Patent ID: 8383029

Claim:
A method of manufacturing a carrier plate for supporting a plurality of electronic components, comprising: placing a carrier core between a first mold part and a second mold part, wherein the first mold part includes a facing surface facing the carrier core and a first plurality of pins extending therefrom and the second mold part includes a facing surface facing the carrier core and a second plurality of pins extending therefrom and the carrier core includes: a frame portion forming an outer peripheral edge of the carrier core; a web portion surrounded by core frame portion and recessed from opposing surfaces of the frame portion facing the facing surfaces of the first mold part and the second mold part; and a plurality of hexagonally-arranged bores extending through the web portion and perpendicular to the facing surfaces of the first mold part and the second mold part, and each of the plurality of first and second pins extending through a respective one of the plurality of hexagonally-arranged bores; injecting a resilient material through a respective gate in each of the first mold part and the second mold part to form a molded part, wherein the carrier core is placed between the first mold part and the second mold part such that a distance between each upstream one of the plurality of hexagonally-arranged bores and its adjacent downstream one of the plurality of hexagonally-arranged bores is greater than a distance between each bore of the plurality of hexagonally-arranged bores and its nearest adjacent bore; and finishing opposing surfaces of the molded part to a desired thickness.