into complex shapes having small radius bends and/or features positioned in close proximity to each other. Thus, the skilled artisan will recognize that the desired final shape of the flexible lamp layer 12 may be used to design the shape of the printed circuit 24 and the paths forming the various connections of the printed circuit 24 in order to maintain control of the individual LEDs 26.

As schematically illustrated in fig. 3C, the IMC layer 16 is injected into the mold cavity 52 onto the side of the flexible lamp layer 12 opposite the thermoplastic shell 14. The IMC layer 16 is injected via IMC injector 62 and the flexible lamp layer 12 is coated while the flexible lamp layer 12 is still within the molding apparatus 50. This process generally forms the a-side aesthetic and protective layers of the lamp assembly 10. The IMC layer 16 is shown shaded in fig. 3C to schematically illustrate the injected portion.

The injection molding apparatus 50 schematically illustrated in fig. 3A-C may represent a number of different molding systems or structures, including but not limited to: a rotary injection system, a movable chamber system, or a pick and place system. In some configurations, the mold cavity 52 may include, or be partially defined by, the movable wall 64 being illustrated in fig. 3B and 3C. In such a movable chamber system, the movable wall 64 may form all or a portion of the lamp sidewall 58.

Injection molding apparatus 50 may slide movable wall 64 between at least a first position and a second position. The first position of the movable wall 64 is illustrated in fig. 3B, and the second position of the movable wall 64 is illustrated in fig. 3C. In the second position, the movable wall 64 has moved downward relative to the views of fig. 3B and 3C.

When the movable wall 64 is in the first position, the thermoplastic housing 14 is injected, and the injected thermoplastic housing 14 pushes the flexible lamp layer 12 against the movable wall 64, as shown in fig. 3B. The injection molding apparatus 50 may then slide the movable wall 64 outward (downward, as viewed in fig. 3C) to create space for the IMC layer 16. When the movable wall 64 is in the second position, the IMC layer 16 is injected such that both the thermoplastic housing 14 and the IMC layer 16 are injected into the same mold cavity 52 in the movable cavity system.

The additional space created by the movable walls 64 allows the IMC layer 16 to cover the LEDs 26 that have been pressed against the mold cavity 52 during injection of the thermoplastic housing 14. The IMC layer 16 also covers and protects the printed circuit 24 and/or the a-side face of the flexible substrate 22.

In other configurations, the injection molding apparatus 50 may be part of a rotary molding machine such that each of the views of fig. 3A, 3B, and 3C represents a stage or station of a rotary molding process. The flexible lamp layer 12 may be placed into the mold cavity 52 at the same station as the injection of the thermoplastic shell 14, or may be placed into the mold cavity 52 at a previous station.

The thermoplastic shell 14 may be injected at a first station of the rotary molding machine and the IMC layer 16 may be injected at a second station such that the rotary molding machine moves the thermoplastic shell 14 from the first station to the second station. Depending on the configuration of the rotary injection molding apparatus 50, the movement of the thermoplastic housing 14 may occur after at least a portion of the thermoplastic housing 14 cools or solidifies.

For example, but not limiting of, portions of the first platen 54 may be moved with the thermoplastic shell 14 from the first station to the second station. The second station will have additional space in the mold cavity 52 for injecting the IMC layer 16 (as represented by the comparison between fig. 3B and 3C). Note that the size and shape of the first and second platens 54, 56, in addition to the remainder of the injection molding apparatus 50, are also merely illustrative and may not represent the structure of a rotary molding system.

In another configuration, which may be somewhat similar to a rotary molding machine, the injection molding apparatus 50 may be part of a pick and place system. For example, the flexible lamp layer 12 may be placed into the mold cavity 52 and the thermoplastic housing 14 injected onto the B-side thereof, as shown in fig. 3B. However, the flexible lamp layer 12 and the thermoplastic housing 14 will then be removed from the mold cavity 52 and moved into a second cavity (one cavity having space for the IMC layer 16). The movement may be effected by a human operator or a robot.

Then, similar to the view of fig. 3C, in the second cavity, the IMC layer 16 will be injected on the flexible lamp layer 12 and the a side of the thermoplastic housing 14. Pick and place systems may be more labor intensive relative to movable mold or rotary systems, but may have reduced set-up costs.

Again, note that some configurations may have complex shapes on the a side of the lamp assembly 10. Thus, the flexible lamp layer 12 may be thermoformed prior to injecting the thermoplastic shell 14, prior to inserting the flexible lamp layer 12 into the mold cavity 52, or as a first step within the injection molding apparatus 50. This may be a full or partial thermoforming step such that the flexible lamp layer 12 may be formed to substantially its final shape, or may be partially formed to allow final forming to occur during injection of the thermoplastic shell 14.

For example, the shape of the flexible lamp layer 12 shown in fig. 3A may have been thermoformed from a generally flat shape to the shape shown. Thus, the flexible lamp layer 12 partially matches the shape of the lamp sidewall 58 and is better equipped to conform to the shape of that portion of the mold cavity 52 due to thermoforming.

The detailed description and the accompanying drawings or figures support and describe the subject matter herein. While some of the best modes and other embodiments have been described in detail, various alternative designs, embodiments and configurations exist.

Furthermore, the features of any embodiments shown in the drawings or of the various embodiments mentioned in this description are not necessarily to be understood as embodiments independent of each other. Furthermore, it is possible that each of the features described in one example of an embodiment may be combined with one or more desired features from other embodiments, resulting in other embodiments that are not described in text or by reference to the drawings. Accordingly, such other embodiments are within the scope of the following claims.

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