Method and apparatus for layout independent test point placement on a printed circuit board

1. A method for implementing a test access point structure for a printed circuit board, the method comprising:

designing an optimal circuit board layout with at least one trace on an outer surface of the optimal circuit board layout;

determining a location along said trace for a test access point without disturbing the optimal circuit board layout;

manufacturing the optimal circuit board layout; and

conductively connecting the test access point to the trace without disturbing the optimal circuit board layout, the test access point comprising a deformable localized high point of solder along the trace of the printed circuit board and substantially the same width as the trace, the test access point projecting above an exposed surface of the printed circuit board to be accessible for probing by a test probe with a substantially flat contact tip.

2. The method according to claim 1 , wherein the step of conductively connecting said test access point to the trace comprises:

depositing a solder mask over the trace, the solder mask having a hole exposing a portion of the trace and running along an upper surface of the trace at a location for a test access point, the solder mask characterized by a substantially constant thickness;

placing a solder stencil mask over the solder mask, wherein the solder stencil mask has a hole slightly larger than the solder mask hole; and

conductively connecting a test access point structure to the exposed portion of the trace in the hole in the solder stencil over the hole in the solder mask.

3. A method in accordance with claim 2 , wherein the hole in the solder mask is substantially an obround hole.

4. A method in accordance with claim 2 , wherein:

the method of conductively connecting a test access point structure to the exposed portion of the trace in the hole of the solder mask comprises:

filling the hole in the solder stencil over the hole in the solder mask with solder paste, the solder paste comprising solder and flux; and

melting the solder paste to burn off the flux and to cause the solder to retract and form a solder bead that projects above the walls of the hole in the solder mask.

5. A method in accordance with claim 4 , wherein the hole in the solder stencil mask is substantially a square.

6. A method in accordance with claim 5 , wherein the substantially square hole in the solder stencil mask is layered over the substantially obround hole in the solder mask such that a diagonal of the substantially square hole runs along a length of the obround hole.

7. A method for implementing a test access point structure for a printed circuit board with an optimal circuit layout, the method comprising:

determining a location of a test access point along a trace of the printed circuit board having one or more printed circuit board layers with a predetermined thickness over the trace without disturbing the optimal circuit layout on the printed circuit board;

forming a hole in the one or more printed circuit board layers over the location of a test access point along the trace, exposing a portion of the trace; and

forming a deformable test access point structure electrically connected to the exposed portion of the trace, the deformable test access point structure comprising a localized high point of solder along the trace, substantially the same width as the trace, the deformable test access point structure being higher than a top surface of the printed circuit board enabling the deformable test access point structure to be probed by a probe having a substantially flat contact tip that is substantially wider than the deformable test access point structure.

8. The method of claim 7 , wherein the one or more printed circuit layers comprises a solder mask layer.

9. The method of claim 8 , wherein the hole in said one or more printed circuit board layers comprises an obround hole running along and exposing a portion of the trace thereunder.

10. The method of claim 9 , wherein the step of forming a test access point structure electrically connected to the exposed portion of the trace comprises:

filling the hole in the solder mask with solder paste, and

heating the solder paste causeing the solder to retract and form a deformable test access point that projects above top surface of the printed circuit board enabling the deformable test access point to be probed by a probe having a substantially flat contact tip that is substantially wider than the deformable test access point structure.