Patent ID: 7884471

Claim:
An intermediate structure, comprising: a primary solder column comprising primary solder material formed in a column shape on a bonding pad area comprising a bonding pad on a semiconductor substrate, the primary solder column electrically contacting the bonding pad along a base defining an overall width of the primary solder column; at least one secondary solder column comprising secondary solder material formed in a column shape on the bonding pad area distinct from the primary solder column, the at least one secondary solder column electrically contacting the bonding pad along a base defining an overall width of the at least one secondary solder column, and having a substantially similar column shape to the primary solder column but with a height, width and volume less than a height, width and volume of the primary solder column; a joining channel, formed on the bonding pad, physically and electrically connecting an exterior sidewall of the secondary solder column at one end of the channel with an exterior sidewall of the primary solder column at the opposite end of the channel so that the secondary column is horizontally adjacent to the primary solder column along the bonding pad, the joining channel having a width, measured along the channel, and a volume less than the overall width and volume of the secondary solder column; and wherein the primary solder column is further configured to form a primary solder bump comprising the primary solder material and at least a portion of the secondary solder material and the joining solder material through cohesion from the at least one secondary solder column when the intermediate structure undergoes a reflow process.