Patent ID: 7837923

Claim:
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; removing said stack from said first and second molding tools, wherein the volume of said core member is greater before said core member is compressed between said first and said second molding tools than the volume of said core member after said stack is removed from said first and second molding tools and wherein said core member has an uncompressed volume that is greater than a volume of a space formed by closure of said first and second molding tools.