Abstract:
A method and apparatus are disclosed for placing solder spheres on electronic receiving pads of a ball grid array (BGA) component package, such as by a BGA solder sphere placement apparatus. The solder spheres are held to a pattern of solder sphere apertures in a foil and against a solder sphere backing rib of a second layer by a vacuum holding force. After locating the solder spheres to receiving pads of a BGA component package, the system removes the holding force and the solder spheres are then released and placed on the receiving pads. Optionally, the apparatus can ensure release of the solder spheres as well as seating the solder spheres onto the receiving pads by applying a tapping or vibrational force.

Description:
FIELD OF THE INVENTION 
   This invention relates in general to the field of solder sphere placement systems for surface mount technology, and in particular to a method and apparatus for placing solder balls on electronic pads that are on a substrate such as for a ball grid array (BGA) package. 
   BACKGROUND OF THE INVENTION 
   Conventional methods for manufacturing surface mount components, or for manufacturing circuit supporting substrates for surface mount components, typically include methods for placing conductive preforms, e.g., solder balls, solder spheres, preformed solder bumps, and the like on electronic pads arranged in a predetermined placement pattern that is sometimes called a ball grid array (BGA). The term “Solder spheres” is used herein being representative of the various form factors of conductive preforms. 
   A known method for placing solder bumps on electronic pads on a substrate utilizes a stencil placed over the electronic pads on the substrate to guide solder paste to flow through openings in the stencil plate onto the electronic pads. The solder paste is typically spread over the stencil using a squeegee to evenly distribute the solder paste as well as remove the excess solder paste. After the stencil is removed from the substrate, solder bumps are formed on, and remain attached to, the electronic pads. This method technically forms the solder bumps on the electronic pads and does not place solder that has been preformed on the electronic pads. 
   The solder paste, as formed in this method, has a tendency to develop internal structural defects, such as voids, or variation of fused solder volumes during the fusing process, thereby introducing potential defects to the manufacturing process and/or risk of failure during the life of the product. This is an undesirable consequence of this method. 
   A first known method for placing solder balls on electronic pads on a substrate utilizes a stencil plate placed over the electronic pads on the substrate to guide solder balls to drop through openings in the stencil plate onto the electronic pads. The electronic pads having been pre-printed with solder paste, the solder balls then adhere to the electronic pads via the solder paste. During a reflow operation, the solder balls fuse to the electronic pads on the substrate. 
   Besides requiring a guiding force to reliably introduce the solder balls into the openings in the stencil plate, this method additionally suffers from a hot-air knife reflow heating step that unevenly distributes heat over the solder balls in the stencil plate. Further, the heating step applied while the solder balls are in the stencil may cause the solder to melt and adhere to the stencil. Furthermore, a heating-knife motion control mechanism can be expensive. 
   A second known method for placing solder balls on electronic pads on a substrate utilizes tubes to hold the solder balls over the electronic pads. Each tube applies a vacuum force to hold a solder ball to the end of the tube. After locating the tubes holding the solder balls over the electronic pads, the solder balls are placed on the electronic pads by removing the vacuum force from the tubes and vertically vibrating the tubes to release the solder balls onto the electronic pads. 
   The apparatus for this second method tends to be complicated and can be expensive to produce and maintain. Since the solder balls are placed sequentially, the process is not conducive to cycle time. It also may not be suitable for micro-BGA placement where the pitch of the pads is very fine and requires tight tolerances in locating the solder spheres. 
   A third known method for placing solder balls on electronic pads on a substrate utilizes a plate with solder bumps attached to the plate in a pattern corresponding to the pattern of the electronic pads on the substrate. The solder bumps are attached to the plate by etching a pattern of openings in a photoresist mask over the plate according to a predefined artwork, and then depositing solder composition on the plate at the openings (where the plate surface is exposed) by an electroplating operation. Lastly, after removing the photoresist layer, the solder bumps remain attached to plate. The solder bumps are then placed on the electronic pads on the substrate by positioning the plate over the electronic pads to allow the solder bumps to contact the electronic pads. By heating the entire assembly, the solder bumps melt and transfer onto the electronic pads. 
