# Patent

## Title
Circuit board testing using a probe

## Abstract

A test point of a circuit board is probed using an edge probe provided in a fixed orientation when the edge of the probe contacts a solder mound of the test point. The solder mound has an elongated shape. A length of the edge is substantially perpendicular to a length of the solder mound when the edge contacts the solder mound and is maintained in the fixed orientation.

## Background
PRIORITY
This application is a continuation-in-part of U.S. patent application Ser. No. 11/781,146 filed on Jul. 20, 2007 now U.S. Pat. No. 7,463,046 and entitled Arcuate Blade Probe, by Alexander Leon. U.S. patent application Ser. No. 11/781,146 is a divisional of U.S. Pat. No. 7,248,065 filed on Sep. 6, 2005. U.S. Pat. No. 7,248,065 is a continuation-in-part of U.S. patent application Ser. No. 11/112,279 filed on Apr. 22, 2005, which is now abandoned.


BACKGROUND
Printed circuit assemblies (PCA's), such as printed circuit boards (PCB's) that include electronic components soldered to the PCB, are used in a majority of electronic products. Those products include consumer electronics products such as personal computers, laptop computers, hard disc drives, cell phones, personal digital assistants (PDA's), digital music players, and video display and playback systems, just to name a few. Contact repeatability failures during an in-circuit-test (ICT) of the PCA's is one factor that effects a manufacturing cost and a reliability of electronic products.
The contact repeatability failures are due to probes (also called plungers) that are connected with a test fixture that is positioned relative to the PCA so that a tip of the probe contacts a test point on the PCA. Typically, the test point is a test pad, a through hole via, or a blind via connected with the PCA. For economic and environmental reasons, a no-clean manufacturing process is preferred to assemble PCAs during which paste is applied to test vias or test pads with a lead-based or lead-free solder paste. After the pasting, the solder paste is heated to reflow the solder paste so that a solder component of the paste wets a pad surface of the via or test pad. The reflowing also causes a flux component of the paste to be released. The resulting flux pools in the via holes or in an areas surrounding the test via pads can result in the aforementioned contact repeatability failures by preventing the test probe from making electrical contact with the via.
For example, in the case of a via, during reflow, a portion of the solder wets a pad of the via and another portion of the solder flows into a hole of the via and partially or completely fills the hole. Additionally, the flux also flows into the hole and pools on top of the solder. As a result, the hole is clogged by the flux/solder and the clog can be partially recessed below a level of the pad, can be flush with the pad, or can extend above the level of the pad. During ICT when the probe on the test fixture is urged into contact with the via in order to electrically contact the solder on the pad, a plunger tip of the probe cannot enter into the hole due to the clogging. Consequently, an electrical contact between the probe and the solder is prevented and the ICT may indicate that the unit-under-test (UUT) is defective because of a contact failure between the probe and the via. Examples of prior plunger tip styles that may not reliably contact the solder on the test point include single needle tips, headed and headless, chisel tips, spear tips, star tips, multi-sided arrowhead tips, and multi-pointed crown and tulip tips, just to name a few.
The economic impact of contact repeatability failures include passing bad boards, rejecting or discarding good boards, down time necessary to troubleshoot the test fixture or the UUT, increase warranty cost due to product failures in the field, unhappy consumers who purchase defective products, and loss of goodwill and brand loyalty due to defective products.
Prior solutions to the contact repeatability failures include not pasting the pads for lead-based processes that use a hot air solder leveling finish (HASL). finishes such as ENIG and electrolytic nickel-gold (Ni/Au) can be used, but those finishes increase production costs and risk some intermetallic reliability issues. Immersion silver (Ag) is not as costly as ENIG or electrolytic Ni/Au but can result in reliability issues, whisker growth and solderability issues. Similarly, an immersion tin (Sn) finish poses a high risk of whisker growth and reliability issues. Another solution is solder paste overprinting; however, the overprinting requires the use of microvias which create problems of their own and can result in solder bleeding to the other side of the PCB creating an obstruction for pasting and loading components on the opposite side of the PCB. Finally, one solution includes wave soldering the test points along with other through hole components on the PCB. However, wave soldering solution is not suitable for all applications.
Of all of the aforementioned solutions, an organic solderability preservative (OSP) finish is the lowest cost and currently most reliable finish. OSP's are applied to a bare surface of a conductor (e.g. a copper trace or pad) on a PCB. The OSP's are applied after the PCB is manufactured to prevent oxidation of the copper conductors while the PCB awaits the assembly process where the solder paste is applied, components are loaded on the PCB, and the PCB is reflowed. By preventing oxidation of the copper, the OSP's ensure the solderability of the PCB. In general, all test points (e.g. vias or test pads) are more probable (i.e. have better contact reliability) when pasted and then reflowed so that the solder wets the surface of the pad.
Screen printing with no-clean lead-free solder paste which has a higher flux content results in flux pools and contamination. Consequently, plunger tips with multiple points become clogged by the high no-clean flux residue of the solder. Moreover, the high no-clean flux residue contaminates the pad or via so that electrical continuity cannot be established between the plunger tip and the UUT. Plunger tips with multiple points or edges can exasperate the contact reliability problem because a contact pressure of the plunger tip with the pad is a force being applied by the tip (usually via a helical coil spring) divided by a contact area of the tip with the pad. The contact area increases with the number of points/edges in contact with the pad and reduces the contact pressure. As a result, a pressure necessary to cut through the contamination on the pad is reduced and the plunger tip does not make an electrical contact with the solder on the pad.
Consequently, there is a need for a probe that includes a tip that overcomes the problems created by OSP's and a no-clean high flux content solder pasting process. There is also a need for a probe tip that reduces the number of edges that come into contact with a solder on a pad so that contact pressure is not compromised, and that also minimizes the risk of making contact with adjacent circuits if misaligned.



BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 depicts a face view of an arcuate blade probe with an edge including an elliptical profile.
FIG. 2 depicts a face view of an arcuate blade probe with an edge including a circular profile.
FIG. 3a depicts a side angle view of an arcuate blade probe.
FIGS. 3b and 3c depict a face view and a side view respectively of an arcuate blade probe.
FIGS. 4a and 4b depict a face view and a side view respectively of a headed arcuate blade probe.
FIG. 5a depicts an edge end view of the arcuate blade probes depicted in FIGS. 1 and 2.
FIG. 5b depicts an edge view of the arcuate blade probe depicted in FIG. 4a. 
FIG. 5c depicts an edge view of the arcuate blade probe depicted in FIG. 3b. 
FIGS. 6a, 6b, 6c are side angle views depicting examples of a side angle view for an arcuate blade probe.
FIG. 6d depicts examples of an arcuate taper and an angular taper for a shaft of an arcuate blade probe.
FIGS. 7a and 7b are top plan and cross-sectional views respectively of a board substrate including a via and a test pad.
FIGS. 7c and 7d are top plan views depicting a pad of a via and a test pad respectively.
FIGS. 8a and 8b are top plan and cross-sectional views respectively of a stencil for applying a solder paste to a pad.
FIG. 9 is a cross-sectional view depicting a solder paste being applied to a pad of a via.
FIGS. 10a and 10b are top plan views depicting solder paste applied to a pad of a via and a test pad respectively.
FIGS. 11a and 11b are cross-sectional views of through hole vias including solder and flux plugging a hole of the via after a reflow process.
FIG. 11c is a cross-sectional view depicting a test pad with solder disposed thereon after a reflow process.
FIG. 11d depicts an edge end view of an arcuate blade probe with a tapered portion having a dimension that is smaller than a dimension of a shaft.
FIGS. 12a and 12b depict an edge face view and a side angle view respectively of an arcuate blade probe probing solder disposed on a pad of a via.
FIG. 12c depicts a test pad being probed by an arcuate blade probe.
FIGS. 13a and 13b depict an arcuate blade probe with two portions of an edge in contact with solder on a pad of a via.
FIG. 13c depicts an arcuate blade probe with one portion of an edge in contact with solder on a pad of a via.
FIGS. 14a and 14b depict an arcuate blade probe with one portion of an edge in contact with solder on a test pad.
FIG. 14c depicts a shaft of an arcuate blade probe that includes a plunger body and a plunger tail.
FIG. 14d is a cross-sectional view depicting a barrel and an arcuate blade probe positioned in the barrel.
FIG. 14e is a cross-sectional view depicting a barrel inserted into a receptacle.
FIGS. 15a and 15b are a top plan view and a cross-sectional view depicting a stencil including a pattern that includes a shield and a plurality of apertures.
FIG. 16a is a top plan view depicting a hole of a via and a first portion of a pad of the via covered by a shield of a pattern and a second portion of a pad covered by an aperture of the pattern.
FIG. 16b is a top plan view depicting dimensional relationships between a pattern and a via.
FIG. 17a is a cross-sectional view depicting an applying of a lead-free solder paste to a pad of a via through the apertures of a stencil.
FIG. 17b is a top plan view depicting a lead-free solder paste applied to a second portion of a pad of a via.
FIG. 17c is a top plan view depicting a lead-free solder connected with a second portion of a pad of a via after a reflowing process.
FIG. 18a is a top plan view depicting a preferred orientation of an edge of an arcuate blade probe relative to a lead-free solder on a pad of a via.
FIG. 18b is a top plan view depicting an alternative orientation of an edge of an arcuate blade probe relative to a lead-free solder on a pad of a via.
FIGS. 19a through 19c depict one example of a structure for connecting an arcuate blade probe with a barrel with an axis of an edge disposed in a preferred orientation.
FIG. 19d depicts one example of a structure for connecting a barrel with a receptacle with an axis of an edge disposed in a preferred orientation.
FIG. 20 is a top plan view depicting a receptacle connected with a test fixture with an axis of an edge of arcuate blade probe disposed in a preferred orientation.
FIG. 21 is a cross-sectional view of a test fixture aligned with a board substrate with an edge of an arcuate blade probe in contact with a node.
FIG. 22 is a top view of a solder mound formed on a trace.
FIG. 23 is a flow chart of a method for forming solder mounds.
FIG. 24 is a cross-section view across a width of a solder mound and trace and also shows a probe contacting the solder mound.
FIG. 25a is a cross-section view along a length of the solder mound and the trace shown in FIG. 24 and also shows the probe contacting the solder mound.
FIG. 25b shows axes for depicting a perpendicular orientation of a probe edge and elongated solder mound.
FIG. 26 is a top see-through view of a probe edge contacting a solder mound, and the probe edge is misaligned with the center of the solder mound.
FIG. 27 is a flow chart of a method for probing a test point.



DETAILED DESCRIPTION
In the following detailed description and in the several figures of the drawings, like elements are identified with like reference numerals.
As shown in the drawings for purpose of illustration, the present invention is embodied in an arcuate blade probe for probing a node of a circuit. The arcuate blade probe includes a shaft made from an electrically conductive material. The shaft includes a pair of faces that are symmetrically positioned about a probe axis in facing opposition to each other. The faces converge towards each other along the probe axis at a face angle and terminate at an edge. The edge includes an arcuate profile and the edge is aligned with the probe axis. When the edge and the node are urged into contact with each other, the edge makes a contact with the node along a portion or portions of the edge.
The arcuate blade probe makes contact with the node at any portion or portions along the edge when the probe and the node are urged into contact with each other. Pressure at the portions of contact is higher than if the edge was a straight edge. Additionally, the arcuate edge avoids the flux and contamination which prevents pointed tips from making contact with the node. The arcuate profile of the edge is useful for electrically probing a variety of node types, such as test pads, through hole vias, and blind vias that have been pasted with lead-based or lead-free solder.
The face angle and the contact pressure where the edge makes contact with the node allow the edge to penetrate contaminants that cover solder on the node so that a good electrical contact is made between the arcuate blade probe and the node. Moreover, the face angle and the arcuate profile reduce build up of contamination on the edge that can result in contact repeatability problems and down time for cleaning or replacing probes. Unlike prior plunger tips that include sharp points that contact the flux that plugs a hole of a via and therefore doesn't make an electrical contact with the node, the arcuate profile of the edge provides a surface without sharp protrusions so that one or two portions of the edge make contact only with the solder on the node.
a. An Arcuate Blade Probe
Referring to FIGS. 3a, 3b, 3c, 5a, and 6c an arcuate blade probe 10 includes a shaft 11 and a pair of faces 13 that are preferably symmetrically positioned about a probe axis AP. The faces 13 are positioned in facing opposition to each other and the faces 13 converge towards each other along the probe axis AP at a face angle θ and terminate at an edge 15. That is, the faces 13 converge to form a single edge 15. The edge 15 is preferably aligned with the probe axis AP so that in FIG. 6c the probe axis AP passes through a vertex where the two faces 13 converge at the edge 15. In FIG. 3b, the edge 15 includes an arcuate profile. The arcuate profile can include but is not limited to a circular profile, an elliptical profile, an oval profile, any curved function or a combination of any of these. In FIG. 3b, the arcuate profile is an elliptical profile because the profile of the edge 15 traces a portion of an ellipse as denoted by an elliptical dashed line 12e. 
The arcuate blade probe 10 can be made from an electrically conductive material including but not limited to brass, copper, beryllium copper, steel, stainless steel, aluminum, and titanium. Those materials may optionally be gold (Au) or other plated. The shaft 11 can have a circular cross-section as depicted in FIG. 5c, where the view is looking into the edge 15 with the probe axis AP pointing out of the drawing sheet. The arcuate profile of the edge 15 can span an entire diameter dS of the shaft 11 when the shaft 11 has the circular cross-section. An edge axis AE is colinear with the edge 15. The edge 15 has a width We, which can be the same as the diameter dS.
A section I-I of FIG. 3c is depicted in greater detail in FIG. 6c. The face angle θ will be application specific and will depend on several factors including but not limited to the diameter dS of the shaft 11, the type of node being probed (e.g. a via or a test pad), and the material of the shaft 11. Preferably, the face angle θ is in a range from about 10.0 degrees to about 35.0 degrees. The arcuate profile for the edge 15 and the face angle θ can be formed using manufacturing processes that are well understood in the probe art and include but are not limited to machining, milling, grinding, stamping, casting, molding, sharpening and polishing.
b. An Arcuate Blade Probe with a Tapered Shaft
Turning to FIGS. 1, 2, 3a, 5a, 6a, and 11d the shaft 11 can include a portion 11t that tapers (i.e. reduces in dimension) in a direction towards the edge 15. The portion 11t includes the faces 13 and the edge 15. In FIG. 6d, the tapering to portion 11t can include an arcuate profile (see dashed line 11c), an angular profile (see dashed line 11a), a stepped profile (not shown) or a combination of these (not shown). In FIG. 5a, the portion 11t is depicted in a view looking into the edge 15 with the probe axis AP pointing out of the drawing sheet. The taper of the portion 11t eventually blends into the faces 13 which in turn terminate at the edge 15. Although the shaft 11 is depicted having a circular cross-section, the portion 11t may include a circular cross-section like the shaft 11 or a non-circular cross-section. A section I-I of FIG. 3a is depicted in greater detail in FIG. 6a., where the face angle θ can be in the same range as was describe above. Moreover, the shaft 11 can be made from the same materials as set forth above. The taper in the portion 11t can be selected to reduce the dimension of the shaft 11 so that the arcuate blade probe 10 can be used to probe small vias or the like. The taper portion can also be stepped as shown in FIG. 11d. Preferably, the tapering of the shaft should be gradual, so that collection of residue is minimized by facilitating a self-cleaning action.
The arcuate profile of the edge 15 can have an elliptical profile (see 12e in FIG. 1) or a circular profile (see 12c in FIG. 2). Although not depicted in FIG. 1 or 2, the arcuate profile can also be an oval profile, or any combination of elliptical, circular, oval or other curved function profiles. Referring to FIG. 1, for the elliptical profile 12e, a major diameter d1 of the ellipse is preferably greater than the diameter dS of the shaft 11 and a minor diameter d2 of the ellipse may be less than, equal to, or greater than the diameter dS of the shaft 11. Similarly, in FIG. 2, a diameter dC of the circular profile 12c is preferably greater than the diameter dS of the shaft 11. Here, the edge width We, is shown to be the same as the diameter dS.
c. A Headed Arcuate Blade Probe
In FIGS. 4a, 4b, 5b, and 6b, the shaft 11 includes a head 17. The head 17 has a dimension dh that is greater than the dimension dS of the shaft 11. If the shaft 11 and the head 17 have circular cross-sections, then the dimensions ds and dh can be the diameters of the shaft 11 and the head 17 respectively. A portion of the head 17 tapers in a direction towards the edge 15 and the head 17 includes the faces 13 and the edge 15. The taper in a circular cross-section head (not shown) can have an arcuate profile, an angular profile, or a combination of arcuate and angular profiles as depicted in FIG. 6b and FIG. 6d). The edge 15 can include the circular, elliptical, and oval profiles, or any combination of curved profiles as previously described above. The head may also have a rectangular cross-section as depicted in FIGS. 4b and 5b with faces parallel to each other, which in turn taper on faces 13 towards the arcuate blade edge 15. In FIG. 5b, the dashed line for the shaft 11 depicts the smaller dimension dS of the shaft 11 relative to the dimension dH of the head 17. A section II-II of FIG. 4b is depicted in greater detail in FIG. 6c, where the face angle θ can be in the same range as was described above. Moreover, the shaft 11 and the head 17 can be made from the same materials as set forth above. The head 17 can be useful for probing nodes that are larger in dimension than the dimension dS of the shaft 11. The rectangular head 17 may be attached symmetrically on a common axis to the shaft 11 on one end, and forming the arcuate edge at the other end.
d. Probing of Nodes
In FIGS. 7a and 7b a substrate 21 includes nodes 100 and 200. The substrate 21 can be a printed circuit board (PCB) or a printed circuit assembly (PCA). The node 100 is a through hole via that includes a pad 120, a hole 130 with an interior surface 130s that terminates at a rim 130r and an exterior surface 115. Although not depicted, those skilled in the electronics art will appreciate that the interior and exterior surfaces (130s, 115) can be in contact with conductive traces positioned at various levels within a thickness t of the substrate 21. The node 200 is a test pad that includes a pad surface 200s. A conductive trace 225 is in contact with the node 200. One skilled in the electronics art will also appreciate that the nodes (100, 200) may be in electrical communication with components that are connected with the substrate 21 and that the electrical communication can be established through the aforementioned traces. The type of nodes that can be probed by the arcuate blade probe 10 are not limited to those depicted herein. For example, the node 100 can be a blind via in which the hole 130 does not extend through both sides (21t, 21b) of the substrate 21. Hereinafter, the node 100 will be referred to as the via 100 and the node 200 will be referred to as the test pad 200.
In FIG. 7c, the pad 120 of the via 100 includes a via diameter dV, a hole diameter dH, and a pad width WP as measured from an edge 120e of the pad 120 to the rim 130r of the hole 130. On the other hand, in FIG. 7d, the test pad 200 includes a width WT and a height HT. Those dimensions are relevant in determining the dimensions of the arcuate blade probe 10 that are suitable for probing a particular node.
For instance, it is preferable in the case of the via 100, that the dimension width We of the edge 15 be about that of the via diameter dV and always larger than the hole diameter dH by at least 10 mils and more preferably by 20 mils as an extra precaution to ensure that the edge 15 does not fit into the hole 130. Moreover, a finished hole size (FHS) of the diameter dH should be used as the starting point for determining how to appropriately size the dimension width We of the edge 15. Although vias can be made to any desired size, typical via sizes for through hole or blind vias found in current PCB's and PCA's can have a via diameter dV in a range from about 25 mils to about 50 mils and a FHS diameter dH in a range from about 10 mils to about 20 mils.
As one example, for a via 100 with a diameter dV of 40 mils and a FHS diameter dH of 18 mils, a suitable dimension width We of the edge 15 is in a range from about 28 mils to about 50 mils. As another example, for a via 100 with a diameter dV of 28 mils and a FHS diameter dH of 10 mils, a suitable dimension width We of the edge 15 is in a range from about 20 mils to about 40 mils. The above examples apply when the dimension for the edge 15 as measured along the edge 15 is dS (see dS in FIG. 5c). However, when the shaft 11 tapers to the portion 11t, it is possible for a length of the edge 15 to be less than dS as is depicted in FIG. 11d where a dimension dT of the portion 11t is less than the dimension dS. Therefore, the dimension dT should be selected so that it is greater than the FHS of the hole 130 by an appropriate amount (e.g. by 5 to 30 mils).
As yet another example, for a test pad 200 with a width WT of 50 mils and a height HT 50 mils, a suitable dimension We for the edge 15 would be in a range from about 30 mils to about 60 mils. As will be described below, after the test pad 200 is pasted and reflowed, the solder wetting the surface 200s may not cover the entire surface 200s; therefore, selecting the dimension We to be about or equal to the smaller of WT or HT will ensure that the edge 15 is sufficiently wide along the edge axis AE to probe the solder.
Referring to FIGS. 8a through 11c, one skilled in the electronics art will appreciate that vias, test pads, and the like are screen printed through a stencil with a solder paste to print the paste on the pads in preparation for a solder reflowing process. Accordingly, in FIGS. 8a and 8b a stencil 70 includes an aperture 71 that has a diameter dA that is sized to approximately the diameter dV of the via 100 or to be approximately the dimensions WT and/or HT of the test pad 200. In FIG. 9, the stencil 70 is positioned in contact with the substrate 21 so that the aperture 71 is positioned over the pad 120 of the via 100 and a solder paste 60 is printed on the pad 120 using a blade 69 that moves M across the stencil 70 to squeeze S the solder paste 60 through the aperture 71 and onto the pad 120. The solder paste 60 can be a lead-based solder paste or a lead-free solder paste. After the pasting process, in FIGS. 10a and 10b, the pad 120 of the via 100 is covered with the solder paste 60 and a portion of the surface 200s of the test pad 200 is covered with the paste 60. Heat H is applied to the paste 60 to reflow the paste so that a solder component of the paste 60 wets the pad 120 or the surface 200s. A flux component of the paste is also released by the reflowing process.
After the reflowing, in FIGS. 11a and 11b, a solder 60s from the paste 60 wets the pad 120 and a portion of the solder 60s flows into the hole 130 and partially fills up the hole 130. Additionally, a flux 60f released by the reflowing process, pools on top of the solder 60s. The flux 60f may be flush with the rim 130r as shown in FIG. 11b, be recessed below the rim (not shown), or may extend above the rim 130r as depicted in FIG. 11a. The solder 60s may wet the pad 120 all the way to its edge (see FIG. 11a) or the solder 60s may be inset from the edge (see FIG. 11b). For the test pad 200, the result of reflowing is that the solder 60s wets the surface 200s, but because there is no hole 130 to fill up, excess solder 60s and flux 60f flow off of the surface 200s and onto an area surrounding the test pad 200 on the substrate 21. The excess solder 60s and flux 60f can accumulate in quantities sufficient to make contact with prior plunger tips and can result in the tip becoming contaminated and can block contact between the tip and the solder 60s on the surface 200s. In either case, contact reliability can be compromised.
For the aforementioned prior plunger tips that rely on the tip to penetrate into the hole 130 so that a surface of the plunger tip can contact the solder 60s of the via 100, the plugging up of the hole 130 by the solder 60s and the flux 60f can lead to contact reliability problems because the tip cannot penetrate into the flux 60f in the hole 130; therefore, the surfaces of the plunger tip cannot make contact with the solder 60s on the rim 130r. As a result, there is no electrical continuity between the prior probe and the node to be probed. Moreover, repeated contact between the plunger tip and the flux 60f can cause the flux 60f to accumulate on the plunger tip and contaminate the tip. The contamination can act like an insulating material that prevents electrical communication between the prior probe and the via 100.
In FIGS. 12a through 12c, the arcuate profile of the edge 15 of the arcuate blade probe 10 can contact the solder 60s on the pad 120 or the surface 200s without being disturbed by pooled flux 60f and solder 60s in the hole 130 or by excess solder 60s and flux 60f that accumulate around the test pad 200, or the via 100.
e. Contact between the Edge and the Node
In FIG. 13a, a contact between the edge 15 and the solder 60s on the pad 120 of the via 100 is depicted in greater detail. The solder 60s wets the pad 120 and abuts with the rim 130r of the hole 130. Additionally, solder 60s and flux 60f plug the hole 130. When the arcuate blade probe 10 and the via 100 are urged into contact with each other, the edge 15 makes a contact C with the solder 60s at two portions along the edge 15 such that the arcuate blade probe 10 and the via 100 are in electrical communication with each other. Even though the flux 60f extends outward of the hole 130 and above the rim 130r, the arcuate profile of the edge 15 doesn't make contact with the flux 60f. Consequently, a potential for the flux 60f to accumulate on the edge 15 or the faces 13 is significantly reduced; thereby, reducing one possible source of contact reliability failure for the arcuate blade probe 10. This can be further ensured if the printed paste to the hole volume ration is kept below a certain ratio. For example, for lead free-solder, the solder to hole volume ratio is kept to 30% or less after reflow.
Referring now to FIG. 13b, the contact C between the edge 15 and the solder 60s can occur at two portions along the edge 15 even when the solder 60s is inset from the edge of the pad 120 by a distance di. The point of contact C along the edge 15 is slightly further out than was the case where the solder 60s extended all the way to the rim 130r in FIG. 13a. Therefore, another advantage to the arcuate blade probe 10 is that a reliable electrical connection between the node and the edge 15 can be made even when the solder 60s does not wet an entirety of the pad 120 and/or does not extend all the way to the rim 130r, or edge of the pad 120.
In FIG. 13a, the probe axis AP and a via axis AV are aligned with each other such that the arcuate blade probe 10 is substantially centered on a bore of the hole 130 of the via 100. In contrast, in FIG. 13c, the axes (AP, AV) are not aligned with each other and the probe axis AP is offset to the right of the via axis AV by a distance dO. However, even with the axes non-aligned, the edge 15 makes a contact C with the solder 60s at one portion along the edge 15 such that the arcuate blade probe 10 and the via 100 are in electrical communication with each other even though another portion of the edge 15 is not in contact with the solder 60s (see NC in FIG. 13c).
The blade probe 10 can also compensate if the misalignment is not along the edge 15 of the blades. For example, if the misalignment is perpendicular to the edge of the blade probe 10, the edge 15 makes contact at two points which are increasingly closer to each other until the blade is tangential to the rim of the via 100. At that point the blade still makes contact across the width of the flange.
FIGS. 13a-c also show how the blade probe 10 and the edge 13 can be used in a method for probing a node of a circuit wherein the node has a pad surface surrounding a node hole. The blade probe 10 with the edge 13 is urged in a direction generally parallel to the longitudinal probe axis to make contact C with the solder 60s on the surface of the pad 120. The contact C creates at least one electrical contact point between solder 60s and the edge 11, thereby establishing electrical coupling above the hole between the probe blade and the node through the at least one electrical contact point.
Note that the solder 60s rises above the elevation of the hole. Consequently, a potential for the flux 60f to accumulate on the edge 15 or the faces 13 is significantly reduced; thereby, reducing one possible source of contact reliability failure for the arcuate blade probe 10. Thus, once contact C is achieved, the node can be electrically evaluated, and the evaluation of the node is performed without the edge 15 penetrating the hole 130 and contacting the flux 60f or any solder in the hole 130. Also, note that the length of the edge 15 is greater than the diameter of the hole 130 to further prevent the edge 15 from entering the hole 130 and contacting the flux 60f. 
The probe 10 can be aligned along the longitudinal probe axis with the solder 60s disposed upon the pad 120. Also, the edge 15 can be disposed apart from an approximate center of the hole 130 when the electrical contact point is made., such as shown in FIG. 13c. 
