Patent ID: 7323360

Claim:
A component package fabricated by: depositing an underfill material over a plurality of pads in a component-mounting area of a substrate, the underfill material comprising a filler material containing particles; placing a component on the component-mounting area, such that terminals of the component are aligned with corresponding pads and substantially enveloped in the underfill material, the particles potentially inhibiting a suitable connection between corresponding terminals and pads unless the particles are substantially removed; applying suitable pressure to cause the terminals to physically contact the pads and to remove most but not all potentially inhibiting particles from between corresponding terminals and pads, with one or more particles being embedded in one of the terminals, in its corresponding pad, or in both the one terminal and its corresponding pad without preventing adequate physical and electrical contact; and applying suitable heat to melt solder situated between the terminals and pads, which when cooled results in an electrical and mechanical connection between corresponding terminals and pads.