Patent ID: 7070725

Claim:
A method ( 10 ) of making a part ( 46 ) comprising the steps of: placing an insert ( 12 ) having a first coefficient of thermal expansion and sides ( 14 ) and an open top ( 16 ) and a bottom surface ( 18 ) into a first mold cavity ( 20 ), injecting an insulating layer composition ( 28 ) into said first mold cavity ( 20 ) to bond to the bottom surface ( 18 ) and the sides ( 14 ) of the insert ( 12 ) to form an insulating layer ( 30 ) of an expanded compressible polymer with said insulating layer ( 30 ) having sides ( 32 ) and a bottom ( 34 ) to expose the open top ( 16 ), and injecting a part composition ( 44 ), having a second coefficient of thermal expansion different from the insert over the bottom ( 34 ) and the sides ( 32 ) of the insulating layer ( 30 ) to expose the open top ( 16 ) of the insert and completely isolate the insert ( 12 ) from the part ( 46 ) whereby the insulating layer ( 30 ) adapts to differences in thermal expansion between the insert ( 12 ) and the part ( 46 ).