Abstract:
A disposable apparatus with a plurality of preloaded pins such as solder columns, micro-coil springs, or other cylindrically shaped metallic parts (solder columns, et al.) in an array pattern is provided for aligning and dispensing onto a column grid array (CGA) substrate. The apparatus includes a carrier plate with a pattern of holes that is covered by removable covers to retain, position and hold an array of solder columns, et al. Alignment features on the top of the carrier plate plugs into a jig-alignment fixture or frame that precisely positions the solder columns, et al. over a CGA substrate. After inverting (flipping over) the apparatus and jig-fixture or frame upside down, the payload of solder columns, et al. detaches and transfers by gravity onto a pattern of metal pads on the CGA substrate, without the use of vacuum or vibration.

Description:
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS 
     Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57. 
     BACKGROUND 
     Field 
     The present invention relates generally to column grid array (CGA) semiconductor packaging, and more particularly to an apparatus for aligning and depositing a plurality of electrical interconnect members, such as pins, solder columns, micro-coil springs, or other cylindrically shaped metallic parts in an array pattern on a ceramic or plastic substrate. 
     Description of the Related Art 
     Typically, an intermetallic connection is formed between a plurality of solder columns and the conductive pads on a land grid array (LGA) substrate. Initially, a layer of solder paste is applied to cover the array of conductive pads on the LGA. After heating, the solder paste reflows on the conductive pads causing an intermetallic connection between the solder columns and the conductive pads on the LGA. The LGA substrate material may consist of ceramic or plastic materials. After completion of the reflow process, the LGA with solder columns is known in the art as a column grid array (CGA) or ceramic column grid array (CCGA). 
     In general, the number of solder columns on a CGA device may range from 4 to 3000, or more, as the density of electronic devices and integrated circuit packages continues to increase. 
     An alternative to CGA column grid array devices is ball grid array (BGA) devices. BGA devices contain an array of solder spheres (balls) to provide electrical connections between the conductive pads on a BGA substrate and the printed circuit board (PCB). In the art, BGA substrates that are constructed of ceramic material (such as alumina or Al 2 O 3 ) are known as a ceramic ball grid array (CBGA). Ceramic substrates are often required in harsh environments or when excessive heat and power is present. 
     However, one problem with BGA devices is that a substantial difference in the coefficient of thermal expansion (CTE) can exist between BGA substrates and the PCB board. The problem with CTE differences becomes more problematic when large size ceramic CBGA substrates are attached to PCB boards that are made of plastic glass-woven material such as FR-4, FR-5 or polyimide. Such differences in the coefficient of thermal expansion causes deformation of the solder spheres (solder balls) interconnecting a ceramic BGA device to a PCB board. Over time, the electrical connection between the solder ball and metal pad will break between large size ceramic BGA substrates and a plastic glass-woven PCB due to CTE mismatching issues. 
     The problem with CTE mismatch has been addressed by using cylindrical solder columns instead of solder spheres (solder balls) as the electrical interconnect between ceramic substrates and the plastic PCB boards. Taller cylindrically shaped solder columns are generally more compliant to better absorb CTE differential thermal expansion rates between the CGA and the PCB board. Wider solder columns are generally more structurally robust to support the load weight of heavy ceramic substrates. However, the maximum diameter of the solder column is normally constrained by the pitch (spacing) of the conductive pads on the CGA package as well as by the diameter of the conductive pads. 
     Traditionally, solder columns are cylindrically shaped and typically have a diameter of approximately 0.51 mm (0.020-inch) and a height of approximately 2.21 mm (0.087-inch). Solder columns may also be as small as 0.20 mm (0.008-inch) in diameter or more than 0.889 mm (0.035-inch) in diameter. Furthermore, the length of solder columns may be as short as 0.25 mm (0.010-inch) or as long as 3.81 mm (0.150-inch) or more. 
     The conductive pads on the LGA substrate are covered with a controlled thickness of solder paste before attaching a plurality of solder columns to the LGA substrate. Typically, solder paste consisting of low melting point tin-lead alloy, such as Sn63/Pb37, is preferred for applications within the fields of aerospace, military and defense industries. However, lead free solder paste alloys such as SAC305 (Sn96.5/Ag3.0/Cu0.5), or other Pb-free alloys, may be used for applications requiring lead-free materials. 
     Solder columns are typically made of high melting temperature solder such as Pb90/Sn10, Pb85/Sn15 or Pb80/Sn20. Solder columns may be wrapped with copper ribbon tape as disclosed in U.S. Pat. No. 4,664,309. 
