Patent ID: 7416104
Filing Date: 2008-08-26
Classification: B23K,H01L

Abstract:
1. A method of injection molding solder into a plurality of cavities in a non-rectangular mold, the method comprising: aligning a substantially curved fill head with a non-rectangular mold, wherein the substantially curved fill head is curved to match a curvature of a perimeter of the non-rectangular mold, wherein the non-rectangular mold includes a plurality of cavities and is a circular shape; and wherein aligning the fill head comprises: forcing solder out of the fill head toward the non-rectangular mold; providing the solder into each cavity in the plurality of cavities contemporaneous with each cavity being in proximity to the fill head; receiving temperature feedback from at least one thermocouple situated within the fill head; channeling a first gas about a first edge of the fill head, the first gas having a temperature above a melting point of the solder thereby maintaining the solder in a molten state as the solder and the at least first gas are in close proximity to one another; channeling a second gas about a second edge of the fill head, the second gas having a temperature below the melting point of the solder thereby substantially solidifying the solder within each cavity as the each cavity passes under the second region of the fill head with the at least second gas; and transitioning the fill head from the non-rectangular mold, the fill head passing over an adapter coupled to the non-rectangular mold, to an adjacent non-rectangular mold as the fill head transitions from the non-rectangular mold to the adjacent non-rectangular mold thereby preventing spillage of solder from the fill head that is transitioning, wherein transitioning the fill head comprises: