Probe Board Repair via Reserved Channel Cavities
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Solution Overview
Problem
The increasing complexity and density of wiring on circuit boards, particularly in high-integrated and small-sized products, make it difficult to repair defects such as open or short circuits, often requiring the entire board to be discarded, leading to increased manufacturing costs and waste.
Innovation Solution
A method for repairing probe boards involves forming cavities between damaged main channels and reserved channels, creating repair connection parts using conductive and insulating layers to reconnect the damaged channels, allowing for the transfer of electrical signals while maintaining the board's original appearance and functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the density of wirings on the circuit board is increased to reduce board size, then the board size is reduced, but the difficulty of repairing wiring defects increases
Solution Approach 1:
The patent applies preliminary action by forming reserved channels alongside main channels during the initial board manufacturing process. These reserved channels are prepared in advance as backup pathways, so when wiring defects occur in densely packed boards, repair can be performed by switching to reserved channels without requiring complete board replacement. This pre-prepared infrastructure enables easier repair of high-density boards.
Solution Approach 2:
The patent segments the wiring infrastructure into main channels and reserved channels as separate functional components. This segmentation allows the reserved channels to serve as independent backup pathways that can be activated when main channels fail. In high-density boards where repair difficulty increases, this segmentation enables targeted repair of specific channel segments without affecting the entire board.
2Volume of moving object
If various functions are integrated on a single circuit board to reduce size, then the board size is reduced, but the complexity of the board increases
Solution Approach 1:
The patent applies universality by designing reserved channels that can serve multiple functions: they act as backup pathways for damaged main channels, provide alternative routing for signal redistribution, and can be activated based on defect location. This multi-functionality allows a single board structure to handle various failure modes and functional requirements, managing the complexity inherent in high-integration designs.
Solution Approach 2:
The patent utilizes parameter changes by dynamically selecting which channels (main or reserved) are active based on the operational state and defect conditions. The system can change the functional parameter of channels from 'active main pathway' to 'backup pathway' or 'inactive' depending on repair needs, allowing flexible management of complex integrated circuits without physical restructuring.
3Adaptability or versatility
If the number of nets and paths on the circuit board is increased to provide various functions, then the functionality is enhanced, but the probability of wiring defects increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating reserved channels as a protective measure against wiring defects. These reserved channels are prepared in advance as a buffer or safety margin, so when defects occur in the increased number of nets and paths, the system has pre-positioned alternatives to maintain functionality. This cushioning approach directly addresses the increased defect probability by providing built-in redundancy.
Solution Approach 2:
The patent implements discarding and recovering by deactivating defective main channels and recovering functionality through reserved channels. When wiring defects are detected in the high-density net structure, the system discards the defective pathways and recovers operational capability by activating reserved channels, thereby maintaining the enhanced functionality despite the increased defect probability.
4Productivity
If wiring defects occur in heat-treated products, then the manufacturing process is completed, but the difficulty of repair increases
Solution Approach 1:
The patent applies preliminary action by forming reserved channels and repair infrastructure during the heat treatment and manufacturing process itself, before final product completion. This allows the board to be repaired after heat treatment by utilizing pre-formed channels, rather than attempting to create new pathways in the already-sintered ceramic material, which would be extremely difficult.
5Volume of moving object
If inner layer nets are used to provide functionality, then the board density is increased, but the ease of repair decreases
Solution Approach 1:
The patent introduces an intermediary approach by using reserved channels as intermediate pathways that connect to inner layer nets. When inner layer defects occur, the reserved channels serve as intermediary routes that can bypass the defective areas, allowing repair without requiring direct access to or modification of the difficult-to-reach inner layer structures.
Data Source
AI summary
There are provided a method of repairing a probe card and a repaired probe board. The method of repairing a probe card includes: in a board body composed of a sintered ceramic having first and second pillar surfaces disposed at a position opposed to each other, preparing the board body including a plurality of main channels for electrically connecting a first pad formed on the first pillar surface to a second pad formed on a second pillar surface and reserved channels disposed to be adjacent to the main channels to repair to damaged main channels; when the main channels are damaged; removing the first and second pads formed in the main channels and the reserved channels; forming cavities by partially removing the board between the damaged main channels and the reserved channels adjacent to the main channel; and forming repair connection parts in the cavities in order to electrically connect the damaged main channels to the reserved channels adjacent thereto.