Also, the solder 60s can have a distal ridge defining a second plane above a first plane where the hole 130 lies. The contact C between the edge 15 and solder 60s is proximate to the second plane. The contact C between the edge 15 and the solder 60s can occur along a slope that is generally transverse to the second plane.
Turning now to FIGS. 14a and 14b, in the case of the test pad 200, the edge 15 makes a contact C with the solder 60s when the probe axis AP and a node axis AN are aligned with each other as depicted in FIG. 14a. However, the contact C with the solder 60s is also made when the probe axis AP and the node axis AN are not aligned with each other as depicted in FIG. 14b, where the probe axis AP is offset to the right of the node axis AN by a distance dO. Therefore, the arcuate profile of the edge 15 allows for some misalignment error between the node to be probed and the arcuate blade probe 10 while still effectuating an electrical connection with the solder 60s connected with the node. Misalignment perpendicular to the edge 15 will also work.
f. Plunger, Barrels, and Receptacles
The probe shaft 11 can be shaped to be received and retained in a barrel as is well understood in the electronics art. Accordingly, in FIG. 14c, the shaft 11 can include a plunger body 11r that includes a dimension dR that is less than the dimension dS of the shaft 11. If the shaft 11 is circular in cross-section, then the dimension dR can be a reduced diameter section of the shaft 11. The shaft 11 also includes a plunger tail 11p that is connected with the plunger body 11r. The plunger tail 11p can include a portion 11f that is adapted to engage a spring as will be described below.
In FIG. 14d, a barrel 72 includes a cavity 78 adapted to receive the shaft 11 and a spring 76 positioned in the cavity 78 and in contact with the plunger tail 11p. The barrel 72 also includes a structure 74 that retains the shaft 11 in the cavity 78 with the spring 76 compressed and in contact with the plunger tail 11p. There are several means for implementing the structure 74. For example, the shaft 11 can be inserted into the cavity 78 to compress the spring 76 and the barrel 72 can be intentionally deformed (i.e. crimped) so that the structure 74 reduces a dimension dB of the barrel 72 in the region proximate the plunger body 11r so that the plunger tail 11p is in contact with and is captured by the structure 74 and the shaft 11 is retained in the barrel with the spring 76 in compression and in contact with the plunger tail 11p. The portion 11f can be flat in order to provide a planar surface for the spring 76 to engage with. The dimension dB is selected so that the dimension dS of the shaft 11 will fit into the cavity 78 without binding and the shaft 11 can move up and down in the cavity 78 when the edge 15 is urged into contact with a node.
In FIG. 14e, a receptacle 90 includes a cavity 92 adapted to receive the barrel 72. The receptacle 90 can include a structure 94 that retains the barrel 72 in the cavity 92. As one example, the structure 94 can be a dimple that extends into the cavity 92 and provides a friction fit between the barrel 72 and the receptacle 90 so that the barrel 72 is retained in the cavity 92 but can be removed by applying a force sufficient to pull the barrel 72 out of the receptacle 90. The friction fit can also be used to rotate the barrel 72 in the receptacle 90 so that the edge 15 has a preferred orientation with respect to an axis of a node to be probe by the arcuate blade probe 10 as will be described below. The receptacle 90 is adapted to be connected with a test fixture (not shown). The test fixture can be of the kind used for ICT of PCB's and PCA's. A structure 98 on the receptacle 90 can be used to retain the receptacle 90 in a bore of the test fixture that is adapted to receive the receptacle 90. For example, the structure 98 can provide a friction fit between the bore and the receptacle 90. Moreover, the friction fit can be used to position the edge 15 in the aforementioned preferred orientation by rotating the receptacle 90 in the bore, for example. A section 96 of the receptacle 90 can be used to facilitate a connection of a wire (not shown) to the receptacle 90. The connection of the wire to the section 96 can be accomplished by crimping, wire wrapping, or soldering, for example.
g. Fabricating a Butterfly Pattern of a Lead-Free Solder
Because many countries are mandating by law, the elimination of lead-based solder from electronic products, many manufactures are turning to lead-free solder in the production of the PCB's and PCA's. However, the move to lead-free solder has problems of its own. Particularly, the higher solids content of the flux used in lead-free solder formulations. Essentially, a lead-free solder paste is reflowed and a higher volume of the flux component of the lead-free solder paste flows into the hole 130 of the via 100 and causes the aforementioned plugging of the hole 130.
One solution to the problems associated with the use of lead-free solder paste is to not over paste the pad 120 of the via 100. Typically, the aperture 71 of the stencil 70 has the diameter dR selected so that the solder paste 60 is applied to an entire surface area of the pad 120 so that the pad 120 is pasted at a ratio of 1:1 or greater than 1:1 (see FIG. 10a). The over pasting of the pad 120 places more solder 60s on the pad 120 than is necessary to effectuate a probing of the pad 120 and results in excess flux 60f flowing into the hole 130 and contributing to the plugging up of the hole 130.
Reference is now made to FIGS. 15a and 15b, where a stencil 50 includes a pattern 30 with a plurality of apertures 31 and a shield 33. The apertures 31 extend between a top surface 51t and a bottom surface 51b of the shield 50. Although the shield 33 is depicted in hashed outline, the shield 33 can be made from the same material as the stencil 50 and the apertures 31 can be formed using a process such as stamping, cutting, punching, laser cutting, or perforating, for example. An edge 31e of the apertures 31 that are adjacent to the shield 33 may be aligned with the rim 130r in the hole 130 as will be described below. The stencil 50 can be made from the same materials that are customarily used for forming stencils for the printing of a lead-free solder paste on the vias and pads of a PCB or a PCA. The stencil 50 may also include one or more fiducial marks 32 that may be used to facilitate aligning the stencil 50 with the substrate 21 as will be described below.
The shapes of the apertures 31 and the shield 33 will be application specific and are not limited to the rectangular shapes depicted herein. Factors that can determine the shape of the apertures 31 and the shield 33 include but are not limited to a shape of the pad 120, the diameter dV of the via 100, the diameter dH of the hole 130, a surface finish on the pad 120, and a composition of the lead-free solder paste to be printed on the pad 120. A shape of the apertures 31 can include but is not limited to a rectangular shape, an arcuate shape, an angular shape, and a complex shape. Similarly, a shape of the shield 33 can include but is not limited to a rectangular shape, an arcuate shape, an angular shape, and a complex shape. For the discussion that follows, the apertures 31 and the shield 33 will have a rectangular shape.
In FIGS. 15b, 16a, and 16b, the shield 33 can have a width WS that is selected so that when the stencil 50 and the substrate 21 are aligned with each other and are positioned in contact with each other, the shield 33 will be positioned over the hole 130 and the width WS of the shield 33 will cover the hole 130 and a first portion 1p of the pad 120 as depicted in a dashed outline of the shield 33 in FIG. 16a. Similarly, the apertures 31 can have a width WA that is selected so that the apertures 31 are positioned over a second portion 2p of the pad 120 when the substrate 21 and the stencil 50 are aligned and in contact with each other as depicted by the dashed outline of the apertures 31 in FIG. 16a. In FIGS. 16a and 16b, the dashed outlines of the shield 33 and the apertures 31 depict a top view of a relative position of the pattern 30 and the via 100 when the stencil 50 and the substrate 21 are properly aligned with each other and are in contact with each other.
In FIG. 16b, the width WA of the apertures 31 can be selected so that the width WA is greater than, less than, or equal to the width WP of the pad 120. Similarly, a height HA of the apertures 31 can be selected so that the height HA it is greater than, less than, or equal to the diameter dV of the via 100. The width WS of the shield 33 can be selected so that the width WS is greater than or equal to the diameter dV of the hole 130. The width WS of the shield 33 should be selected to ensure that a lead-free solder paste that is applied to the stencil 50 does not enter into the hole 130. Preferably, WA and HA are as small as allowable to permit good paste transfer and still wet the rim 130r of the via hole 130.
In FIG. 17a, the stencil 50 and the substrate 21 are urged into contact with each other and are in alignment A with each other so that the apertures 31 and the shield 33 are positioned over the pad 120 and the hole 130 respectively as was depicted in FIGS. 15a and 15b. A blade 69 can be used to apply a lead-free solder paste 60 (paste 60 hereinafter) to the stencil 50 to print the paste 60 only on the second portion 2p of the pad 120. That is, the shield 33 prevents (i.e. blocks) the paste 60 from entering the hole 130 or from being printed on the first portion 1p of the pad 120. If the via 100 is a through hole via, then there may be pads 120 on both sides of the substrate 21. However, the paste 60 need only be applied to the pad 120 on a side of the via 100 that the via 100 will be probed from by the arcuate blade probe 10.