   Hertz (U.S. Pat. No. 6,202,918) teaches a solder sphere placement apparatus which utilizes an etched stencil to create a pattern for the solder spheres and a moving backing plate for releasing the solder spheres from the etched stencil. Hertz &#39;918 is limited in the complexity of the placement head. 
   Hertz (U.S. Pat. Nos. 6,230,963 and 6,510,977) teaches a laminated foil design for the solder sphere placement apparatus, reducing the complexity of the solder sphere placement apparatus of Hertz &#39;918. Hertz &#39;963 is limited in the requirement for a custom backing plate for each solder sphere pattern. Additionally, the design taught by Hertz is limited in that the backing plate does not support the solder sphere at the apex of the solder sphere when placed into the pattern aperture. 
   Hertz (U.S. Pat. No. 6,412,685) teaches a plurality of release mechanisms. Included is a vibrational release mechanism, which provides a tapping release force. 
   Brown, et al (U.S. Pat. No. 5,205,896) teaches applying a tapping mechanism for aiding in the transfer of the solder spheres. 
   Besides constituting a relatively expensive process to implement in a mass production environment or use for occasional rework, this method requires trained operators to perform numerous steps, including chemical processing steps that can subject an operator to environmental hazards. The overall process, therefore, can be environmentally unfriendly, time consuming, expensive, and generally requiring trained operators to be effective. 
   The use of Ball Grid Array technology is increasing as the advantages of the interconnect process are recognized. The disadvantage of this technology is where rework or salvage of components using Ball Grid Array technology is required; once the component is removed a portion of the solder spheres remains on the component and a portion of the solder spheres remains on the Printed Circuit Board (PCB). Thus, what is necessary is a low cost and efficient method and apparatus for placing conductive spheres on pads on a component, or on a substrate. 
   While each of these improvements has contributed to the art, the art can be improved by the utilization of a new backing member design. 
   SUMMARY OF THE INVENTION 
   One aspect of the present invention is to provide a low cost tool for locating and placing the solder spheres onto the pads of substrates or components. The tool preferably comprises a foil structure that includes a plurality of openings that are used to locate, hold, and place the solder spheres onto the pads. 
   Another aspect of the present invention is the use of current state of the art technology, including artwork and a photo developing and etching process on the foil to create the openings. This process eliminates significant variation in locating and forming the openings in the foil while maintaining a low cost for the tool. As the distance between the centers of the pads (pitch) decreases, such as for fine pitch, or micro BGA (μBGA) manufacturing, the variation in locating and shaping the openings becomes significantly more critical for maintaining an accurate and reliable solder sphere placement process. 
   Another aspect of the present invention is the ability to facilitate changing a pattern of openings on a foil for placing solder spheres on different arrangements (patterns) of pads. By using different foils with different etched patterns (different patterns of openings etched in the foils), the low cost tool can efficiently place solder spheres on different patterns of pads on a substrate. 
   Another aspect of the present invention is the ability to utilize one aperture pattern and modify the placed pattern of solder spheres by filling or covering the undesirable apertures. The material partially covering the first foil aperture can increase the reliability of filler material located inside the undesired apertures of the foil. 
   Another aspect of the present invention is the ability to include a mechanism to hold the solder spheres at the openings in the foil and then remove the holding force to place the solder spheres on the pads. 
   Another aspect of the present invention is the ability to allow flow of a vacuum force to the apertures of the foil. 
   Another aspect of the present invention is the ability to utilize apertures to locate a pattern of solder spheres, in conjunction with a second feature which retains the solder spheres from entering the vacuum chamber. This aspect ensures release of the solder spheres. The feature that controls the distance that the solder spheres enter into the vacuum chamber comprising a backing member aperture having at least one rib member. 
   Yet, another aspect of the present invention is the utilization of a single rib member spanning across said backing member aperture. 
   Yet another aspect of the present invention is the utilization of a rib member spanning across said backing member aperture, said rib member having a width that is less than 50% of the diameter of the backing aperture and greater than 20% of the diameter of the backing aperture. 
   Yet another aspect of the present invention is the utilization of a rib member spanning across said backing member aperture, said rib member having a width that is approximate ¼ of the diameter of the backing aperture. 
   Yet another aspect of the present invention is the utilization of a rib member spanning across said backing member aperture, said rib member having a width that is approximate ⅓ of the diameter of the backing aperture. 
