Patent ID: 8342387

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 high-temperature resist film; (C) injecting a molten solder into the at least two cavities, wherein the injection occurs in an environment having an oxygen concentration which is higher than about 5 parts per million; (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 an oxide skin over a top of the solidified solder; (F) dispensing flux over a top of the at least two cavities of the mold plate; (G) inserting a spacer over a top of the mold plate; (H) placing a layer of a high-temperature resist film over a top of the spacer, wherein the high-temperature resist film is unreactive with the molten solder; and (I) reflowing the solder to form at least two solder balls, wherein a height of the spacer is about ⅓ to about ¾ of a diameter of each of the at least two solder balls.