Method to manufacture multi-layer electrical article

A mold comprising:

• (A) A mold housing comprising (a) at least one injection port, and (b) defining a mold cavity within which are positioned two deformable, pre-molded polymeric sheets;
• and
• (B) A removable, hollow core that is multi-segmented comprising two or more center segments and two end segments, and a sintered metal vent having a porosity from 20% to 30% by volume between each end segment and a center segment, the removable, hollow core positioned between and spaced apart from the two polymeric sheets;
• (C) a vacuum pulling apparatus comprising a compressed air powered vacuum pulling system attached to the removable, hollow core and operable to draw a pressure on the mold through each sintered metal vent.

A process for making a multilayered article, the process comprising the steps of:

• (A) providing a removable, hollow core equipped with at least one vent and having a center section connected to an end section by a threaded connecting rod, the removable, hollow core having
• (1) two washer components on the connecting rod and sandwiched between the center section and the end section;
• and
• (2) one washer component comprising a channel machined into a washer face, the channel forming the vent and allowing air to move to the center of the core;
• (B) providing a mold comprising
• (1) a mold housing comprising (a) at least one injection port, and (b) defining a mold cavity within which are positioned two deformable, pre-molded polymeric sheets;
• and
• (2) the removable, hollow core positioned between and spaced apart from the two polymeric sheets;
• (C) chilling the mold to an internal mold temperature from 10° C. to 20° C.;
• (D) injecting at a pressure of 1 MPa to 300 MPa a viscous, crosslinkable, thermoplastic polymer into the mold cavity between the two polymeric sheets and around the removable core,
• (E) drawing a vacuum on the mold cavity through the vent in the removable, hollow core before, during and/or after the polymer has been injected into the mold;
• (F) forming a less than fully cured multilayered article in the mold cavity;
• and
• (G) removing the less than fully cured multilayer article from the mold cavity.