   Yet another aspect of the present invention is the utilization of a pair of rib members spanning across said backing member aperture, said rib members are placed at a right angle to each other. 
   Yet, another aspect of the present invention is a backing member aperture, said backing member aperture having a diameter that is equal to a diameter of a BGA pattern aperture. 
   Yet, another aspect of the present invention is a backing member aperture, said backing member aperture having a diameter that is larger than a diameter of a BGA pattern aperture. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated utilizing a chemical etch process. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated utilizing a laser etch process. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated placing a generic pattern of backing apertures across said backing member aperture plate. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated placing a generic pattern of backing apertures across said backing member aperture plate, placing an odd numbered pattern with a centered aperture registered to a center of the backing member aperture plate. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated placing a generic pattern of backing apertures across said backing member aperture plate, placing an even numbered pattern with a non aperture center registered to a center of the backing member aperture plate. 
   Yet another aspect of the present invention is a backing member aperture plate, said backing member aperture plate fabricated placing a generic pattern of backing apertures across said backing member aperture plate, said generic pattern having a standard pitch (distance between two adjacent apertures). 
   Yet, another aspect of the present invention is a backing member aperture, said backing member aperture having a diameter that is smaller than a diameter of a BGA pattern aperture. 
   Yet, another aspect of the present invention is a flux application method. 
   Yet another aspect of the present invention is a flux application method, said flux application method comprising screen printing said flux onto said receiving pads of said component. 
   Yet another aspect of the present invention is a flux application method, said flux application method comprising dipping said pattern of solder spheres into a flux reservoir. 
   Yet another aspect of the present invention is a flux application method, said flux application method comprising dipping said pattern of solder spheres into a flux reservoir, said flux reservoir having a fixed depth of flux medium. 
   Yet, another aspect of the present invention is a vibrational release mechanism. 
   Yet, another aspect of the present invention is a vibrational release mechanism, said vibrational release mechanism comprising a vibrational energy source coupled to a cantilevered tapping mechanism. 
   Yet, another aspect of the present invention is a vibrational release mechanism, said vibrational release mechanism comprising at least one of an off balanced motor, a piezoelectric crystal, a mass resonant device, and the like. 
   Yet another aspect of the present invention is a vibrational release mechanism, said vibrational release mechanism controlled by a foot pedal. 
   Yet, another aspect of the present invention is a vibrational release mechanism, a vacuum holding force and said vibrational release mechanism both controlled by a foot pedal. 
   Yet another aspect of the present invention is a vibrational release mechanism, said vacuum holding force and said vibrational release mechanism both controlled by a foot pedal, wherein when a user depresses said foot pedal, said vacuum holding force is removed and said vibrational release mechanism is activated. 
   Yet, another aspect of the present invention is the utilization of registration pins for alignment of both a flux applicator and a solder sphere placement apparatus to a component. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric view of a solder sphere placement apparatus in an exemplary embodiment of the present invention; 
       FIG. 2  is a top view of a solder sphere placement apparatus backing plate in accordance with a first pattern; 
       FIG. 3  is a top view of a solder sphere placement apparatus backing plate in accordance with an alternate pattern; 
       FIG. 4  is a top view of a solder sphere placement apparatus pattern plate in accordance with an exemplary pattern; 
       FIG. 5  is a top and respective isometric view of an exemplary embodiment of solder sphere backing aperture; 
       FIG. 6  is a top and respective isometric view of an alternate exemplary embodiment of solder sphere backing aperture; 
       FIG. 7  is a detailed isometric illustration presenting a solder sphere pattern plate and a solder sphere placement backing plate; 
       FIG. 8  is an isometric illustration presenting the relation between the solder sphere placement apparatus and a Ball Grid Array (BGA) component; 
       FIG. 9  is an elevation view illustrating a cross sectional view of a solder sphere placement apparatus during the process of creating a solder sphere placement pattern; 
       FIG. 10  is an elevation view illustrating a cross sectional view of a solder sphere placement apparatus during the process of placing said solder sphere placement pattern onto a receiving component; 
       FIG. 11  presents a solder sphere placement apparatus manufacturing flow diagram; 
       FIG. 12  presents a solder sphere placement pattern creation and placement flow diagram; and 
