Patent ID: 7063811

Claim:
A method of preparing an article comprising: (a) providing a thermoplastic sheet having a first surface and a second surface; (b) providing a support having a plurality of perforations having edges, a first surface and a second surface; (c) heating said thermoplastic sheet to a temperature that is at least equal to the softening point and less than the melting point of said thermoplastic sheet; (d) bringing at least a portion of the second surface of the heated thermoplastic sheet into contact with at least a portion of the first surface of said support; (e) forming reduced gaseous pressure on the second surface of said support, thereby drawing portions of said heated thermoplastic sheet through at least some of said perforations, the edges of said perforations being embedded in the thermoplastic material drawn therethrough; (f) forming at least one thermoplastic attachment head on the second surface side of said support, said thermoplastic attachment head being formed from and being continuous with the portions of said thermoplastic sheet that are drawn through said perforations; and (g) cooling the heated thermoplastic sheet below its softening point, wherein said thermoplastic sheet is fixedly attached to said support by means of said attachment heads and the edges of said perforations being embedded in the thermoplastic material drawn therethrough.