     An alternative to solder columns is micro-coil springs that are typically made of beryllium copper (Be—Cu) alloy and electroplated with tin-lead solder (Sn60/Pb40) or other plating such as nickel-gold (Ni—Au) or Silver (Ag). Yet another alternative to solder columns are solid copper columns or other conductive materials. 
     Solder columns are generally vertically positioned perpendicularly onto a corresponding array of conductive pads on the LGA substrate. The substrate together with high temperature solder columns, or alternative pins and a layer of low temperature solder paste are then heated so that the solder paste is reflowed to make an intermetallic fillet connection between the solder columns and the LGA pads, without melting or damaging the solder columns. The completed package with attached solder columns is known in the art as a column grid array (CGA) or ceramic column grid array (CCGA) package. 
     A secondary procedure is required to mount the CGA package onto the PCB board. The process of connecting the CGA package to the PCB board requires the CGA to be reflowed again, without melting or collapsing the solder columns. A controlled layer of low temperature melting solder paste is applied to a corresponding plurality of contact pads on the PCB board. The CGA package is placed onto the solder paste covered pads on the PCB board. The PCB board along with one or a plurality of CGA packages (as well as other components) is heated and reflowed resulting in an intermetallic fillet that holds the CGA solder columns to the PCB board. 
     In the prior art, various methods and apparatuses have been utilized to mount cylindrically shaped solder columns into an array pattern by hand using tweezers or via vibration or with a vacuum pick-up tool. 
     In the prior art, methods using tweezers to place solder columns by hand are time consuming and require an operator with dexterity to perform many repeated steps. For example, it may require roughly one-hour to load 900 solder columns onto a CGA substrate by hand, assuming that a person using tweezers is able to pick-up, transfer and place one solder column every four seconds. In addition, in the prior art, a person using hand placement methods may result in errors as the operator often fails to complete the specified pattern. 
     In the prior art, methods to deliver interconnect members use vibration (e.g., require an inclined vibration machine with elongated alignment and a vacuum pick-up tool to position solder pins onto a CGA substrate package) or a sacrificial adhesive tacky tape layer in a carrier plate to retain and position an array of solder pins onto a CGA substrate package. 
     SUMMARY 
     Accordingly, there is a need for a simpler and more elegant system and method for aligning and dispensing electrical interconnect members (e.g., solder columns, micro-coil springs, conductive pins, etc.) onto LGA, CGA or CCGA substrates without the use of vacuum, vibration or adhesive tacky tape. 
     In accordance with one aspect of the invention, a refillable apparatus and method is provided for aligning and dispensing electrical interconnect members (e.g., solder columns, micro-coil springs, conductive pins, etc.) onto LGA, CGA or CCGA substrates under the force of gravity. 
     In accordance with another aspect of the invention, an apparatus and method is provided that significantly speeds up the process for dispensing electrical interconnect members (e.g., solder columns, micro-coil springs, conductive pins, etc.) onto LGA, CGA or CCGA substrate packages relative to the time it takes an operator to manually insert solder columns using tweezers onto a ceramic or plastic LGA, CGA or CCGA substrate packages. 
     In accordance with another aspect of the invention, an apparatus and method is provided that accommodates a variety of different shapes and sizes of interconnect members (e.g., solder columns, micro-coil springs, conductive pins, etc.) without the need to use tweezers, vibration machinery, vacuum pick-up tools or sacrificial tacky adhesive tape. 
     In accordance with another aspect of the invention, an apparatus and method is provided that minimizes errors caused by an operator incorrectly placing interconnect members (e.g., solder columns, et al.) or failing to insert said interconnect member onto a CGA pad that requires one. 
     In accordance with another aspect of the invention, an apparatus and method is provided that holds, transports and feeds or delivers interconnect members (e.g., solder columns, et al.) onto a LGA, CGA or CCGA substrate package that is low cost and refillable. 
     In accordance with another aspect of the invention, an apparatus comprising a dispensing apparatus and method is provided. An LGA with a layer of solder paste covering the conductive pads of the LGA is placed inside the receiving apparatus. A plastic plate with a plurality of cylindrical holes (silos) is loaded with a plurality of electrical interconnect members (e.g., solder columns, micro-coil springs, or other types of cylindrical pins, etc.). The interconnect members (e.g., solder columns, etc.) are held in place in the silos (cylindrical holes) of the apparatus. A removable cover plate is fastened to the top side of the apparatus. A removable retention plate is fastened to the lower side of the apparatus. The interconnect members are held and protected inside the plurality of holes in the apparatus by the cover and retentions plates until released by removing the top cover plate. After the top cover plate is removed from the apparatus, the apparatus (holding the interconnect members) is inverted 180 degrees (i.e., flipped over upside down). The array of interconnect members are transferred by gravity (e.g., dropped) onto a plurality of corresponding pads (e.g., a corresponding pattern of pads) on a ceramic or plastic LGA, CGA or CCGA substrate without the use of vacuum or vibration. 