In FIG. 17b, after the paste 60 is printed on the second portion 2p of the pads 120, the stencil 50 is removed from the substrate 21. After the removing, the paste 60 remains on the second portion 2p. If the edges 31e of the apertures 31 were aligned with the rim 130r, then a portion of the paste 60 abuts with a portion of the rim 130r of the hole 13 as is depicted by the via 100 on a right side of the substrate 21. On the other hand, if the edges 31e were not aligned with the rim 130r, then the paste 60 can be inset from the rim 130r as is depicted on the via 100 on a left side of the substrate 21.
Subsequently, heat H is applied to reflow the paste 60. The process of heating a substrate, such as a PCB, for example, to reflow a lead-free solder paste is well understood in the electronics art. Accordingly, the reflowing can be accomplished by heating H the paste 60 and/or the substrate 21. During the reflowing, a flux 61 in the paste 60 drains through the hole 130 and a lead-free solder 62 (solder 62 hereinafter) in the paste 60 wets only a portion of a surface area of the pad 120 and remains on the pad 120. Unlike prior lead-free solder pasting processes where a pad of a via is pasted 1:1 or an entirety of the pad is over pasted (i.e. >1:1) by a lead-free solder paste, the reduced amount of the paste 60 results in a reduced amount of the solder 62 and a reduced amount of the flux 61. Therefore, very little or none of the solder 62 that wets the pad 120 flows into the hole 130. Consequently, the hole 130 is not filled up (i.e. is not plugged up) by the solder 62. Additionally, the reduced amount of the paste 60 also reduces the amount of the flux 61 so that a volume of the flux 61 that flows into the hole 130 during reflow is not sufficient to pool in the hole 130 thereby plugging the hole 130. Therefore, even if a small volume of the solder 62 flows into the hole 130 during the reflowing, that volume of solder 62 will not be sufficient to fill up the hole 130. As a result, the flux 61 that flows into the hole 130 does not have a foundation of solder 62 upon which to pool and the flux 61 does not reside at or near the rim 130r. Consequently, the hole 130 is not obstructed by the solder 62 or the flux 61 and can be probed during ICT.
In FIG. 17c, after the reflowing, the solder 62 wets (i.e. covers) and adheres to the pad 120. During the reflowing, depending on how close to the rim 130r the paste 60 was applied to the pad 120, as the solder 62 wets the pad 120 some of the solder 62 may abut with and partially encircle the rim 130r. If the paste 60 was inset from the rim 130r, then after reflowing, the solder may partially encircle the rim 130r but may not abut with the rim 130r. Moreover, a remainder of the solder 62 covers a portion of a surface area of the pad 120. That surface area can include some or all of the second portion 2p and some of the first portion 1p. Depending on an amount of the paste 60 that is printed on the pad 120, a composition of the paste 60, the pattern 30, and a position of the paste 60 on the pad 120, the solder 62 may extend all the way to the edge 120e of the pad 120 after the reflowing. The resulting pattern of solder 62 formed on the pad 120 resembles the wings of a butterfly and the solder 62 is symmetrically positioned around the hole 130. Additionally, a surface coating including but not limited to an organic solderability preservative (OSP) may be applied to the pad 120. Typically, the OSP is applied to the pad 120 during the manufacturing of the PCB or PCA and prior to the applying of the paste 60.
h. Probing a Butterfly Pattern of a Lead-Free Solder
In FIG. 18a, the solder 62 is symmetrically positioned around the hole 130 and on opposite sides of a node axis AN that symmetrically bisects that pad 120 through the first portion 1p. Preferably, when the via 100 is probed using the arcuate blade probe 10, the edge axis AE of the edge 15 has a preferred orientation Δ with respect to the node axis AN such that an angle between the edge axis AE and the node axis AN is substantially a right angle (i.e. Δ is 90 degrees). The edge 15 makes the contact C with the solder 62 at a first portion and a second portion. In FIG. 18a, the probe axis AP and the via axis AV are aligned. However, as was described above in reference to FIG. 13c, contact between the edge 15 and the solder 62 may still occur at a first portion when the probe axis AP and the via axis AV are not aligned. Moreover, as was described above in reference to FIG. 13b, when the solder 62 is inset from the rim 130r, the contact C may occur at the first portion and the second portion.
In FIG. 18b, even if the probe axis AP and the via axis AV are aligned, the edge 15 may be rotated out of a substantially perpendicular alignment with the node axis AN by an angle Δ1. For example, the angle Δ1 can be ∀ 15 degrees from the preferred orientation Δ. However, even when the preferred orientation Δ is not obtained, the edge 15 may contact the solder 62 at a first portion and a second portion.
In FIGS. 19a through 19d, depict examples of how the preferred orientation Δ can be obtained. In FIG. 19a, the shaft 11 can include a key 11k and the barrel 72 can include a slot 72s that complements a shape of the key 11k. In FIG. 19b, when the shaft 11 is inserted i into the barrel 72 with the key 11k aligned with the slot 72s, the edge axis AE has a set orientation relative to the barrel 72. Preferably, the key 11k is symmetrically positioned on the shaft 11 so that the shaft 11 moves in the barrel 72 without binding in the cavity 78 as is depicted in FIG. 19c (i.e. a cross-sectional view along a line I-I of FIG. 19b).
Similarly, the barrel 72 can include a key 72k and the receptacle 90 can include a slot 90s that complements a shape of the key 72k. When the barrel 72 is inserted into the cavity 92 with the key 72k aligned with the slot 90s, the edge axis AE has set orientation relative to the receptacle 90. Moreover, in FIG. 20, if the receptacle 90 is mounted to a test fixture 80 in a proper orientation, then the edge axis AE will have the preferred orientation Δ with respect to the node axis AN.
For example, the receptacle 90 can be inserted into a bore 80a in the test fixture 80 with the structure 98 providing a friction fit between the bore 80a and the receptacle 90. The receptacle 90 can then be rotated in the bore 80a to obtain the preferred orientation Δ of the edge axis AE. In FIG. 21, a set of pins 82 on the test fixture 80 can be inserted into apertures 22 on the substrate 21 to align A the test fixture 80 with the substrate 21 in preparation for ICT. The alignment A and the mounting of the receptacle 90 in the bore 80a, also aligns the arcuate blade probe 10 with the via 100 to be probed and positions the edge 15 in the preferred orientation Δ so that the edge axis AE and the node axis AN are substantially perpendicular to each other.
i. Correcting ICT Fixture Manufacturing Defects
The fixed (preferred) orientation of the arcuate blade probe 10 may also be used to correct for probe to target misalignments derived from ICT fixture defects. In this case, a fixed orientation probe may be used to improve contact repeatability with the test pads 120 or vias 100. Furthermore, a fixed orientation probe could also be embodied as non-symmetrical (not shown). In this case, when a shaft is misaligned with a node, the preferred orientation, non-symmetrical probe can be used to center the blade over the node. The preferred orientation may also be used to avoid contact with adjacent nodes, traces and components.
j. Solder Mounds Formed on a Circuit Board
FIG. 22 is a top view of a solder mound 300 formed on a trace. Unlike many of the embodiments described above showing a round solder mound on a substrate (such as the solder 60s shown in FIG. 10a), the solder mound 300, according to a new embodiment, has an elongated form. In at least one embodiment, solder mound 300 may be considered as an elongated solder mound 300 or linear solder mound 300. As shown in FIG. 22 the solder mound 300 has a length I and width w. Note that I>w, and thus the shape of the solder mound is elongated or in a rectangular-like shape. In one example, the length I may be in the range of about 30 to 35 mils inclusive and the width w may be 4 to 5 mils inclusive. 1 mil=0.0254 millimeters. The length and width may vary however. For example, the width w may be substantially the width of a trace contacting the solder mound 300, and the length I may be at least 4 to 8 times the width w. In one example, height of the solder mound 300 may be in the range of about 3.5 to 6 mils inclusive. It should be noted that as technology evolves, traces could be narrower, requiring lengths larger than 8 times the width, and if accuracy increases in fixtures, the length could be less than 4 times the width.
Moreover, round solder mounds such as 60s shown in FIG. 10a are structures provided for testing purposes, and in many instance are provided specifically to achieve a dedicated testing spot. As physical space upon the circuit board (i.e. PCA) is limited, incorporating dedicated testing areas may pose a design challenge. It is of course realized that the circuit upon the substrate has trace lines that serve an initial first function to provide conductivity between components. In at least one embodiment, solder mound 300 is formed upon an otherwise existing trace line. Moreover, solder mound 300 is formed over the trace line such that a testing location is advantageously provided upon an existing structure thereby advantageously saving area space upon the substrate. As is discussed below, conductive probes attached to a fixture contact the test points provided by solder mound(s) 300 to test signal transmission in the traces on the board.
FIG. 23 shows a flowchart of a method 400 for forming elongated solder mounds on a circuit board, according to an embodiment. The method 400 is described with respect to the solder mound 300 shown in FIG. 22 by way of example and limitation. Solder mounds with other elongated shapes may be used.
At step 401, the board is designed with solder mask openings along signal traces. For example, a trace having a 4 to 5 mils width may have a 30 to 35 mils solder mask opening along the traces length, thus exposing a portion of the trace along its length. FIG. 22 shows a solder mask opening 302 in a solder mask 301 on the board. The solder mask opening 302 is provided above a trace 303. A solder mask opening is provided for each test point on the board.
