Method of making a multipad solder preform

Claim 1

A method of soldering leaded electronic components to printed circuit substrate comprising: providing a substantially solid multipad solder preform of predetermined thickness with a plurality of perforations at locations in a pattern complementing the pattern of locations of leads on the components, said perforations being in number at a ratio of substantially 2:1 to the number of leads per component to be soldered, said providing step including determining the thickness of the preform, and perforation shape, size and spacing as a function of the component lead size, shape and spacing, substrate land dimensions and desired solder fillet dimensions, and calculating the perforation size, to be in a range of about 0.33 to about 0.90 of its maximum where its maximum equals √2/4 times lead to lead distance; fluxing the perform; sandwiching the preform between the component and the printed circuit substrate so as to align the component leads, non perforated preform areas, and lands on the substrate; and reflowing the solder.

Claim 2

A method of soldering leaded electronic components to printed circuit substrate comprising: providing a substantially solid multipad solder preform of predetermined thickness with a plurality of perforations at locations in a pattern complementing the pattern of locations of leads on the components, said perforations being in number at a ratio of substantially 2:1 to the number of leads per component to be soldered, said providing step including determining the thickness of the preform, and perforation shape, size and spacing as a function of the component lead size, shape and spacing, substrate land dimensions and desired solder fillet dimensions, and calculating the perforation size, to be in a range of about 0.33 to about 0.90 of its maximum where its maximum equals √2/4 times lead to lead distance; fluxing the perform; sandwiching the preform between the component and the printed circuit substrate so as to align the component leads, non perforated preform areas, and lands on the substrate; and reflowing the solder.

Claim 4

A method of making a multipad solder preform for mounting a pinned component having uniform pin to pin spacing to circuit boards having metallized through holes comprising: determining the planar dimensions of a solid solder blank having an area corresponding to the planar configuration of the component; forming holes in the solder blank at locations surrounding areas corresponding to component pin locations, said forming step including calculating optimum hole radius size to be in a range from about 0.3 to about 0.9 of its maximum where its maximum equals the square root 2 of divided by 4 times the pin to pin spacing and selecting the locations to be at a ratio of substantially 2:1 to the number of pins on the component; and choosing the thickness and hole diameter as a function of pin size, shape and spacing, pad size and shape, and desired solder fillet size and shape.

Claim 5

A method of making a multipad solder preform for mounting a pinned component having uniform pin to pin spacing to circuit boards having metallized through holes comprising: determining the planar dimensions of a solid solder blank having an area corresponding to the planar configuration of the component; forming holes in the solder blank at locations surrounding areas corresponding to component pin locations, said forming step including calculating optimum hole radius size to be in a range from about 0.3 to about 0.9 of its maximum where its maximum equals the square root 2 of divided by 4 times the pin to pin spacing and selecting the locations to be at a ratio of substantially 2:1 to the number of pins on the component; and choosing the thickness and hole diameter as a function of pin size, shape and spacing, pad size and shape, and desired solder fillet size and shape.