       FIG. 13  presents a solder sphere placement pattern placement flow diagram further utilizing a release mechanism. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1  presents an isometric illustration of a complete solder sphere placement system, said system comprising a vacuum control center  100 , a BGA placement workstation  120  and a solder sphere placement head assembly  140 . Said vacuum control center  100  comprising a vacuum motor (not shown), an optional vacuum flow control valve, an optional control circuit board, and a main power switch  110 . Said BGA placement workstation  120  comprising a BGA placement workstation baseplate  122 , said BGA placement workstation baseplate  122  incorporating a solder sphere reservoir  130 , at least one storage recess  132  and a component work area, said component work area comprising a pair of BGA alignment plate registration pins  124 , a pair of finger clearance(s)  126 , and a BGA placement workstation vacuum port  128 . Said solder sphere placement head assembly  140  comprising a solder sphere placement head  142 , and a lamination of a solder sphere placement backing plate  150  and a solder sphere pattern plate  160 . Said vacuum control center  100  interfaces with the peripheral assemblies, specifically said BGA placement workstation  120  and said solder sphere placement head assembly  140  via a vacuum control-base workstation vacuum coupler  104 , a vacuum control-placement head vacuum coupler  106  and a release mechanism control coupler  108 . Said vacuum control-base workstation vacuum coupler  104  and a respective vacuum control-base workstation vacuum conduit  105  are used to transfer a vacuum force generated by said vacuum motor of said vacuum control center  100  to said BGA placement workstation  120 . Said vacuum control-placement head vacuum coupler  106  and a respective vacuum control-placement head vacuum conduit  107  are used to transfer said vacuum force generated by said vacuum motor of said vacuum control center  100  to said solder sphere placement head assembly  140 . A release mechanism control is provided via a release mechanism control cable  109 , which is electro-mechanically coupled to said vacuum control center  100  via said release mechanism control coupler  108 . It is recognized that a foot pedal can be interfaced with said optional control circuit board, wherein said control circuit board can be utilized to control the operation of said vacuum motor and release mechanism. One presented mode of operation is accomplished when said main power switch  110  is powered on, said vacuum motor applies a vacuum force to said BGA placement workstation  120  and said solder sphere placement head assembly  140 . The user places an alignment plate  170  onto said BGA placement workstation  120  utilizing BGA alignment plate registration pins  124  of said BGA placement workstation  120  and alignment plate registration aperture(s)  176  machined into a alignment plate stock  172  to provide alignment of a component (shown later) to a placement pattern (shown later) of said solder sphere placement head assembly  140 . The user places a component into a component registration aperture  174  of said alignment plate  170  with the solder sphere receiving side facing upwards. A component securing vacuum force is provided via a BGA placement workstation vacuum port  128  of said BGA placement workstation  120 , said component securing vacuum force temporarily secures the component in location during placement of the solder spheres. 
     FIGS. 2 and 3  present two embodiments of said solder sphere placement backing plate  150 . Said solder sphere placement backing plate  150  comprising a placement backing plate material  152 , said placement backing plate material  152  is then processed via any known etching process to create a pair of registration aperture(s)  158 , a plurality of adhesive enhancing aperture(s)  156  and a pattern of solder sphere backing aperture pattern  154 . One such process would be laser etching. Alternately, chemical etching can be used, as the dimensions of said solder sphere backing aperture pattern  154  are not as critical as placement pattern apertures (shown later).  FIG. 2  presents a pattern comprising an even number of said solder sphere backing aperture pattern(s)  154  in each of a horizontal (row) and vertical (column) directions. The even numbered pattern is oriented with a center of the pattern (lacking an aperture) aligned to a plate center  165 , said plate center  165  is a center of each of a vertical centerline  166  and a horizontal centerline  167 .  FIG. 3  presents a pattern comprising an odd number of said solder sphere backing aperture pattern(s)  154  in each of a horizontal and vertical directions. The odd numbered pattern is oriented with a center of the pattern (center aperture) aligned to said plate center  165 . Each pattern would be of an industry standard pitch. Examples are 50 mm, 40 mm, 30 mm, and the like. It is desirable that the pattern of said solder sphere backing aperture pattern  154  is complete, wherein said complete pattern is defined as apertures in every grid of an array. This provides a standard set of said solder sphere placement backing plate  150  that can be used within a large variety of desired placement patterns in an easy and economic manner. Details of said solder sphere backing aperture pattern  154  will be described later herein. A plurality of said adhesive enhancing aperture(s)  156  are incorporated about a perimeter of said pattern of said solder sphere backing aperture pattern  154  to provide an increase in adhesion between said solder sphere placement backing plate  150  and said solder sphere pattern plate  160 . 