     In accordance with another aspect of the invention, a system for aligning, dispensing and depositing a plurality of interconnect members onto a column grid array substrate package is provided. The system comprises a dispensing apparatus body having a peripheral rim and an alignment carrier plate protruding (e.g., male) relative to said peripheral rim, the alignment carrier plate having a plurality of holes extending therethrough from a top surface of the plate to a bottom surface of the plate and arranged in a pattern. The alignment carrier plate in the receiving apparatus has a plurality of holes extending therethrough from a top surface of the plate to a bottom surface of the plate and arranged in a pattern. The protruding male side of the apparatus seats into the recessed (e.g., female receptacle) of a receiving apparatus which holds the LGA. The system also comprises a cover plate having a non-adhesive surface in contact with the top protruding (e.g., male) surface of the apparatus such that the plate covers the plurality of holes in the alignment carrier plate, said non-adhesive cover plate prevents the plurality of cylindrically shaped interconnect members from escaping the plurality of holes until removed by the operator. The top cover is fastened to the top surface with one or more fasteners, such as threaded screws. The top cover is removable (detachable) from the top surface by removing the fasteners from the apparatus. The receiving apparatus is placed over the dispensing apparatus (holding a LGA) and the system is flipped over (turned upside down). After turning the apparatus upside down (flipping over), the plurality of interconnect members drop under the force of gravity onto an array pattern of metallic pads of a column grid array substrate without the use of vibration or vacuum. The system also comprises a frame for holding the apparatus on a table to aid in removing the top cover plate, and positioning the apparatus for loading the receiving apparatus. 
     In accordance with another aspect of the invention, an apparatus for aligning, dispensing and depositing a plurality of interconnect members onto a column grid array (CGA) substrate package is provided. The apparatus comprises a body having a peripheral rim and an alignment carrier plate protruding (e.g., male) relative to said peripheral rim. The alignment carrier plate has a plurality of holes extending therethrough from a top surface of the plate to a bottom surface of the plate and arranged in a pattern. The top surface of the alignment carrier plate is removably coverable with a non-adhesive cover plate having a parallel surface such that the cover plate removably covers the plurality of holes in the alignment carrier plate. The top cover plate on the apparatus is manually detachable from the top surface of the alignment carrier plate to release the plurality of interconnect members such that the plurality of interconnect members drop under the force of gravity from the alignment carrier plate when inverted (e.g., flipped) upside down. 
     These and other objects, features and advantages of the present invention will become more apparent from the detailed description of the preferred embodiment when read in conjunction with the drawings. 
     In accordance with one aspect, a system for aligning, dispensing and depositing a plurality of interconnect members onto a column grid array substrate package is provided. The system comprises a body having a peripheral rim and an alignment carrier plate protruding relative to said peripheral rim, the alignment carrier plate having a plurality of holes extending therethrough from a top surface of the alignment carrier plate to a bottom surface of the alignment carrier plate and arranged in a pattern. The system also comprises a cover plate without adhesive removably coupleable with the top surface and a retention plate without adhesive removably coupleable with the bottom surface of the alignment carrier plate such that the cover and retention plates removably covers the plurality of holes in the alignment carrier plate, said plates not attached to either end of a plurality of cylindrically shaped interconnect members releasably disposed in the plurality of holes, the cover plate manually detachable from the top surface of the alignment carrier plate to release the plurality of interconnect members when inverted upside down such that the plurality of interconnect members drop under the force of gravity onto an array pattern of metallic pads of a column grid array substrate without the use of vibration or vacuum. The system also comprises a frame for aligning said carrier plate over said column grid array substrate. 
