Patent ID: 7784664

Claim:
A system for injection molding solder into a plurality of cavities in a surface of a circular mold, the system comprising: a circular mold having a surface including a plurality of cavities; a solder placement device for providing solder into the plurality of cavities in the surface of the circular mold, the solder placement device comprising: a fill head comprising a first gas channel, a second gas channel, a third gas channel, and a fourth gas channel; and a solder reservoir mechanically coupled to the fill head for providing solder to the fill head from the solder reservoir, and wherein the solder placement device being adapted to: align the fill head with the surface of the circular mold, wherein the fill head is slightly longer than a diameter of the surface of the circular mold, and further wherein the fill head comprises a substantially curved configuration substantially matching a curvature of a perimeter of the surface of the circular mold, the fill head being aligned relative to a radius of the surface of the circular mold; place the fill head in substantial contact with the surface; channel a first gas through the first gas channel and about a first region of the fill head, the first gas having a temperature above a melting point of solder residing in the reservoir mechanically coupled to the fill head thereby maintaining the solder in a molten state as the solder and the first gas are in close proximity to one another; force the solder out of the fill head toward the surface; provide the solder into at least one cavity of the plurality of cavities contemporaneous with the at least one cavity being in proximity to the fill head; channel a second gas through the second gas channel and about a second region of the fill head, the second gas having a temperature below the melting point of the solder thereby substantially solidifying the solder within the at least one cavity as the at least one cavity passes under the second region of the fill head with the second gas; channel the first gas to the third gas channel, wherein the third gas channel is mechanically coupled to the first gas channel and is situated about a third region of the fill head that is different than the first region of the fill head; and channel the second gas to the fourth gas channel, wherein the fourth gas channel is mechanically coupled to the second gas channel and is situated about a fourth region of the fill head that is different than the second region of the fill head.