Patent ID: 7810702

Claim:
A method of forming solder standoffs for solder in injection molded solder molds, said method comprising: providing a mold consisting of a silicon material and having a plurality of cavities formed in a surface thereof; filling each of said cavities with a solder paste to a level of said mold surface using a standard injection molding process, the solder paste comprising a mixture of solder, flux, diverse metallic particles to increase conductivity, and organic constituents to vary volumetric changes and wettability; imparting heat to said solder paste in said mold cavities so as to burn off said organic constituents and form voids and metallic solder balls of a size reaching to the surface level of said mold wherein the voids form about said solder balls; filling said voids present in said cavities about said solder balls with a solder material possessing a lower melting point than the solder paste initially filled into said cavities; cooling said mold such that the solder balls which are constituted of the higher melting point material are embedded in said lower melting point solder material; and transferring said embedded solder balls and solder material to a semiconductor wafer so as to form said standoffs having precisely defined dimensions.