     FIG. 4  presents an exemplary embodiment of said solder sphere pattern plate  160  illustrating a pattern of BGA pattern aperture(s)  164  etched into a BGA pattern plate material  162 . The presented pattern illustrates several features of the present invention. The first is the use of a generic version of said solder sphere placement backing plate  150 . Said solder sphere placement backing plate  150  of  FIG. 2  comprising an array of said solder sphere backing aperture pattern  154 , said array being ten (10) horizontally and ten (10) vertically. Said solder sphere pattern plate  160  presented comprising an array of said BGA pattern aperture(s)  164 , said array being eight (8) horizontally and eight (8) vertically, and more so, omitting the four (4) center apertures. It is recognized that any pattern can be created within said BGA pattern plate material  162  and if said pattern is of a standard pitch, a generic solder sphere placement backing plate  150  can be utilized. Said solder sphere pattern plate  160  as presented would be laminated to said solder sphere placement backing plate  150  as presented in  FIG. 2  herein. 
     FIGS. 5 and 6  present two preferred versions of said solder sphere backing aperture pattern  154 .  FIG. 5  presents a solder sphere backing aperture pattern  154  comprising a single sphere backing rib  155 , which creates a pair of backing airflow aperture(s)  157 . Said sphere backing rib  155  is unique over the prior art in that said sphere backing rib  155  provides a backing for containing said solder sphere within said BGA pattern aperture(s)  164 , wherein the backing is centered about the sphere.  FIG. 6  presents a solder sphere backing aperture pattern  154  comprising a pair of sphere backing ribs  155  arranged at right angles to each other, which creates four (4) separate backing airflow aperture(s)  157 . Said sphere backing rib  155  can be dimensioned as a ratio to a solder sphere backing aperture diameter D. Said sphere backing rib  155  is dimensioned by a solder sphere backing rib width W. The desirable ratio presents a W:D ratio wherein said W is generally ¼ to ⅓ of D; slightly smaller for a pair of said sphere backing rib  155 . Solder sphere backing aperture diameter D can be of any reasonable size, with the preferred dimension being slightly larger than the typical diameter of said BGA pattern aperture(s)  164 . 
     FIG. 7  illustrates an assembly relation between said solder sphere placement backing plate  150  and said solder sphere pattern plate  160 . The pair of said registration aperture(s)  158  can be utilized for registration of said solder sphere placement backing plate  150  and solder sphere pattern plate  160  to each other. Any said solder sphere backing aperture pattern  154  which are not paired to a BGA pattern aperture(s)  164  as well as all said adhesive enhancing aperture(s)  156  are utilized to provide additional mechanical support for adhesion between said solder sphere placement backing plate  150  and said solder sphere pattern plate  160 . The pattern of said BGA pattern aperture(s)  164  limits the vacuum flow and resulting pattern generation of said solder spheres to only those BGA pattern aperture(s)  164  incorporated into said solder sphere pattern plate  160 . Any apertures of said solder sphere placement backing plate  150  not paired with a BGA pattern aperture(s)  164  are sealed by the remaining said BGA pattern plate material  162 . 
     FIG. 8  presents an isometric illustration of the pattern and laminated assembly of  FIG. 7  in relation to a respective Ball Grid Array (BGA) component  200 . Said Ball Grid Array (BGA) component  200  comprising a pattern of solder sphere(s)  199  placed onto a solder sphere receiving substrate  202 . One can note the laminated foils solder sphere placement backing plate  150  and said solder sphere pattern plate  160  only provide a vacuum holding force respective to the pattern of said solder sphere pattern aperture(s)  164  of solder sphere pattern plate  160 . Said pattern of solder sphere pattern aperture(s)  164  can be a subset of said pattern of solder sphere backing aperture pattern  154 . Said subset can be defined where all of said solder sphere pattern aperture(s)  164  have a respective solder sphere backing aperture pattern  154 , but wherein not all of said solder sphere backing aperture pattern  154  have a respective solder sphere pattern aperture(s)  164 . 