     In accordance with another aspect, an apparatus for aligning, dispensing and depositing a plurality of cylindrically shaped interconnect members onto column grid array substrate package is provided. The apparatus comprises a body having a peripheral rim and an alignment carrier plate recessed relative to said peripheral rim, the alignment carrier plate having a plurality of holes extending therethrough from a top surface of the plate to a bottom surface of the plate and arranged in a pattern, the top surface removably coverable with one or more cover plates having a non-adhesive surface such that the cover plate removably covers the plurality of holes in the alignment carrier plate, said non-adhesive surface removably restrains the plurality of cylindrically shaped interconnect members releasably disposed in the plurality of holes, the layer manually detachable from the top surface of the alignment carrier plate to release the plurality of interconnect members such that the plurality of interconnect members drop under the force of gravity from the alignment carrier plate when inverted upside down. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is a top view and  FIG. 1B  is a top perspective view of one embodiment of a dispensing apparatus with an array of holes that house, position and align a plurality of interconnect members prior to placement onto a CCGA substrate. 
         FIG. 2A  is a cross-sectional side view of the apparatus of  FIG. 1A . 
         FIG. 2B  is a partial enlarged cross-sectional side view of the apparatus of  FIG. 1A  showing details of a plurality of interconnect members (e.g., solder columns) seated in the silos (cylindrical holes) of the dispensing apparatus in the upright resting position as well as an interconnect member being placed into a silo. The interconnect members (e.g., solder columns) are prevented from escaping the exit end of the silo by a removable retention plate. 
         FIG. 3A  is an inverted (e.g., positioned upside down) cross-sectional side view of the apparatus of  FIG. 2A . 
         FIG. 3B  is an inverted (positioned upside down) of the enlarged sectional side view of the apparatus of  FIG. 2B  showing details of a plurality of interconnect members (e.g., solder columns) dropping via gravity feed after removing the cover plate and inverting the apparatus upside down. 
         FIG. 4  is an exploded view of the apparatus of  FIG. 1A  with the top cover plate, bottom retention plate, alignment plate with a plurality of holes, an array of interconnect members. 
         FIG. 5  is an exploded view of the inverted (upside down) apparatus of  FIG. 1A  (shown for clarity without the top cover plate), the bottom retention plate, alignment plate with a plurality of holes, an array of interconnect members dropping via gravity feed onto a CCGA substrate with a plurality of metalized pads to receive the interconnect members. 
         FIG. 6A  is a bottom view and  FIG. 6B  is a bottom perspective view of one embodiment of a dispensing apparatus with an array of holes that house, position and align a plurality of interconnect members prior to placement onto a CCGA substrate. 
         FIG. 7  is an exploded view of the inverted (upside down) apparatus of  FIG. 1A  (shown for clarity without the top cover plate), the bottom retention plate, alignment plate with a plurality of holes, an array of interconnect members dropping via gravity feed onto the receiving (e.g., female receptacle) frame apparatus with a plurality of holes, LGA substrate with a plurality of metalized pads to receive the interconnect members and a base jig-fixture with pocket that holds said LGA substrate. 
         FIG. 8A  is a top view and  FIG. 8B  is a top perspective view of the receiving (e.g., female receptacle) alignment frame apparatus with a plurality of holes (e.g., silos) to capture an array of interconnect members dropping via gravity feed from the apparatus of  FIG. 1B . 
         FIG. 9  is an exploded view of the apparatus of  FIG. 6B  (prior to being loaded with an array of interconnect members) and a receiving (e.g., female receptacle) plastic or metal frame jig-fixture to hold and align the apparatus upright before insertion into the frame. 
         FIG. 10A  is a top perspective view of the dispensing apparatus of  FIG. 6B  seated into the receiving (e.g., female receptacle) plastic of metal alignment frame. 
         FIG. 10B  is a cross-sectional side view of the dispensing apparatus seated in the receiving (e.g.; female receptacle) plastic or metal frame jig-fixture of  FIG. 10A . 
         FIG. 11  is an exploded view of a frame apparatus positioned above the dispensing apparatus seated in the plastic frame fixture of  FIG. 10A . 
         FIG. 12A  is a bottom perspective view of an inverted alignment frame apparatus placed on top of the dispensing apparatus seated in the plastic or metal frame fixture of  FIG. 10A . 
         FIG. 12B  is a top perspective view of  FIG. 12A  re-inverted (e.g., flipped over) right side up. 
         FIG. 13  is an exploded view of a frame apparatus positioned right side up after removing the plastic or metal frame jig-fixture and after the dispensing apparatus has dropped its payload via gravity feed of a plurality of interconnect members. 
