Split PCB and Flex Interface for Native IC Testing

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Solution Overview

Problem

Existing methods for testing integrated circuits (ICs) installed in printed circuit boards (PCBs) are costly, labor-intensive, and disrupt the IC's natural environment, often causing signal integrity issues due to the use of sockets or adapters.

Innovation Solution

A unitary printed circuit board (PCB) is designed to be separated into a main board and a flexible PCB portion, allowing direct connection to the IC without additional hardware, using simple soldering and maintaining signal integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a socket or dedicated adapter is used to test ICs after installation, then testing can be performed, but the cost increases and the procedure becomes labor-intensive

Engineering Contradiction:

Improvetesting capabilityVSAvoidtesting procedure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The PCB is segmented into a main board and a flexible PCB portion that can be separated at a separation line. This allows the flexible PCB to be manipulated independently for testing purposes while the main board remains installed in the product, enabling testing without complex sockets or adapters

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible PCB acts as an intermediary between the installed IC on the main board and the testing equipment. It provides a mechanical interface that allows connection and disconnection for testing while maintaining the IC's installed state, eliminating the need for dedicated testing adapters

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a socket or adapter is used for testing, then IC functionality can be tested, but signal integrity issues arise

Engineering Contradiction:

Improvetesting capabilityVSAvoidsignal integrity

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

By separating the flexible PCB from the main board during testing and reconnecting afterward, the system maintains direct soldered connections throughout the testing process. The IC remains soldered to the main board which stays installed in the product, preserving signal integrity while enabling testing through the flexible PCB interface

Inventive Principle:

Principle #1Segmentation

3Reliability

If the IC is removed from the PCB for testing, then testing can be performed, but the IC cannot be inspected in its natural embedded environment

Engineering Contradiction:

Improvetesting capabilityVSAvoidinspection in native environment

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The PCB is divided into main board and flexible PCB portions that can be separated. The main board with the installed IC remains in the product allowing inspection in the natural embedded environment, while the flexible PCB can be manipulated for testing purposes

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flexible PCB serves as an intermediary that provides testing access without requiring removal of the IC from its installed position. The IC stays mounted on the main board which remains installed in the product, allowing both native environment inspection and testing through the flexible PCB interface

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If a socket or adapter is incorporated into the PCB for testing, then testing access is provided, but the size prevents installation of product covers

Engineering Contradiction:

Improvetesting accessVSAvoidPCB assembly size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

A flexible PCB is used instead of a rigid socket or adapter. The flexible PCB can be folded back or positioned to fit within the limited space available on the PCB assembly, providing testing access without increasing the overall volume enough to prevent cover installation

Inventive Principle:

Principle #30Flexible shells and thin films

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables cost-effective, efficient testing of ICs in their native environment with minimal disruption, preserving signal integrity and allowing testing under real-world conditions.

Implementation Method 1

reattaching the flexible PCB portion to the main board portion by soldering at least a portion of the through-holes of the flexible PCB portion to a corresponding at least a portion of the first plurality of pads

Methodology Applied

Scientific EffectSoldering: Soldering

Data Source

PatentUS12399214B2Systems, devices, and methods for testing integrated circuits in their native environments

Publication Date: 2025.08.26 SANDISK TECHNOLOGIES LLC

AI summary

Disclosed herein are unitary printed circuit boards (PCBs) and methods of using them for testing an integrated circuit (IC). In some embodiments, a unitary PCB comprises a main board portion and a flexible PCB portion, which are configured to be detached from each other at a separation location on the unitary PCB. The main board portion comprises a plurality of pads, and the flexible PCB portion comprises a plurality of through-holes, where a layout of the through-holes corresponds to a layout of the plurality of pads. In some embodiments, a method of testing an IC of a device comprises separating the unitary PCB into a main board portion and a flexible PCB portion, attaching the IC to the main board portion, soldering the main board portion to a platform PCB of the device, and attaching the flexible PCB portion to the main board portion.