At step 402, solder paste is applied to the traces on the board by placing a preferred amount of the solder paste in each solder mask opening on the board. A properly calculated amount of solder paste is applied to form a solder mound having desired dimensions after reflow.
At step 403, after the solder paste is applied, the solder paste is heated to reflow the solder paste so that a solder component of the paste adheres to the trace. The reflowing also causes a flux component of the paste to be released. As a result of reflowing, the solder paste applied to each mask opening becomes an elongated solder mound, such as the solder mound 300 shown in FIG. 22. Examples of the dimensions of the elongated solder mound are described above.
k. Contact Between Probe Edge and Solder Mound Alleviating Misalignment
FIG. 24 is a cross-section view across a width of the solder mound 300 and across a width of the trace 303. FIG. 25a is a different cross section view of the solder mound 300. In particular, FIG. 25a is a cross-section view along the length of the solder mound 300 and the length of the trace 303, rather than the width of the solder mound 300 and trace 303. As shown in FIGS. 24 and 25a, the solder mound 300 is formed on the trace 303, and the trace 303 may be formed on the circuit board substrate 310 or another layer.
Also shown in FIGS. 24 and 25a is a probe 311 contacting the solder mound 300. The probe 311 is an edge probe. An edge probe is a probe that has an edge that contacts a test point, which is the solder mound 300 in this embodiment. An edge 312 of the probe 311 is formed by two surfaces or faces 313 and 314 of the probe 311 that converge or substantially converge to form the edge 312.
In one example, the probe 311 is the arcuate edge probe 10 having an edge 15, which is described in detail above. The view of the probe 311 in FIG. 24 corresponds to the view of the arcuate edge probe 10 shown in FIG. 3b (face view), and the view of the probe 311 in FIG. 25a corresponds to the view of the arcuate edge probe 10 shown in FIG. 3c (side view).
In other examples, an edge 312 of the probe 311 is not curved like the edge 15 of the arcuate edge probe 10. In at least one alternative embodiment, the edge 312 may not be curved. Alternatively, in yet further embodiments, the edge 312 may have less of a curve or more of a curve than the edge 15 of the probe 10.
The length of the edge 312 of the probe 311 may be similar to or greater than the length of the solder mound 300. This helps in situations where the edge 312 is misaligned with the center of the solder mound 300 when the edge 312 contacts the solder mound, such as described below with respect to FIG. 26.
FIG. 25a partially shows a shaft upper portion of the probe 311. The shaft upper portion may have a shape other than shown in FIG. 25a, such as described with respect to FIGS. 6a-d. 
According to an embodiment, a preferred orientation of the edge 312 is such that the edge 312 along its length is transverse, if not substantially perpendicular to the elongated solder mound 300 along its length. This is shown in the different cross-sections represented in FIGS. 24 and 25a. An axis 320 is shown along a length of the edge 312 in FIG. 24. An axis 321 is shown along a length of the solder mound 300 in FIG. 25a. The axis 320 and the axis 321 are perpendicular or substantially perpendicular. This helps in situations where the edge 312 is misaligned with the center of the solder mound 300 when the edge 312 contacts the solder mound, such as described below with respect to FIG. 26.
The perpendicular arrangement of the axes 320 and 321 is also shown in FIG. 25b. FIG. 25b shows a top view of the axes 320 and 321 corresponding to the cross-section view shown in FIG. 25a. The angle α may be in a range from about 75 degrees to about 105 degrees. However, it is preferable for a to be about 90 degrees with a tolerance of plus or minus 5 degrees or plus or minus 10 degrees.
FIG. 26 shows a top see-through view of a probe edge in contact with a solder mound. The dashed lines indicate features that would be hidden by the probe shaft or barrel in this view.
FIG. 26 shows two situations comprised of (1) when the edge 312 of the probe 311 is aligned with the center of the solder mound 300 when making contact with the solder mound 300, and (2) when the edge 312 is misaligned with the solder mound 300. Even when the edge 312 contacts the solder mound 300 in close proximity to an end of the solder mound 300 rather than in close proximity to the center solder mound 300, the edge 312 is still able to make sufficient contact with the solder mound 300 to establish a conductive electrical connection with the solder mound 300 to test the trace 303. Note that the misalignment may be in either direction along either of the axes 320 and 321. As shown in FIG. 26, the edge 312 may be misaligned along the axis 321 and be closer to an edge of the solder mound 300 rather than the center. Also, the edge 312 may be misaligned along the axis 320. For example, in the shown misalignment, the edge 312 does not contact the entire width of the solder mound 300, but the contact may still be sufficient to establish the electrical connection between the probe 311 and the solder mound 300.
The perpendicular arrangement of the edge 312 to the length of the solder mound 300 allows for the electrical connection between the probe 311 and the solder mound 300 to be formed even when there is misalignment. Misalignment commonly occurs as a result of misaligned fixtures holding probes and boards. The perpendicular arrangement of the edge 312 and the solder mound 300 allows boards to be tested even in situations where there is misalignment.
It should be noted that the probe makes contact with a solder covered copper surface, i.e., the solder mound 300 on the test target, and avoids the flux contamination residue that typically accumulates in a via hole. This avoids the problems of the probe becoming contaminated or bogged down in the typical flux accumulation of vias, which can result in the probe failing to make contact with a test point. The blade may be of different shapes and profiles. In this embodiment, the probe edge is in a fixed orientation, e.g., substantially perpendicular to the elongation of the solder mound. However, in other embodiments, the probe may be in other orientations or “free wheeling”, and still avoid the problem of flux contamination.
FIG. 27 shows a flowchart of a method 500 for testing boards. The method 500 is described with respect to one or more of FIGS. 22-26 by way of example and not limitation.
At step 501, probes are attached to a fixture in a preferred and fixed orientation, such that the probe edges are substantially perpendicular to the length of the elongated solder mounds already formed on a board. The perpendicular orientation of the probe is shown in FIGS. 23-26. The solder mounds may have been formed on the board using the method 400 described above. Each elongated solder mound may be similar to the solder mound 300 described with respect to FIG. 22. The fixture is a testing fixture that is positioned relative to the board so that the edge of each probe in the fixture contacts a solder mound of a test point when the fixture is moved towards the board. Attaching probes to the testing fixture is described in detail above.
At step 502, the fixture having the probes in the fixed, preferred orientation in the fixture are urged towards the test points.
At step 503, the edges of the probes contact the solder mounds of the test points. This is shown in FIGS. 24, 25a and 26. Because of the fixed, preferred orientation of the edges, an electrical connection can be formed between the probes and the traces below the solder mounds even when there is misalignment.
A probe edge makes contact with a solder mound at any portion along the edge and at any point along the solder mound when the probe and the solder mound are urged into contact with each other. The edge of the probe makes the probe self-cleaning, as opposed to a flat face probe which has a substantially larger and flat surface contacting the solder mound. Any flux build-up on the edge from previous use is pushed off the edge as the edge makes contact with the solder mound, thus making the edge self-cleaning. For a flat face probe, the flux and contaminations builds-up on the surface of the probe contacting the solder. These contaminants can result in the ability to form an electrical connection between the probe and the trace.
When the probe edge contacts the solder mound, the probe edge penetrates into the solder mound. Sufficient force is provided to allow for the probe edge to penetrate a desired distance into the solder mound, but not too deep as to damage the trace. The probe force to be applied is calculated accordingly. Probe force can be reduced inversely with the sharpness of the edge when calculating the appropriate probe force to apply. Thus, the edge probe exerts much less force on the board being tested than a flat face probe.
At step 504, after the probes make contact with the solder mounds, the board is tested using the probes. The probes are conductive and may be used to test the conductivity of the traces on the board. This is referred to electrically evaluating the traces at the test points. The probes may also be used to test circuit functionality or measure component parameters such as voltage, resistance, capacitance, etc.
At step 505, the probes are extracted from the solder mounds, and the extraction reveals an indentation in the solder mounds. Then, the probes may be used for testing the next board.
Although several embodiments of the present invention have been disclosed and illustrated, the invention is not limited to the specific forms or arrangements of parts so described and illustrated. The invention is only limited by the claims.

