Patent ID: 8875978

Claim:
An apparatus for forming metal solder balls comprising: a conveyor belt containing a plurality of cavities; a plurality of guides to receive said conveyor belt and said plurality of cavities, said guides directing said plurality of cavities passed a plurality of processing stations in sequential order; a first processing station includes a hot stage for heating said plurality of cavities and includes an injection molded solder tool for filling said plurality of cavities with molten metal as said plurality of cavities passes by said first processing station; a second processing station includes a hot stage for heating said plurality of cavities and solder, a housing for containing a gaseous environment and a gas input port for filling said housing with a first gas; a third processing station includes a hot stage for heating said plurality of cavities and metal above the melting temperature of said metal, a housing for containing a gaseous environment and a gas input port for filling said housing with a second gas; a fourth processing station includes a cold stage for cooling said plurality of cavities and said metal to solidify said metal; and a fifth processing station includes a manifold and openings for directing a third gas at the lower side of said plurality of cavities and an input port for filling said manifold with said third gas whereby said directed gas loosens and removes said metal balls from said plurality of cavities.