     
    
    
     DETAILED DESCRIPTION 
     Referring first to  FIGS. 1A and 1B , is an apparatus (shown for clarity without the retention plate  50  in  FIG. 2B ,  FIG. 4 ,  FIG. 5  and  FIG. 7 ), generally designated at  10 , that can hold, align and dispense one or more (e.g., a plurality of) electrical interconnect members  80  in  FIG. 4 ,  FIG. 5 ,  FIG. 7  and  FIG. 9  in any desired array pattern. The apparatus  10  can be shaped like a tray or carrier plate with a plurality (e.g., an array) of holes  40  in  FIGS. 1A, 1B ,  FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIG. 4 ,  FIG. 5 ,  FIGS. 6A, 6B ,  FIG. 7 ,  FIG. 9 ,  FIG. 10  and  FIG. 11  that extend through an alignment carrier plate P of the tray (e.g., extend through from surface  11  to surface  12  of the alignment carrier plate P). The apparatus of carrier plate  10  can have a square shape. In other embodiments, the apparatus or carrier plate  10  can have other suitable shapes (e.g., rectangular, etc.). The one or more electrical interconnect members  80  can be solder columns, micro-coil springs, pins or other suitable generally cylindrical members that are releasably disposed in the holes  40  of the apparatus  10 , as discussed further below. 
       FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIG. 4 ,  FIG. 5 ,  FIG. 7 ,  FIG. 10B ,  FIG. 12B  and  FIG. 13  show the retention plate  50  that can be removably coupled to the apparatus  10  by one or more fasteners  52  shown in  FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIG. 4 ,  FIG. 5 ,  FIG. 7 ,  FIG. 10B ,  FIG. 12B , and  FIG. 13 . Non-threaded holes  51   b  and  51   d  of retention plate  50  shown in  FIG. 4 ,  FIG. 5 ,  FIG. 7  and  FIG. 13  are larger than the diameter of the threaded fasteners  52  to provide a path for one or more fastener  52  to removably couple with corresponding threaded-holes  42   b  and  42   d  in apparatus  10  shown in  FIG. 4 ,  FIG. 5 ,  FIGS. 6A, 6B  and  FIG. 7 . Non-threaded holes  51   a  and  51   c  of retention plate  50  shown in  FIG. 4 ,  FIG. 5 ,  FIG. 7  and  FIG. 13  are larger than the diameter of the threaded fasteners  61  shown in  FIG. 4  to provide an opening (e.g., silo) for the free-end of one or more fasteners  61 , removably coupled to apparatus  10  and protruding beyond the underside of apparatus  10  into retention plate  50 . The parallel surface of retention plate  50  prevents the plurality of electrical interconnect members  80 , as shown in  FIGS. 2A, 2B  and  FIG. 7  from exiting side  11  of apparatus  10  while positioned in one or more holes  40 . A cover plate  60  shown in  FIG. 4  can be removably coupled to apparatus  10  by one or more fasteners  61  through corresponding threaded-holes  42   a  and  42   c . Non-threaded holes  62   a  and  62   c  of cover plate  60  shown in  FIG. 4  provide a path for fastener  61  to screw into threaded holes  42   a  and  42   c  in apparatus  10 . The parallel surface of  60  prevents the plurality of electrical interconnect members  80 , as shown in  FIG. 4  from exiting side  12  of apparatus  10  while positioned in one or more holes  40  of the apparatus  10 . 
     The one or more interconnect members  80  can be arranged in an array A shown in  FIG. 4 ,  FIG. 5 ,  FIG. 7  and  FIG. 9 . The one or more interconnect members  80  can drop and fall from the apparatus  10  via (e.g., solely under the force of) gravity after the cover plate  60  is removed from a planar surface  12  of the tray as shown in  FIG. 4  after apparatus  10  is inverted upside down as shown in  FIG. 3B ,  FIG. 5  and  FIG. 7 . 
     Interconnect member  80   c  and  80   b  shown in  FIG. 2B  is one or more solder columns depositing (e.g. loading) into side  12  in the tray of apparatus  10 . Interconnect member  80   a  shown in  FIG. 2B  is one or more solder columns resting in holes  40 , can be prevented from exiting side  11  by retention plate  50 . Interconnect member  80   a  shown in  FIG. 3B  is one or more solder columns positioned in holes  40  prior to exiting (e.g., dropping) apparatus  10  through side  12 . Interconnect member  80   b  and  80   c  shown in  FIG. 3B  is one or more solder columns exiting (e.g. dropping) from side  12  of the tray (carrier plate) after cover plate  60  has been removed from apparatus  10  and inverting (e.g., flipping) apparatus  10  upside down. The retention plate  50  can be a transparent or translucent material so that the operator can visually see that all interconnect members  80  have dropped and fallen under the force of gravity after apparatus  10  is inverted upside down as shown in  FIG. 5 ,  FIG. 7 ,  FIG. 12B  and  FIG. 13 . Retainer plate  50  can be removed by unscrewing all fasteners  52  and using a tool with one or more pointed probes, or other mechanisms, to dislodge one or more stuck interconnect members  80 . Interconnect member  80   e  is a solder column shown in  FIG. 4 ,  FIG. 5 ,  FIG. 7 ,  FIG. 9  and  FIG. 11  in a perspective view outside of the tray of the apparatus  10 . The array pattern of interconnect members (e.g., solder columns)  80  is shown dropping onto a pattern of corresponding metallic pads  91  on a top surface of a CCGA substrate  90  in  FIG. 5  and  FIG. 7 . 
