Abstract: A method of soldering a ball grid array device onto a circuit board which includes: positioning a solder paste brick on top of a contact pad of the circuit board, said solder past brick defining an irregularly shaped structure such that a majority of a top surface of the solder paste brick is not in contact with the solder ball terminal, wherein volatized flux gases formed during heating escape via the top surface without migrating upwardly into the solder ball terminal; attaching the ball grid array device onto the circuit board such that a solder ball terminal of the ball grid array device makes contact with a portion of an edge of the solder paste brick while remaining substantially aligned with a center of the pad; and heating the ball grid array device and the circuit board so as to melt the solder ball terminal and the solder paste brick, thereby forming a solder joint between the ball grid array device and the circuit board.

Abstract: A wave solder pallet having a first side that is adapted to receive a printed circuit board and a plurality of through holes or apertures that will allow solder to be transmitted through to selected regions on the printed circuit board. The surface of the base plate that is positioned adjacent the solder wave has channels formed therein, the channels being tapered inwardly so that the overall volume of the channel is greatest at the periphery of the pallet. The increased volume of the channel reduces the pressure effect of the solder wave as it contacts the pallet at the periphery thereby reducing the amount of solder that is splashed over the pallet. The tapering of the channel uniformly increases the pressure so that the pressure effect of the solder wave is increased when it travels through the apertures.

Abstract: An alignment fixture for aligning components of a solder-wave machine during manufacturing processes of PCB assemblies and other electronic devices. In one embodiment, an alignment fixture has a calibration member that is adapted to be positioned at least in part over a solder-wave of the solder-wave machine. The calibration member may be positioned at a PCB elevation defined by the elevation at which PCB assemblies move over the solder-wave during processing. The calibration member may be an alignment bar or other device that has a solder indicator to indicate the height of the solder-wave relative to the PCB elevation. Additionally, the solder indicator may indicate the extent of deviations between the height of the solder-wave and the PCB elevation across at least a portion of the solder-wave.

Abstract: A solder paste brick, for attaching a ball grid array device to a circuit board. The solder paste brick is configured as an irregularly shaped structure so as to reduce distances in which volatized flux gasses must travel in order to escape from within the solder paste brick, thereby reducing voiding in a solder joint formed by the solder paste brick and a solder ball terminal of the ball grid array device as a result of a reflow soldering process. The solder paste brick is further configured so as to allow the solder ball terminal to make contact with a portion of an edge of the solder paste brick, while remaining substantially aligned with a center of a pad of the circuit board, such that a majority of a top surface of the solder paste brick is not in contact with the solder ball terminal. In this way, volatized flux gases formed during a reflow soldering process are caused to escape via the top surface without migrating upwardly into the solder ball terminal during the reflow soldering process.

Abstract: A universal fixture for holding printed circuit board assemblies during stencil printing, pick-and-place processing, and other PCB assembly processes. In one embodiment, a universal printed circuit board holder has a base and a plurality of support members movably attached to the base. The support members may project away from the base along support paths, and the support members are selectively positionable along the support paths when the support members engage a side of a printed circuit board assembly. Accordingly, the support members may be selectively positioned at heights corresponding to a topography of the side of the printed circuit board assembly to uniformly support the printed circuit board assembly.

Abstract: A device for preserving solder paste in the manufacturing of printed circuit board assemblies. In one embodiment, the preserving device has a frame adapted to be positioned on a stencil plate of a solder paste stenciling machine and a cover coupled to the frame. The frame has a wall that is configured to substantially surround at least a portion of the solder paste on the stencil plate between printing cycles. In a preferred embodiment, the wall is configured to surround a working region on the stencil plate defined by the area on the stencil plate that the solder paste contacts during a printing cycle. The cover is coupled to the frame to form a protective compartment that substantially houses the solder paste between printing cycles. As a result, the preserving device restricts the airflow across the solder paste to protect the solder paste from environmental elements within the stenciling machine.

Abstract: A method for preserving solder paste in the manufacturing of printed circuit board assemblies. In one embodiment, the method utilizes a preserving device which has a frame adapted to be positioned on a stencil plate of a solder paste stenciling machine and a cover coupled to the frame. The frame has a wall that is configured to substantially surround at least a portion of the solder paste on the stencil plate between printing cycles. In a preferred embodiment, the wall is configured to surround a working region on the stencil plate defined by the area on the stencil plate that the solder paste contacts during a printing cycle. The cover is coupled to the frame to form a protective compartment that substantially houses the solder paste between printing cycles. As a result, the preserving device restricts the airflow across the solder paste to protect the solder paste from environmental elements within the stenciling machine.

Abstract: A fixture tooling for supporting a back side of a printed circuit board during component placement on a top side of the board includes an inflatable air bladder that is sized substantially coextensive with the circuit board. The bladder is positioned below the circuit board within a containment unit adapted for use with conventional railed assembly equipment. The bladder is selectively inflated for supporting the complete back side of the printed circuit board during assembly operations. The bladder provides evenly distributed support across, substantially, the entire circuit board without damaging any components on the back side by pliably conforming to component irregularities on the back side.

Abstract: A device and method for configuring the leads of a light-emitting diode into a desired configuration and testing the polarity of the light-emitting diode before it is mounted to a printed circuit board. In one embodiment, the device has a non-conductive base that has a top surface with a first deformation point defining a location about which a hot lead is desirably deformed and a second deformation point defining a second location about which a ground lead is desirably deformed. The configuring and testing device also has a guide structure on the top surface of the base member, a first peg connected to the base member at the first deformation point, a first conductive contact element positioned to engage the hot lead, a second peg connected to the base member at the second deformation point, and a second conductive contact element positioned to engage the ground lead.

Abstract: An method and apparatus for forming adhesive and solder pads on a printed circuit board to surface mount electrical components to the board. In accordance with an embodiment of the invention, a solder paste is deposited onto the printed circuit board through a first stencil that has a plurality of first openings. The solder paste forms a plurality of solder pads on the board. A second stencil is then positioned on the printed circuit board. The second stencil has a plurality of second openings, and a recess in its bottom face configured to receive the plurality of solder pads. After the second stencil is positioned on the printed circuit board so that the solder pads are received in the recess on the bottom face of the second stencil, an adhesive material is deposited onto the board through the second openings of the second stencil to form a plurality of adhesive pads on the board.

Abstract: A shield (50) for use in wave soldering processes to selectively affix solder to an area of circuit board (20), having one or more electronic components (21) on the solder side of the board, is disclosed. Shield (50) includes a generally planar base member (51) of low thermal conductivity which forms the foundation of shield (50). Marginally disposed registration ridges (54) are formed on the upper surface (52). Registration ridges (54) serve to hold circuit board (20) against shield (50) in a fixed position. Ridges (54) are positioned to closely receive the peripheral edges of circuit board (20). One or more solder flow openings (56) are formed through base member (51) extending from upper side (52) to lower side (53). Solder flow openings (56) are positioned to align with the selected areas of circuit board (20) to which solder is to be affixed. One or more recesses (55) are provided in the upper surface (52) of base member (51) to receive and shield electronic components (21).

Abstract: A shield (50) for use in wave soldering processes to selectively affix solder to an area of circuit board (20), having one or more electronic components (21) on the solder side of the board, is disclosed. Shield (50) includes a generally planar base member (51) of low thermal conductivity which forms the foundation of shield (50). Marginally disposed registration ridges (54) are formed on the upper surface (52). Registration ridges (54) serve to hold circuit board (20) against shield (50) in a fixed position. Ridges (54) are positioned to closely receive the peripheral edges of circuit board (20). One or more solder flow openings (56) are formed through base member (51) extending from upper side (52) to lower side (53). Solder flow openings (56) are positioned to align with the selected areas of circuit board (20) to which solder is to be affixed. One or more recesses (55) are provided in the upper surface (52) of base member (51) to receive and shield electronic components (21).