Process for forming a multilayer, multidensity composite insulator

摘要

A process for forming a multilayer composite insulator includes the steps of forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer and a polymer based blanket layer, applying differential heat to two opposing sides of the insulator precursor and applying pressure to the insulator precursor. Together, the applied differential heat and applied pressure mold the insulator precursor to a desired shape while also providing the polymer based blanket material with a first relatively high density adjacent a warmer of the two opposing sides and a zone of relatively low density adjacent the cooler of the two opposing sides. The process also includes the cooling of a molded precursor to set the insulator in the desired shape.