     FIG. 9  presents a cross-sectional view of said solder sphere placement head assembly  140  illustrating details of the pattern generation process. A primary vacuum flow  222  is provided via a placement head vacuum conduit  220  and distributed within said solder sphere placement head  142  via a placement head vacuum chamber  210 . The desired vacuum is one having a continuous flow, as opposed to a suction vacuum, which generates a low pressure. The vacuum flow pulls air through said solder sphere pattern aperture(s)  164  and continuing through said backing airflow aperture(s)  157  into said placement head vacuum chamber  210 . As the air flows, it pulls a solder sphere(s)  199  from said solder sphere reservoir  130  and towards/into said solder sphere pattern aperture(s)  164  and once said solder sphere(s)  199  is seated within said solder sphere pattern aperture(s)  164  and against said sphere backing rib  155 , it remains held in position via a solder sphere vacuum flow holding force  224 . The illustration presents said solder sphere pattern aperture(s)  164  having a diameter that is slightly smaller than the diameter D of said solder sphere backing aperture pattern  154 . By placing said sphere backing rib  155  centered within said solder sphere pattern aperture(s)  164 , the geometry ensures that said solder sphere(s)  199  will be seated in the center of said solder sphere pattern aperture(s)  164 . A release mechanism is presented, said release mechanism comprising a vibrating mechanism  212  mounted upon a vibrating member cantilever  214 , said vibrating member cantilever  214  is then coupled to an interior wall of said solder sphere placement head  142  within said placement head vacuum chamber  210 . Said vibrating mechanism  212  is operated via power provided through a release mechanism control cable  109 . As said vibrating mechanism  212  is activated, said vibrating mechanism  212  creates vibrational energy, wherein said vibrational energy causes said vibrating member cantilever  214  to oscillate in a vibrating motion  216  as illustrated. Said vibrating motion  216  provides a tapping force applied to an inner surface of said solder sphere placement backing plate  150 . 
   The tapping force ensures release and transfer of said solder sphere(s)  199  from said solder sphere pattern aperture(s)  164  onto said solder sphere receiving pad(s)  204  as illustrated in  FIG. 10 . A tacky media/flux  206  is applied to either said solder sphere receiving pad(s)  204  or onto said solder sphere(s)  199  (not shown), wherein said tacky media/flux  206  provides several ingredients for the process. The first being temporarily holding said solder sphere(s)  199  to said solder sphere receiving pad(s)  204 . The second being a cleaning process to provide a reliable interconnection between said solder sphere(s)  199  and said solder sphere receiving pad(s)  204  during a reflow process. 
     FIG. 11  presents a placement head fabrication flow diagram  300 , said placement head fabrication flow diagram  300  comprising primary steps of a placement foil fabrication steps  302  and a placement head fabrication steps  304 . Said placement foil fabrication steps  302  initiates with a designer creating a pattern for each of said solder sphere placement backing plate  150  and solder sphere pattern plate  160  in accordance with a pattern artwork creation step  306 . The pattern artwork for said solder sphere placement backing plate  150  would be provided in accordance with the details provided in  FIGS. 2 ,  3 ,  5 , and  6 . The pattern artwork for said solder sphere pattern plate  160  would be provided in accordance with the details provided in  FIG. 4 . The stencil fabricator then utilizing an etching process to fabricate said solder sphere placement backing plate  150  and said solder sphere pattern plate  160  from a sheet of raw material in accordance with a stencil etching step  308 . The raw material would be of stainless steel, brass, copper, and the like. The thickness would be respective to the diameter D of said solder sphere(s)  199 . One design utilizes a BGA pattern plate material  162  having a thickness of approximately ½ to ⅔ of the diameter of said solder sphere(s)  199 . Any known etching process can be utilized, including laser etching (accurate), chemical etching (slightly less accurate), and the like. Since said solder sphere(s)  199  are generally shiny silver in color and said BGA pattern plate material  162  is generally shiny and silver (assuming stainless steel is used), it is difficult to inspect the completeness of the pattern of said solder sphere(s)  199  placed within said solder sphere pattern plate  160 . To improve the inspection process, an optional foil-colorizing step  310  can be utilized. A number of methods are known