Patent ID: 8162203

Claim:
A method of preventing or reducing bridging of two or more solder balls during an injection molded soldering process comprising: (A) obtaining a mold plate comprising at least two cavities on a top side of the mold plate, and at least one non-recessed space running between the at least two cavities, wherein the at least one non-recessed space is co-planar to the top side of the mold plate, and extends through an entire length of the mold plate; (B) obtaining a coverplate comprising at least two recesses on an underside of the coverplate, and at least one non-recessed space running between the at least two recesses, wherein the at least one non-recessed space is co-planer to the underside of the coverplate, and extends through an entire length of the coverplate; (C) filling the at least two cavities with a molten solder; (D) cooling the molten solder to a temperature that is below about ½ of the solder's melting point to form a solidified solder; (E) forming a gap between a top of the mold plate and the underside of the coverplate by positioning the at least two recesses of the coverplate over a top of the at least two cavities of the mold plate and aligning the recesses of the coverplate, at the cavity scale, with the cavities of the mold plate; and (F) reflowing the solidified solder in an oxide-reducing environment to form at least two solder balls, wherein a height of the gap is about ⅓ to about ¾ of a diameter of each of the at least two solder balls.