Patent ID: 7413698
Filing Date: 2008-08-19
Classification: B29C,B29K,B29L,B65D

Abstract:
1. A method of forming articles including a shape defining compressible core member, and a thermoplastic external shell, said method comprising the steps of: providing a shape defining compressible core member including a first surface and a second surface, wherein at least one surface includes a pattern of features, said core member being comprised of expanded polymer; positioning said core member adjacent to a first heated pliable thermoplastic sheet that is without a preformed contour, to form a stack including said first sheet and said core member, wherein said first pliable thermoplastic sheet is longer and wider than said core member, compressing said stack between a first molding tool, and a second molding tool, wherein said first molding tool has a surface at least as long and as wide as said core member, and said second molding tool has a surface at least as long and as wide as said core member and a contour complimentary to the features of said at least one surface of said core member, wherein said core member is used as a plug assist to move said sheet into the contour of said second molding tool when compressing said stack; holding said stack between said first and said second molding tools until said stack cools and bonds form between portions of said core member and said sheet in contact with one another, wherein the volume of a convex portion of said core member is larger than the volume of a concave portion of said second molding tool configured to receive the convex portion of said core member.