for colorizing foils, including that taught by Hertz &#39;963. The pair of foils, said solder sphere placement backing plate  150  and said solder sphere pattern plate  160  are laminated in accordance with a foil lamination step  312 . In the preferred scenario, the manufacturer would store a quantity of the two versions of said solder sphere placement backing plate  150  in standard pitches and custom fabricate a solder sphere pattern plate  160  in accordance with the desired component solder sphere pattern. Said solder sphere pattern plate  160  is placed with said registration aperture(s)  158  onto registration pins of an alignment jig with the lamination side facing upwards. Adhesive is carefully applied to the lamination side of said solder sphere pattern plate  160  ensuring that adhesive will not encroach into said solder sphere pattern aperture(s)  164 . Said solder sphere placement backing plate  150  is then placed with said registration aperture(s)  158  onto said registration pins of said alignment jig with the lamination side facing down. A compression force is then applied to the laminated foils. Said placement head fabrication steps  304  is accomplished in a separate process flow and once completed, said solder sphere placement head assembly  140  is inventoried. Said placement head fabrication steps  304  initiates with a block fabrication step  314 , wherein said solder sphere placement head  142  is fabricated via a machining process, a molding process, and the like. A vacuum conduit coupling member (not shown but well understood) is then assembled to said solder sphere placement head  142  in accordance with an assemble vacuum conduit step  316 . Additionally, said vacuum control-placement head vacuum conduit  107  is coupled to said vacuum conduit coupling member of said solder sphere placement head  142 . A base member coupling member can optionally be installed to the opposing end of said vacuum control-placement head vacuum conduit  107  providing a removable coupling means for coupling said vacuum control-placement head vacuum conduit  107  and said vacuum control-placement head vacuum coupler  106 . An optional release mechanism is then fabricated and installed in accordance with a release mechanism assembly step  318 . In the preferred embodiment, said vibrating member cantilever  214  is fabricated. A vibrating mechanism  212  is then secured to said vibrating member cantilever  214 . Said release mechanism control cable  109  is then fed through a small opening within said solder sphere placement head  142  and electro-mechanically coupled to said vibrating mechanism  212 . The completed assembly is installed and secured to the inside wall of said solder sphere placement head  142 . Said release mechanism control cable  109  comprising an electro-mechanical coupling member for coupling said release mechanism control cable  109  and said release mechanism control coupler  108 . The subassembly is then stored until an order arrives and a custom solder sphere pattern plate  160  is fabricated. An order arrives and the fabrication of said laminated foil assembly is completed. Said laminated foil assembly is adhesively secured to said solder sphere placement head  142  in accordance with an assemble foils to block step  320 . Said solder sphere placement head assembly  140  is coupled to said vacuum control center  100  via said vacuum control-placement head vacuum coupler  106  and said release mechanism control coupler  108 . 
   Said BGA placement workstation  120  is machined and said BGA alignment plate registration pins  124  are inserted in accordance with the preferred design. A workstation vacuum conduit is formed by drilling a horizontal hole from the rear wall of said BGA placement workstation baseplate  122  towards and under said BGA placement workstation vacuum port  128 . Said BGA placement workstation vacuum port  128  is formed by drilling a vertical hole connecting with the horizontal hole. A connector can be assembled by threading the rear opening of the workstation vacuum conduit and inserting said connector. 
   Said vacuum control center  100  is formed via two pieces of sheet metal. The various components (vacuum motor, circuit board, etc.) are mounted in accordance with the selected components. A power cable and optional foot pedal are assembled. Vacuum plumbing and respective connectors are then installed. The optional release mechanism controlled is then wired and installed. 
   Said alignment plate  170  and flux solder stencil (not shown) are then fabricated via a machining and/or etching processes. Each is fabricated respective to a specific component design, comprising said component registration aperture  174  and a pair of said alignment plate registration aperture(s)  176  machined into an alignment plate stock  172 . 
