Patent ID: 7097801

Claim:
A method of making an integrated mold product with a molding tool, the method comprising: introducing a polymeric material in a mold cavity at between about 2,000 and 3,000 pounds per square inch gauge (psig) defined by first and second mold cores of a molding tool, the second mold core having a polymeric skin for insulation; moving the second mold core relative to the first mold core; moving one of the first and second mold cores relative to the other mold core to form a polymeric outer layer with the polymeric material in the molding tool, the outer layer having an engaging surface contacting the first mold core and an open surface having a channel formed thereon; introducing molten metal in the channel of the outer layer when the outer layer is at about the same temperature as the molding tool to insulate the molten metal from the first mold core; and cooling the molten metal in the channel to define a metal insert in the channel for electrical conductivity thereacross; introducing a second polymeric material in the molding tool at between about 12,000 and 45,000 psig, after cooling the first molten metal; forming a middle layer with the second polymeric material in the molding tool, the middle layer having a second contact surface engaging the first open surface to insulate the first metal insert and a second open surface on which a second channel is formed; introducing a second molten metal in the second channel of the middle layer for insulating the second molten metal within the second channel from the molding tool; cooling the second molten metal in the second channel to define a second metal insert for electrical conductivity; introducing a third polymeric material in the molding tool at between about 12,000 and 45,000 psig; forming a cover layer with the third polymeric material in the mold tool, the cover layer having a third contact surface contacting the second open surface to insulate the second metal insert and an outer surface opposite the second molten metal.