     As shown in  FIGS. 1A, 1B ,  FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIG. 4 ,  FIG. 5 ,  FIGS. 6A, 6B ,  FIG. 7 ,  FIG. 9 ,  FIG. 10A  and  FIG. 11 , a pattern array of holes  40  may be arranged in any desired pattern such as an even number matrix (e.g., 2×2 or more than 42×42) or in an odd number matrix (e.g., 3×3 or more than 41×41). The center-line of the tray apparatus  10  intersects between the array of pattern holes  40  of an even numbered array (e.g., between rows of holes  40  in an even numbered array). The center-line of the tray apparatus  10  intersects through the array pattern of holes  40  of an odd numbered array (e.g., intersects a row of holes  40  in an odd numbered array). 
     The array pattern of non-countersink holes or apertures  40  and  40   a  shown in  FIG. 6B  on the surface of side  12  can include a plurality of countersink holes or apertures  41  and  41   a  formed on planar surface  11  in the apparatus  10  shown in  FIG. 1B , which can include a refillable alignment carrier plate P through which the plurality of holes  41  extend. The plurality of holes  41  can be arranged in any desired array pattern  40  for removably housing a plurality of interconnect members  80 , such as solder columns. The four corners  70   a ,  70   b ,  70   c  and  70   d  in  FIG. 1A  form the perimeter boundary for retention plate  50  to seat onto the parallel surface of side  11  of tray apparatus  10 . As shown in  FIGS. 3A-3B , the retention plate  50  can extend into the recessed opening defined by the sidewalls  26  of a peripheral frame that protrudes above the surface  11 . Optionally, the retention plate  50  can sit in said recessed opening so that surface of the plate  50  is substantially flush with a surface of the peripheral frame  21  of the apparatus  10 . 
     An alignment frame (e.g., graphite alignment frame) can include two jig-fixtures plates  200  and  211  as discussed further below. The top plate  200  is shown in  FIG. 7 ,  FIGS. 8A, 8B ,  FIG. 11 ,  FIGS. 12A, 12B , and  FIG. 13 . The top surface  207  of the top plate  200  is shown in  FIG. 7 ,  FIGS. 8A, 8B  and  FIG. 13 . The bottom surface  208  of the top plate  200  is shown in  FIG. 7  and  FIG. 8B . The base plate  211  is shown in  FIG. 7 ,  FIG. 11 ,  FIGS. 12A, 12B  and  FIG. 13 . The top surface  213  of the base plate  211  is shown in  FIG. 7 . The bottom surface  212  of the base plate  211  is shown in  FIG. 7  and  FIGS. 12A, 12B . The bottom side  208  of the top plate  200  is removably coupled to the top side  213  of the base plate  211  shown in  FIG. 7 . The four corners  71   a ,  71   b ,  71   c  and  71   d  as well as the four side walls  25  shown in  FIGS. 2A, 2B ,  FIGS. 3A, 3B  and  FIGS. 6A, 6B  form the perimeter boundary of an alignment feature on side  12  of tray apparatus  10  that inserts into the four wall receiving (e.g., female) receptacle  204  of the frame  200  shown in  FIG. 7  and  FIGS. 8A, 8B . The parallel surface  12  of tray apparatus  10  rests on the parallel surface  205  of the receptacle of frame  200  shown in  FIGS. 8A, 8B . The four corners  73   a ,  73   b ,  73   c  and  73   c  as well as the four walls  28  form another perimeter boundary alignment feature on tray apparatus  10  as shown in  FIGS. 1A, 1B ,  FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIG. 4 ,  FIG. 5 ,  FIG. 6B ,  FIG. 7  and  FIG. 9  that inserts into the four inside walls  203  of receiving (e.g., female receptacle) frame  200  shown in  FIG. 7  and  FIGS. 8A, 8B . The four ledges  22  of tray apparatus  10  shown in  FIGS. 2A, 2B ,  FIGS. 3A, 3B ,  FIGS. 6A, 6B ,  FIGS. 10A, 10B , and  FIG. 11  rests on the parallel surface of the four ledges  206  of frame  200  shown in  FIGS. 8A, 8B . The plurality of holes  202  on surface  205  of the receiving member (e.g., female receptacle) is recessed below the surface  207  of the top frame  200  shown in  FIGS. 8A, 8B , and recessed below the four ledges  206 . The bottom side  212  of the base  211  is shown in  FIG. 7 ,  FIG. 11  and  FIGS. 12A, 12B . 
