Aggregate Board Wiring for Individual LED Testing
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Solution Overview
Problem
Existing methods for testing light emitting devices require complex processes to test individual light emitting elements before they are mounted on a board, making it difficult to individually light and measure the color of light emitting elements before splitting them into individual devices.
Innovation Solution
An aggregate board with specific wiring patterns that allow individual light emitting elements to be illuminated and tested for characteristics, including color, before being split into devices, using a configuration of insulators, conductive members, and inner layer wiring patterns that enable efficient electrical connection and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate testing structure is provided for testing light emitting elements, then individual testing capability is improved, but the manufacturing process complexity increases significantly
Solution Approach 1:
The patent combines the testing structure with the aggregate board by integrating test electrode extensions directly into the board's wiring patterns. The front face wiring patterns and rear face wiring patterns serve dual purposes as both structural support and test electrodes, eliminating the need for separate testing structures and reducing manufacturing process complexity while maintaining individual testing capability
Solution Approach 2:
The wiring patterns on the aggregate board are designed to serve multiple functions: they provide electrical connections for mounting light emitting elements, serve as test electrodes for individual element testing, and enable both group and individual testing modes. This multi-functionality eliminates the need for dedicated separate testing structures
2Reliability
If light emitting elements are transferred from primary storage board through via hole formation and extension wiring, then individual testing becomes possible, but the testing process becomes extremely complicated
Solution Approach 1:
The aggregate board is pre-configured with wiring patterns that extend to the front and rear faces, creating built-in test electrode extensions before light emitting elements are mounted. This preliminary preparation eliminates the need for subsequent via hole formation and extension wiring steps that would otherwise be required to enable individual testing
Solution Approach 2:
The patent extracts the testing function from a separate complex process and integrates it directly into the aggregate board structure. The test electrode extensions are built into the board itself, allowing testing to be performed directly on the aggregate board without requiring element transfer or additional wiring steps
3Measurement precision
If wiring patterns are configured to allow individual lighting of light emitting elements, then individual color measurement becomes possible, but the wiring pattern complexity increases
Solution Approach 1:
The aggregate board features multiple pairs of front face wiring patterns and rear face wiring patterns that are spatially segmented and individually addressable. Each pair can independently control and test a specific light emitting element position, enabling individual color measurement while maintaining organized, systematic wiring arrangements
4Productivity
If testing is performed before splitting the board into individual devices, then yield improvement is achieved, but the testing setup becomes more complex
Solution Approach 1:
The testing functionality is merged directly into the aggregate board structure through integrated wiring patterns that serve as both mounting connections and test electrodes. This allows testing to be performed on the complete aggregate board before splitting, improving yield without requiring complex separate testing setups
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 1E
AI summary
An aggregate board, comprising: an insulator having a front face and a rear face; a pair of a first front face wiring pattern and a second front face wiring pattern, a plurality of which are arranged on the front face of the insulator; a pair of a first rear face wiring pattern and a second rear face wiring pattern, a plurality of which are arranged on the rear face of the insulator; at least one first inner layer wiring pattern that is separated from the second front face wiring pattern and the second rear face wiring pattern, that is connected to the first front face wiring pattern and the first rear face wiring pattern, and that extends in a first direction in an interior of the insulator; at least one second inner layer wiring pattern that is separated from the first front face wiring pattern and the first rear face wiring pattern, that is connected to the second front face wiring pattern and the second rear face wiring pattern, and that has a part that extends in a second direction which is different from the first direction, in the interior of the insulator; and the first inner layer wiring pattern and the second inner layer wiring pattern being positioned in the same layer.