## Claims

1. A method of probing a test point, the method comprising:
affixing a probe in a fixed orientation in a fixture, and the probe comprises an edge;
urging the probe in the fixture towards a solder mound, wherein the solder mound has an elongated shape;
contacting the edge of the probe with the solder mound while maintaining the fixed orientation of the probe, wherein a length of the edge is substantially perpendicular to a length of the solder mound when the edge contacts the solder mound; and
the edge penetrating an upper surface of the solder mound to provide for an electrical connection between a trace connected to the solder mound and the probe.

2. The method of claim 1, wherein the elongated mound is upon a signal trace having an initial first function to provide conductivity between components.

3. The method of claim 1, wherein the length of the edge being substantially perpendicular to the length of the solder mound when the edge contacts the solder mound further comprises:
a first axis running along the length of the edge and a second axis running along the length of the solder mound forming an angle in a range of 75 to 105 degrees inclusive when the edge contacts the solder mound.

4. The method of claim 3, wherein the edge is misaligned with a center of the solder mound when the edge contacts the solder mound.

5. The method of claim 4, wherein the misaligned edge is substantially closer to an end of the solder mound rather than the center of the solder mound when the edge contacts the solder mound.

6. The method of claim 3, wherein the length of the edge of the blade is in a range of 30 to 35 mils, inclusive.

7. The method of claim 3, wherein the length of the solder mound is in a range of 30 to 35 mils, inclusive.

8. The method of claim 3, wherein a height of the solder mound is in a range of 3.5 to 6 mils, inclusive.

9. The method of claim 1, wherein the edge penetrating an upper surface of the solder mound to provide for an electrical connection between a trace connected to the solder mound and the probe further comprises:
penetrating the upper surface causing the edge to be cleaned of flux or contaminants formed on the edge from the edge previously penetrating one or more other solder mounds.

10. The method of claim 1, further comprising:
forming the solder mound in an elongated solder mask trace opening on the board by the following:
applying solder in the mask trace opening and on the trace; and
reflowing the board to form the solder mound in an elongated shape having a length greater than its width.

11. The method of claim 1, further comprising:
electrically evaluating the trace using the probe in contact with the solder mound; and
extracting the probe from the solder mound, the extraction revealing an indentation.

12. The method of claim 1, further comprising:
applying force to urge the probe towards the solder mound, and the amount of force applied is determined as a function of a sharpness of the edge and an inverse relationship of amount of force needed versus sharpness of the edge.

13. The method of claim 1, wherein affixing the probe to a fixture further comprises:
providing a shaft of the probe in a barrel, wherein movement of the shaft in the barrel along a probe axis is permitted;
affixing the barrel to the fixture; and
aligning the barrel and the shaft with each other so that the edge is disposed in the fixed, preferred orientation when the shaft is positioned in the barrel.

14. A method of using a blade probe to probe a test point of a circuit, the method comprising:
providing a probe having an edge;
urging the probe towards the test point, wherein the test point includes an elongated solder mound having a length greater than its width;
maintaining the edge of the probe in a fixed orientation while the edge contacts the solder mound, wherein a first axis running along a length of the edge and a second axis running along the length of the solder mound forms substantially a ninety degree angle in the fixed orientation; and
electrically evaluating the circuit at the test point when the edge is in contact with the solder mound.

15. The method of claim 14, further comprising:
providing a shaft of the probe in a barrel, wherein movement of the shaft in the barrel along a probe axis is permitted; and
aligning the barrel and the shaft with each other so that the edge is disposed in the fixed orientation when the shaft is positioned in the barrel.

16. The method of claim 14, wherein the elongated mound is upon a signal trace having an initial first function to provide conductivity between components.

17. The method of claim 16, wherein the elongated mound provides a test point without requiring additional area space upon the circuit board.

18. A method of probing a test point, the method comprising:
affixing a probe in a fixed orientation in a fixture, and the probe comprises an edge;
urging the probe in the fixture towards a solder mound, wherein the solder mound has an elongated shape;
contacting the edge of the probe with the solder mound while maintaining the fixed orientation of the probe,
wherein a length of the edge is substantially perpendicular to a length of the solder mound when the edge contacts the solder mound, and
wherein the edge contacts an end of the solder mound along its length and the edge contacts only a portion of a width of the solder mound; and

the edge penetrating an upper surface of the solder mound to form an electrical connection between a trace connected to the solder mound and the probe.

19. The method of claim 18, wherein the elongated mound is upon a signal trace having an initial first function to provide conductivity between components.

20. The method of claim 19, wherein the elongated mound provides a test point without requiring additional area space upon the circuit board.

21. A method of using a blade probe for probing a node of a circuit, the node having a pad surface surrounding a node hole, the method comprising:
providing a probe having:
a longitudinal probe axis;
a shaft generally concentric to the longitudinal probe axis, the shaft comprising an electrically conductive material; and
a probe blade disposed at a first end of the shaft and including first and second faces positioned about the longitudinal probe axis in facing opposition to each other, the first and second faces converging towards each other and terminating at an edge;

urging the probe in a direction generally parallel to the longitudinal probe axis to create at least one electrical contact point between solder disposed on a pad surface of a node and rising above the elevation of the hole and the edge of the probe blade thereby establishing electrical coupling above the hole between the probe blade and the node through the at least one electrical contact point; and
electrically evaluating the node, the evaluation of the node performed without the edge of the probe blade penetrating the node hole.

22. The method of claim 21, wherein the evaluation of the node is performed without the edge of the probe blade contacting solder disposed within the node hole.

23. The method of claim 21, wherein the evaluation of the node is performed without the edge of the probe blade penetrating flux residue disposed within the node hole.

24. The method of claim 21, further comprising aligning the longitudinal probe axis with the solder disposed upon the pad about the node hole.

25. The method of claim 21, further comprising aligning the probe edge to be disposed apart from an approximate center of the node hole when the at least one electrical contact point is made.

26. The method of claim 21, wherein the node hole lies in a first plane, the solder upon the pad rising having a distal ridge defining a second plane above the first plane, the at least one electrical contact between the edge of the probe blade and solder being proximate to the second plane.

27. The method of claim 26, wherein the contact between the edge of the probe blade and the solder occurs along a slope that is generally transverse to the second plane.

28. The method of claim 21, wherein providing a probe having a probe blade comprises providing a probe blade having an edge defined by an arcuate profile.

29. The method of claim 21, wherein a length of the probe edge is greater than a diameter of the hole.

30. A method of using a blade probe for probing a node of a circuit, the node having a pad surface surrounding a node hole, the method comprising:
providing a probe having:
a longitudinal probe axis;
a shaft generally concentric to the longitudinal probe axis, the shaft comprising an electrically conductive material; and
a probe blade disposed at a first end of the shaft and including first and second faces positioned about the longitudinal probe axis in facing opposition to each other, the first and second faces converging towards each other and terminating at an edge;

providing a node of a circuit; the node having:
a hole disposed through a first plane and a rim surrounding the hole in the first plane;
at least one area of solder disposed upon the rim, the solder extending generally transverse to the first plane away from the hole; and
a distal ridge of the solder defining a second plane above the first plane;

urging the probe in a direction generally parallel to the longitudinal probe axis to create at least one electrical contact point between solder adjacent to the second plane and the edge of the probe blade thereby establishing electrical coupling between the probe and the node through the at least one electrical contact point above the hole; and
electrically evaluating the node.

31. The method of claim 30, wherein the evaluation of the node is performed without the edge of the probe blade penetrating the node hole.

32. The method of claim 30, wherein the evaluation of the node is performed without the edge of the probe blade contacting solder disposed within the node hole.

33. The method of claim 30, wherein evaluation of the node is performed without the edge of the probe blade penetrating flux residue disposed within the node hole.

34. The method of claim 30, wherein providing a probe having a probe blade comprises providing a probe blade having an edge defined by an arcuate profile.

35. The method of claim 30, further comprising aligning the longitudinal probe axis with the solder disposed upon the rim about the node hole.

36. The method of claim 30, further comprising aligning the probe edge to be disposed apart from an approximate center of the node hole when the at least one electrical contact point is made.

37. The method of claim 30, wherein the contact between the edge of the probe blade and the solder occurs along a slope that is generally transverse to the second plane.

38. The method of claim 30, wherein a length of the probe edge is greater than a diameter of the hole.