     A jig-fixture consisting of plastic, metal or other material  300  forms an insertion alignment frame shown in  FIG. 9 ,  FIGS. 10A, 10B ,  FIG. 11  and  FIG. 13 . The four corners  373   a ,  373   b ,  373   c  and  373   d  on the top side of the insertion alignment frame  300  as well as the eight side walls  328  shown in  FIG. 9  and  FIGS. 10A, 10B  form the perimeter boundary of an alignment feature on the insertion alignment frame  300 . The receiving receptacle perimeter boundaries on surface  301  of the insertion alignment frame  300  are slightly larger than the outline of perimeter  28  of apparatus  10  to permit apparatus  10  to enter the alignment pocket (e.g., female receptacle) on the top side of  300 . The perimeter four walls  306  on insertion alignment frame  300  is slightly smaller than the outline perimeter  28  of apparatus  10 , allowing the four perimeter ledges  22  of apparatus  10  to rest on the shoulder  321  of the insertion alignment frame  300  without falling out as shown in  FIG. 9  and  FIG. 10B . The level of ledge  321  is lower than (e.g., recessed relative to) the surface  301  on insertion alignment frame  300  so that after inserting apparatus  10  into the pocket (e.g., female receptacle) of  300 , substantially all of wall  25  and a portion of wall  28  of apparatus  10  will protrude beyond the surface  301  (see  FIGS. 6B and 10B ). After insertion of apparatus  10  into the pocket formed by walls  328  on the insertion alignment frame  300 , apparatus  10  will be in the upright position with side  12  of apparatus  10  facing upwards. One such embodiment is used when removably coupling the inserting alignment frame  300  into the receiving receptacle of plate  200 . The parallel surface of  207  of the top frame  200  shown in  FIG. 7  and  FIGS. 8A, 8B  removably couples to the top parallel surface  301  of the insertion alignment frame  300  shown in  FIG. 9 ,  FIGS. 10A, 10B ,  FIG. 11  and  FIG. 13 . The bottom side  305  of insertion alignment frame  300  is shown in  FIG. 9 ,  FIG. 10B ,  FIG. 11  and  FIG. 13 . The perimeter outline  329  of the insertion alignment frame  300  shown in  FIG. 9  is of similar shape and size as the perimeter outline of the top frame  200  and base plate  211  for easy handling during the inverting (e.g., flipping over) process discussed below. 
     In operation, the CCGA (LGA) substrate  90  with the corresponding array pattern of pads  91  is held in alignment to the array of interconnect members (e.g., solder columns)  80  while seated in the pocket  210  of a base plate  211  jig-fixture or frame shown in  FIG. 7 . After placement of the CCGA(LGA) substrate  90  into the pocket  210 , in one embodiment the surface height, including the array pattern of pads  91 , extends slightly beyond the surface  213  of base plate  211 . A thin layer of solder paste can optionally be applied to the array pattern of pads  91  of CCGA (LGA) substrate  90 . After optionally applying solder paste to the array pattern of pads  91 , the top plate  200  is coupled to the base plate  211 . In one embodiment, the top plate  200  is coupled to the base plate  211  via rods that extend through holes in both plates (not shown). However, other suitable coupling mechanisms can be used. Apparatus  10  filled with a plurality of interconnect members  80 , securely covered by top cover plate  60  and retention plate  50 , is manually placed into the receiving pocket (e.g., female receptacle) of the insertion alignment frame  300  with the ledge  22  of apparatus  10  resting on the shoulder  321  of the alignment frame  300  shown in  FIG. 9  and  FIGS. 10A, 10B . All fasteners  61  are removed and cover plate  60  is lifted and released from side  12  of apparatus  10 . The protruding (e.g., male) planar surface  12  of apparatus  10  is seated in the insertion alignment frame is shown in  FIG. 10A, 10B  with the cover plate  60  removed. The combined alignment frame consisting of  200  and  211  (internally holding the CCGA (LGA) substrate  90  with solder paste) is manually inverted (flipped upside down) with surface  207  facing downward and surface  212  facing upward. The combined inverted alignment frame is aligned and placed over surface  301  of the insertion alignment frame  300  shown in  FIG. 11 . The upright uncovered protruding (e.g., male)  12  surface of apparatus  10  plugs