     FIG. 12  presents a solder sphere placement process flow diagram  350 , said solder sphere placement process flow diagram  350  comprising steps for creating a pattern of said solder sphere(s)  199  and transferring said pattern of said solder sphere(s)  199  onto a pattern of solder sphere receiving pad(s)  204 . Said solder sphere placement process flow diagram  350  initiates with a placement head vacuum application step  352 , wherein the user would apply power to the system which activates the vacuum motor. The vacuum motor creates and transfers a vacuum force to said solder sphere placement head assembly  140 . Once vacuum is applied to said solder sphere placement head assembly  140 , the user places said solder sphere placement head assembly  140  into said solder sphere reservoir  130 , sliding said solder sphere placement head assembly  140  back and forth in accordance with an expose placement head to solder spheres step  354 . The result is a solder sphere pattern generation step  356 , wherein said solder sphere(s)  199  create a pattern by filling each of the plurality of said solder sphere pattern aperture(s)  164 . In parallel, the user would place said alignment plate  170  onto said BGA placement workstation  120 , being aligned via alignment plate registration aperture(s)  176  and said BGA alignment plate registration pins  124 . The user then places said Ball Grid Array (BGA) component  200  into said component registration aperture  174  of said alignment plate  170 . Said alignment plate  170  provide a means for registering said Ball Grid Array (BGA) component  200  to the pattern of said solder sphere pattern aperture(s)  164  of said solder sphere placement head assembly  140 . A tacky media is then applied either directly to said solder sphere receiving pad(s)  204  of said Ball Grid Array (BGA) component  200  as presented in an application of tacky media to receiving pads step  358  or said tacky media is applied to the contact region of said solder sphere(s)  199  via dipping said pattern of said solder sphere(s)  199  into a vat of tacky media in accordance application of tacky media to solder spheres step  360 . Tacky media can be applied by using a thin stencil (such as a 0.003″ thick stencil material), wherein said stencil is fastened to a frame and aligned to said Ball Grid Array (BGA) component  200  via said BGA alignment plate registration pins  124 . Said Ball Grid Array (BGA) component  200  is held in place via an applied vacuum force, provided via said vacuum control-base workstation vacuum conduit  105 . Once said tacky media is in place, the pattern of said solder sphere(s)  199  are transferred to said solder sphere receiving pad(s)  204  in accordance with a solder sphere application step  362 . The pattern of said solder sphere(s)  199  is aligned via placing said registration aperture(s)  158  onto said BGA alignment plate registration pins  124 . The pattern of said solder sphere(s)  199  are released from said solder sphere placement head assembly  140  via the removal of said primary vacuum flow  222  as provided by a removal of the holding vacuum force step  364 . Once said primary vacuum flow  222  is removed, the user can separate said solder sphere placement head assembly  140  from said Ball Grid Array (BGA) component  200  in accordance with a placement head component separation step  366 . The result is a pattern of said solder sphere(s)  199  left onto said solder sphere receiving pad(s)  204  of said Ball Grid Array (BGA) component  200 . The pattern of said solder sphere(s)  199  is permanently secured to said Ball Grid Array (BGA) component  200  via a reflow or curing step  368 , wherein the placed pattern of said solder sphere(s)  199  are heated to liquefy said solder sphere(s)  199  which creates an electro-mechanical connection between said solder sphere(s)  199  and said solder sphere receiving pad(s)  204 . 
     FIG. 13  presents a solder sphere release mechanism flow diagram  380 , said solder sphere release mechanism flow diagram  380  presenting the steps of utilizing a releasing mechanism for assisting in the transfer of the pattern of said solder sphere(s)  199  onto said solder sphere receiving pad(s)  204  of said Ball Grid Array (BGA) component  200 . Said solder sphere release mechanism flow diagram  380  comprising the same steps of said solder sphere placement process flow diagram  350 , with the additional steps of energizing the release mechanism step  382  and de-energizing said release mechanism step  384 . Said energizing the release mechanism step  382  is provided after removing said vacuum holding force, which can be jointly provided by depressing a foot pedal. The depressing of the foot pedal would activate a solenoid, which removes the vacuum force from said solder sphere placement head assembly  140  and energizes said vibrating mechanism  212 . The user then separates said solder sphere placement head assembly  140  from said Ball Grid Array (BGA) component  200 . Once separated, the user then accomplishes said de-energizing said release mechanism step  384  by releasing pressure applied to the foot pedal. 
   Various changes may be made to the embodiment shown herein without departing from the spirit and scope of the present invention.