into a recessed (e.g., female) socket opening defined by the four inside boundary walls  204  in an inverted (bottom-fed) jig-fixture  200  as shown in  FIGS. 8A, 8B . The socket aperture boundary of four walls of  204  connected by corners  201   a ,  201   b ,  201   c  and  201   d  shown in  FIG. 7  and  FIGS. 8A, 8B  in the jig-fixture is slightly larger than the alignment feature formed by boundary  71   a ,  71   b ,  71   c  and  71   d  shown in  FIGS. 6A, 6B  on side  12  of apparatus  10 . The four side walls of  25  align with corresponding side walls in the jig-fixture. Concurrently, the socket aperture boundary of four walls of  203  connected by corners  273   a ,  273   b ,  273   c  and  273   d  shown in  FIG. 8A  in the jig-fixture is slightly larger than the alignment feature formed by boundary  73   a ,  73   b ,  73   c  and  73   d  shown in  FIG. 1B  and  FIG. 6B  on apparatus  10 . The four side walls of  28  align with corresponding side walls in the jig-fixture. The four ledges  22  in  FIGS. 2A, 2B ,  FIGS. 3A, 3B  and  FIGS. 6A, 6B  on the topside of apparatus  10  rests on the four ledge surfaces  206  of the inverted jig-fixture  200 . Once aligned, apparatus  10  seated upright in the alignment frame  300  and coupled jig-fixtures  200  and  211  shown in  FIG. 12A  are together inverted upside down as shown in  FIG. 12B , as discussed above, allowing the one or more interconnect members  80  to detach from the apparatus and fall under the force of gravity through a corresponding array pattern in a plurality of holes (e.g., silos)  202  in frame  200  shown in  FIG. 7  and  FIGS. 8A, 8B  onto the CCGA substrate  90  such that the one or more interconnect members  80  contact corresponding array pattern of pads  91 . CCGA (LGA) substrate  90  is seated (inserted) into the pocket  210  of the base frame  211  as shown in  FIG. 7   
     After inverting (e.g., flipping over) the three coupled plates  300 ,  200  and  211  shown in  FIG. 12B , alignment plate  300  is manually lifted and removed from the coupled frame  200  and  211  shown in  FIG. 13 . Visual inspection is made by looking through the transparent (or translucent) retainer plate  50  to view if all interconnect members have fallen. Retainer plate  50  can be removed by unscrewing all fasteners  52  and using a tool with one or more pointed probes, or other mechanisms, to dislodge one or more stuck interconnect members  80 . After allowing the one or more interconnect members  80  to detach from the apparatus, apparatus  10  is lifted and removed from the top of frame  200  to position B. Once the apparatus  10  is removed, the frame  200 ,  211  along with the CCGA substrate  90  and interconnect members  80  can be placed in a reflow oven to reflow the solder paste. In one embodiment, the frame  200  can optionally have one or more recesses adjacent the apparatus  10  to facilitate the removal of the apparatus  10  (e.g., allowing the user to grab the sides of the apparatus  10  with their thumbs). Apparatus  10  can be refilled with interconnected members, discarded or recycled. 
     The outside perimeter aperture  23  shown in  FIG. 1A  and side walls  26  of the peripheral frame  21  shown in  FIG. 1B  is slightly larger than the perimeter side walls  25  shown in  FIG. 6  of apparatus  10  thus advantageously allowing a plurality of apparatus  10  to be nested and stacked one-into the other during transport. The surface  11  of the plate P is recessed or axially offset relative to the side walls  26 , such that the side walls  26  extend upward or protrude from the plane of the plate P. 
     As shown in  FIGS. 1A, 1B  and  FIGS. 6A, 6B  one corner  30  of apparatus  10  is chamfered (e.g., at 45-degrees) to provide a visual orientation and alignment with the CCGA substrate  90 . 
     While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims. 
     Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed. 
     Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a sub combination. 
     Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. 
     For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. 
     Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment. 
     Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z. 
     Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree. 
     The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive.