Decoupling capacitor for an integrated circuit and method of manufacturing thereof

A capacitor structure may be incorporated into an interposer or substrate associated with an IC chip to stabilize the input/output signals, such as power and ground, between the IC chip and a printed circuit board. In accordance with one embodiment, the capacitor structure may include a plurality of individual capacitors connected together to form a monolithic capacitor blade having a length, width, and height, wherein each of the length and height of the blade spans multiple of the individual capacitors. The blade includes multiple electrical conductive paths extending the height of the capacitor blade. According to another embodiment, the capacitor structure includes multiple interleaved power and ground layers separated by insulating layers. The power layers connect to power leads and the ground layers connect to ground leads.

FIELD OF THE INVENTION

The present invention relates to voltage supply stabilization and, in particular, to a decoupling capacitor arrangement, to integrated circuit devices that incorporate the decoupling capacitor arrangement, and to methods of manufacturing the foregoing.

BACKGROUND OF THE INVENTION

Integrated circuits or “ICs” are the electronic components that run computers, cell phones, and other equipment. ICs are usually mounted on printed circuit boards (PCBs) housed within the equipment. The PCBs have conductive traces that electrically connect together the ICs and permit connection to other components, such as displays, keyboards, speakers, microphones, etc. The ICs are often the electronic elements that control device operation.

ICs are characterized by their operating speed, which is often indicated using their clock rate. For example, computers may be advertised as having a 500 MHz Intel Pentium III microprocessor. The “500 MHz” designation indicates the clock rate of the Pentium III microprocessor, which is one type of IC. ICs are also characterized by their density, which represents the number of devices built into an IC chip of given dimensions, or by a measure that reflects relative density, such as line width or another critical dimension. Over time, new generations of ICs have become faster in operation and denser than previous generations. The trend is expected to continue for the foreseeable future.

IC packages have pins or leads that conduct address, control or data signals, power, ground, and possibly other inputs/outputs to and from the IC. As the number of electronic devices included in the IC increases, the power needed to operate the devices may also increase. Moreover, operating voltages have decreased in part due to an effort to prevent adjacent device structures from shorting. Operating voltages have decreased, launch voltages and noise budgets have also decreased. As voltages have decreased, the number of pins has increased to provide better signal integrity for both signals and power delivery. Consequently, future ICs are expected to have more input/output pins and operate at higher speeds.

FIGS. 1A and 1Billustrate how the performance of an IC can be affected by factors external to the IC. For example, a relationship exists between the voltage supply to an IC and its clock rate. IC supply voltage (sometimes referred to generally as “Vcc” herein) is commonly indicated as a constant, e.g., 1.5 V. In fact, the actual supply voltage fluctuates or varies to some degree over time and with the downstream load driven by the supply voltage. For example, load fluctuations may occur as the result of switching circuitry within the IC.FIGS. 1A and 1Bare graphs that plot maximum clock rate or frequency for a representative IC over possible voltage supply Vcc values for that IC. It is assumed that the IC voltage supply reaches a reliability wall at 1.65 V.

With respect toFIG. 1A, Vcc is assumed to vary over a range of ±100 mV. If the maximum voltage in the range is set at the reliability wall, then the nominal voltage Vccnom will be 1.55 V and the voltage supply will fluctuate between 1.45 V and 1.65 V. Because the minimum voltage is 1.45 V, the maximum clock rate in this example is 666 MHz.

FIG. 1Bshows that the maximum clock rate can be increased, yielding a faster device, simply by stabilizing the voltage supply. As shown inFIG. 1B, the supply voltage varies within a ±50 mV range. In this case, the nominal voltage supply Vccnom can be set to 1.60 V, with the voltage supply varying from 1.55 V to 1.65 V. The voltage supply minimum of 1.55 V corresponds to a maximum clock rate of 712 MHz, an increase of 46 MHz over the example ofFIG. 1A, achieved simply by stabilizing the voltage supply. Moreover, even higher clock rates can be achieved if the voltage supply is better stabilized.

The voltage supply can be stabilized using decoupling capacitors. As shown inFIG. 2, conventional PCBs often include rows of individual decoupling capacitors2surrounding an IC, such as a microprocessor. The decoupling capacitors2connect in the wiring lines or traces to the IC. The decoupling capacitors are useful from an electrical standpoint, but are far from ideal. For example, the individual capacitors take up too much space on the surface of the PCB, space that could be used by other components or that could be eliminated to achieve a reduction in size. In addition, the placement of the capacitors slows manufacture, leading to reduced manufacturing throughput and higher prices. Furthermore, the distance between the decoupling capacitors and the IC is not short enough. Reducing this distance would improve electrical performance. Moreover, as faster, more dense, lower voltage, higher pin count ICs are developed, these problems will become worse. More space will be required for the capacitors, larger capacitors will be required, and manufacturing will become more expensive.

SUMMARY OF THE INVENTION

The present invention relates to a platform that incorporates decoupling capacitors between an IC chip on one hand and a circuit board on the other hand. For example, decoupling capacitors may be provided in a semiconductor die package, thereby providing a decoupling capacitance between the an IC chip housed within the package and a printed circuit board on which the package is mounted. The decoupling capacitors are provided near the IC chip, yielding a lower inductive path and/or greater effective capacitance that helps to stabilize the supply voltage. This platform can enable, among other things, better supply voltage stability because the charge stored in the decoupling capacitors can offset variations. In particular, the present invention provides novel decoupling capacitor structures. These capacitor structures may be incorporated into the power and ground structures associated with an IC. For example, the decoupling capacitors can be provided in an interposer that mounts between an IC chip and substrate on one hand and the PCB on the other. In accordance with another embodiment, decoupling capacitors can be integrated into the substrate, such that the decoupling capacitors are provided between the IC chip and the PCB. In accordance with a further embodiment, the interposer having the novel decoupling capacitor structure may be adapted to connect to a socket attached to a PCB or other substrate. The structure of the decoupling capacitor may also serve as virtual pins, replacing pins that would otherwise be provided.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Reference will now be made in detail to the present exemplary embodiment(s) of the invention illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.

FIG. 3illustrates an exploded view of a first exemplary embodiment of a device arrangement10. The arrangement includes an IC chip or die100, substrate200, decoupling capacitor block300, electrically-conductive pins400, and main body500. Chip100may include semiconductor devices and circuitry embodying, for example, a microprocessor, microcomputer, application specific integrated circuit, digital signal processor, or other IC. Chip100mounts to substrate200and makes electrical connection thereto using, for example, bumps, a bumpless interface, tape automated bonding, jumpers, or wire bonds. WhileFIG. 3illustrates a single chip100, it should be appreciated that main body500may house multiple chips100.

The substrate200includes traces or wiring paths that couple a first set of landing pads on the first side of the substrate to a second set of landing pads on the second side of the substrate. The landing pads on the first side electrically connect to the chip100, e.g., directly or indirectly using solder, wire bonds, a conductive adhesive, etc. The landing pads on the second side electrically connect to the pins400and to the capacitor block300. Again, this connection may be direct or through a conductive medium, such as solder, a conductive adhesive, or other medium. The density of the first set of landing pads may be greater that the density of the second set.

FIG. 4illustrates a first embodiment of a decoupling capacitor block300. In this example, block300is made up of 16 capacitor blades310, each blade having 58 individual capacitors320. This example of block300provides 928 capacitors in a 15 mm×15 mm area. Of course, these values are intended as examples and other blocks can vary by the number of blades, the spacing of the blades, the number of capacitors per blade, and the size of the capacitors and blades to achieve a variety of capacitor values and sizes.

Some discrete capacitors are specified according to their length and width dimensions in hundredths of an inch. For example, a capacitor 0.04 inches long and 0.02 inches wide is commonly referred to as an 0402 capacitor. The example illustrated inFIG. 4uses 0402 capacitors. However, other capacitors, or combinations of capacitors, may be used.

Assuming each of the 0402 capacitors has a capacitance value of 0.22 μF, the total capacitance of the exemplary capacitor block is over 200 μF. The alternating 1 mm grid pattern results in approximately 14 pH of inductance. Of course, these values are intended to be exemplary and other values may be obtained using other arrangements and/or materials.

As shown inFIG. 4, each blade310may include multiple capacitors320stacked vertically and end-to-end. The capacitors320may be coupled together, for example, by soldering together the endcaps, as shown inFIG. 4. Of course, other mechanisms may be used to couple the capacitors together, such as a conductive adhesive, conductive springs, compression bonding, and welding, for example. When coupled together as shown inFIG. 4, the coupled endcaps of capacitors320may form multiple conductive paths312, each extending from the top to the bottom of the blade310. The conductive paths312form pin columns that can connect between the substrate200and the PCB on which the IC is mounted. More specifically, the upper portion of the conductive path312may connect to the landing pads on the bottom of substrate200. The connection may be direct, or it may be indirect, for example, using solder, a conductive paste or tape or film, a combination of solder and a trace, or another conductive medium, In addition, the lower portion of the conductive path312may connect, either directly or indirectly as above, to landing pads on the PCB to which the IC is mounted.

FIGS. 5 and 6illustrate an example of forming a capacitor blade310using a soldering tray600. The soldering tray can be provided with a shape or form corresponding to the desired shape of the capacitor blade. For example, as shown inFIGS. 5 and 6, the soldering tray600includes an indentation610shaped like the capacitor blade to be formed. Individual capacitors320, or smaller groups of capacitors, may be set in the indentation and soldered together. The individual capacitors320may be of the same size, but this is not required and it is possible to form the capacitor blade310of individual capacitors having more that one size. The tray600may be formed of a non-stick material for easy removal of the completed blade. Alternatively, portions of the tray, for example, portions of the indentations contacting the capacitors, may be formed of or coated with a non-stick material. Using the soldering tray600for placement, the capacitors320may be soldered together to form a capacitor blade310. For example, the soldering tray may position the capacitors for application of solder and hold the capacitors in place during reflow of the solder. The particular solder paste may have a higher melting point than the solder used to couple components in succeeding steps, e.g., soldering leads or pins to the PCB. The solder may be applied to the capacitors by brushing or with a dispenser, such as a jet-type dispenser. Following reflow, the blade may then be removed from the tray. WhileFIGS. 5 and 6illustrate an example of a soldering tray, it should be understood that the capacitor blades may be formed using other arrangements and/or other mechanisms, including other shaping forms or holders.

FIG. 7illustrates an exemplary arrangement of capacitor blade310having alignment notches314. As shown, the alignment notches314may be provided by omitting or removing one or more capacitors320from the blade310at one or more predetermined location. In the example ofFIG. 7, the blade is made up of 15×4 array of capacitors320, with two capacitors omitted, thus totaling58capacitors. It is also possible to remove only a portion of one or more capacitors320to form the alignment notches314. For example, a portion of dielectric material between the endcaps of a capacitor320may be removed.

FIG. 8illustrates an alternative arrangement of a capacitor blade310having alignment notches314. In this example, the alignment notches314are formed by using capacitors320of different dimensions. More specifically, the blade310is made up of a 15×1 array of capacitors320, with two capacitors320-1,320-2having a different dimension (in this case length) than the other capacitors in the blade. Of course, the different dimension may be width or thickness, or a combination of width, thickness, and length.

FIG. 9illustrates an exemplary embodiment of an interposer50including an insulating main body500, signal pins400, and multiple capacitor blades310. The term “signal pins” is used to encompass data input/output and control pins as well as power voltage and ground pins. The insulating main body500may be molded from a polymer material, for example, a liquid crystal polymer or polytetrafluoroethylene. Portions of the main body500may be metallized or plated, for example, to provide electromagnetic interference (EMI) shielding and/or to provide a ground return path for the signal pins and/or act as a ground plane. Main body500may include a plurality of trenches510for receiving the capacitor blades310and a plurality of holes520for receiving the signal pins400. The trenches510are linear with a length sufficient to accommodate and position the capacitor blade310. The holes520may be shaped to retain signals pins400therein, for example, by friction and/or other mechanical expedients. In the example ofFIG. 9, the signal pins400surround the capacitor blades310. However, other arrangements are possible as well. For example, one or more of the capacitor blades may be adjacent to the signal pins, or the pins may be interspersed between one or more blades, or the blades may surround the pins.

In the example ofFIG. 9, the pitch or spacing of the capacitors' conductive paths312matches that of the signal pins400. Alternatively, some or all of the paths312may have a larger (or smaller) pitch than the signal pins.

The insulating main body500may further include corner walls530to aid in positioning and retaining the IC chip(s)100and substrate200. The edges of the corner walls may be chamfered to ease insertion of the substrate200and chip(s)100. Moreover, the corner of one of the corner walls530may be truncated for alignment of the interposer50on a printed circuit board (PCB). In addition, the insulating body may include mounting pegs535to stabilize the interposer50on a PCB or other substrate and/or to provide polarization features to ensure that the interposer50mounts only in a predetermined orientation on the PCB, thereby correctly matching signals between device arrangement10and the PCB to which it mounts.

FIG. 10illustrates a bottom view of the exemplary interposer50ofFIG. 9. As shown inFIG. 10, the signal pins400and the capacitor blades310extend from a bottom surface505of the insulating body500. In the embodiment shown inFIG. 10, the capacitor blades310include alignment notches314as discussed above in connection withFIG. 7. The notches314engage alignment ribs514extending across trenches510. The alignment ribs514aid in aligning and retaining the capacitor blades310. WhileFIG. 10shows alignment ribs514extending across the capacitor section of the interposer50, other arrangements are possible as well. For example, while two alignment ribs514are shown, a single alignment rib may be provided, or three or more ribs. In addition, the alignment ribs514may be provided at the ends of the capacitor blades310. Further, the alignment ribs514may be separated by different widths that key to different capacitor blade310configurations. Accordingly, the alignment ribs514may not appear as parallel, linear stripes, as shown inFIG. 10. It is also possible for the conductive paths312of the capacitor blades310to couple to a lead arrangement above and/or below the blades310to facilitate electrical connection.

FIG. 11illustrates a cross section of an interposer50. The cross section is taken through one of the capacitor blades310. The chip or die may mount to a substrate and the substrate may then mount to the interposer50. Of course, in some embodiments, the chip may mount directly to the interposer50. In general, the substrate200may be made of an insulative material, such as a ceramic or polymer, and may include landing pads on first and second sides thereof and electrically conductive traces between the landing pads, as described above. The landing pads and traces may be used to couple electrical signals (including power and ground voltages as well as information signals) between the chip and the interposer. Landing pads coupled to the chip may be more densely spaced than the landing pads coupled to the signal pins and capacitors. In this case, the traces may spread out from the first side of the substrate to the second side.

In the context ofFIG. 11, the landing pads on the substrate may connect to ends of the conductive paths312of the capacitor blades310and to ends of the pins or conductive elements400. While not shown, these connections may be made using solder, a conductive paste or another conductive adhesive (such as an anisotropic conductive film), or another conductive medium. The capacitor blade310is aligned and retained by alignment ribs514. The pins400are held within the holes520in the main body500. The opposite ends of the conductive paths312and pins400may connect to landing pads on the PCB, as described above.

FIG. 13illustrates a second exemplary embodiment of the invention. In accordance withFIG. 13, a chip or die100mounts to a substrate200. The substrate200couples to an interposer50that can be mounted to a PCB. The interposer50includes a unified capacitor module300, a plurality of signal pins400, and an insulative main body500. The signal pins400extend through individual holes520formed in the main body500. The main body500also includes a hole or window540for receiving the capacitor module300. In this case, the signal pins400surround the capacitor module300.

FIG. 14illustrates the capacitor module300ofFIG. 13in greater detail. As shown, the module300includes a stack of power layers, ground layers insulative layers, and cover layers, which will be described below. Power pins340and ground pins345running through the stack from a first side331to a second side332. The pins340,345may connect power and ground layers within the module300in a checkerboard or other pattern. For example, adjacent pins may alternate between power and ground pins. Capacitance is increased, without a corresponding increase in size, because the need for separate housings for each capacitor is eliminated.

FIGS. 15 and 16illustrate an exemplary power layer350and an exemplary ground layer354of the capacitor module300. The layers350,354have large holes334and small holes336that alternate in a checkerboard pattern. The large holes334provide clearance to the conductive surface, while small holes336provide contact. As above, patterns other than a checkerboard may be used. The pattern of large and small holes inFIG. 15is opposite of that inFIG. 16. The holes may be sized such that pins340,345extending through the holes contact the small holes336but do not touch the large holes334. For example, the pins may press fit against the small holes. Alternatively, a conductive medium may be provided between a layer and a pin to provide an electrical connection. The large holes may have a diameter close to that of the pins without touching the pins and without experiencing dielectric breakdown given the voltages applied to the capacitive structure. The power and ground layers350,354are made of a conductive material, such as a metal plate or film. Highly conductive metals or metal alloys are best, such as copper or gold. The power and ground layers may be made of entirely of metal or metal alloy, or may comprise one or more metal layers, such as a metal- or metal alloy-coated substrate. The material(s) selected for a particular application may depend on cost, workability, conductivity, durability, and ability to form an electrical connection, among other factors. It should be appreciated that, instead of or in addition to varying the size of the holes334,336, the diameter of the pins340,345may be varied to provided the desired contact and clearance pattern.

FIGS. 17 and 18illustrate an exemplary insulator layer358and an exemplary cover layer362of the capacitor module300. The insulator layer358is made of an insulative material, preferably have high dielectric constant, such as a thin film ceramic, an oxide, or a nitride, and in some applications even air may suffice. The insulative layer358may include a grid pattern of large holes334. However, this is not essential. The holes made in the insulator358need only be large enough to receive the pins340,345. The cover layer362may also be made of an insulative material, such as a plastic, and may include a grid pattern of small holes332. The cover layers362are provided on the outside of the stack and are intended to protect the interior layers of the module300from dirt, oxidation, and other factors that could impair the operation of the capacitor module300. It should be noted that the cover layer may extend over the sides of the capacitor module300. For example, it may be a coating over the entire module, except for the end portions of the pins.

While the exemplary capacitor module300has been described and shown with a checkerboard pattern of holes, other hole patterns are possible as well. For example, an offset pattern of holes may be used wherein the holes of adjacent rows are offset by specified distance. In such a case, the offset may be half the distance between holes. The offset pattern may be provided both in row and column directions. Of course, other offset values and other patterns are possible. In addition, instead of planar layers, the capacitor module300may be formed of layers having other shapes, such as cylindrical layers, e.g., with alternating power, insulating, and ground layers. The cylindrical layers may have a circular cross section, an elliptical cross section, or another shape. As a further alternative, the layers may spiral outward. The pins may extend from or along the power and ground layers. Of course, the above are merely intended as examples.

FIG. 19illustrates an exploded view of the exemplary capacitor module300using planar layers. In this example, module300includes a first cover layer362-1, a first ground layer354-1, and first insulative layer358-1, a first power layer350-1, and second insulative layer358-2, a second ground layer354-2, a third insulative layer358-3, a second power layer350-2, a fourth insulative layer358-4, third ground layer354-3, a fifth insulative layer359-5, a third power layer350-3, and a cover layer362-2. Pins340,345extend through the aligned holes, contacting either the ground layers350or the power layers354. The example illustrated inFIG. 19includes three ground layers354and three power layers350. However, it should be understood that another number of ground and/or power layers may be provided, for example, to increase or decrease capacitance value. Increasing the number of layers, forming the insulating layers of material with increased dielectric constant, and reducing the thickness of the insulating layers will each increase the capacitance of the capacitor module300.

FIG. 20illustrates an exemplary embodiment of the interposer50. As noted above, the interposer includes an insulative main body500with holes520to receive the signal pins400and a window540for receiving the capacitor module300. The window540may be through the approximate center of the main body500as shown inFIG. 20, or located elsewhere. Hold down pegs535for engaging a PCB may extend from the bottom surface of the main body500near the corners. The pegs535may function both for polarization as well as for stabilizing the interposer relative to the PCB. The edges of the corner walls530may be chamfered to ease insertion of the chip100and substrate200.

FIG. 21illustrates a bottom surface of the exemplary interposer ofFIG. 20. As shown inFIG. 21, three mounting pegs535may be provided at the corners of the bottom surface for alignment, polarization and mounting stabilization to the PCB.FIG. 21also shows the signal pins400and the capacitor module pins340,345extending from the bottom surface of the main body500. As shown inFIG. 21, the pitch of the capacitor module pins340,345may be the same as the pitch of the signal pins400. However, in alternative arrangements, the module pins may have a larger pitch than the signal pins, or a smaller pitch. The ends of the signal pins400and the capacitor module pins340,345can connect to landing pads on a surface of the PCB, for example, to form a surface-mount connection. If a multi-layer circuit board is provided, the length of the pins340,345,400may be vary depending on the required depth for connection to the appropriate layer of the circuit board. For example, in some multi-layer circuit embodiments, some or all of the signal and/or capacitor module pins can extend into vias or unplated holes formed in the circuit board.

FIG. 22illustrates a cross section of the interposer50with capacitor module300. The cross section is taken through one of the rows of pins340,345of the capacitor module300. As shown inFIG. 22, the capacitor module300is positioned in window540. The capacitor module300may be secured to the main body500using an adhesive and/or one or more ledges or seats formed at the periphery of window540. Alternatively, the capacitor module300may be molded into or insert-molded into the main body500.FIG. 22further shows that holes520through main body50can include funnels or chamfers522at top and/or bottom portions. The funnels or chamfers522can be used to guide pins400through the holes520, in the event that the pins400are inserted. In addition, the funnels or chamfers522may provide a reservoir for solder or other conductive material used in connecting the pins400to the body500or to a PCB or other substrate, if appropriate for the arrangement employed. It should be noted that the main body500may be molded around pins400.

FIG. 23illustrates a magnified cross section of the interposer50with capacitor module300, showing the pin and layer structure of the exemplary capacitor module300. For example, pin345-1is coupled to the first and second cover layers362-1,362-2and electrically and connected to the first, second and third ground layers354-1,354-2,354-3, but spaced from the insulator layers358-1through358-5and the power layers350-1through350-3. Pin340-2, on the other hand, is coupled to the first and second cover layers362-1,362-2and electrically and connected to the first, second, and third power layers350-1,350-2,350-3and is spaced from the insulator layers358-1through358-5and the ground layers354-1through354-3. Thus, pin345-1is a ground pin and pin340-2is a power pin. As noted above, the first and second cover layers362are preferably insulating, such as ceramic, a polymer, or other insulating material.

FIGS. 24 and 25illustrate further exemplary embodiments of the interposer50. In accordance withFIGS. 24 and 25, two mounting pegs535may be provided. One or both of the pegs535may be molded into different unique positions and/or have different diameters and/or shapes to provide multiple polarization and keying options. For example, a peg535may be located in “left” position as shown inFIG. 24or a “right” position as shown inFIG. 25. The position of the pegs535may code to the particular chip(s)100mounted to the interposer50. For example, one chip100may code to the left position of the mounting peg535and another, different chip may code to the right position of peg535. Further, the pegs535may include retention features, such as hooks, shoulders, nubs, etc., to assist retention to a PCB or other substrate.

FIG. 26illustrates a further exemplary embodiment of an interposer50. In accordance withFIG. 26, a set of pins400are located between two sets of capacitor blades310. Bumps121(such as solder bumps) may be used to connect between the pins400and conductive paths312of the capacitor blades on the one hand and the landing pads235-2of the substrate200on the other hand. In addition, bumps221may be used to connect between the pins400and conductive paths312of the capacitor blades on the one hand and the landing pads of the PCB700on the other hand. Of course, another conductive medium or a direct connection may be used instead of bumps121,221. In this example, each set of blades310may extend across the entire length of the pin field400(i.e., in a direction into the drawing page). However, this is not necessary. One or more of the blades310may extend only partially across the length of the pin field400, for example, a length similar to that shown inFIG. 3, so that the pins400surround such blades310. Alternatively, ends of one or more the blades310may be provided at or just inside of the periphery of the interposer, so that the pins400are between capacitor blades310. Such an arrangement permits the power and/or ground voltage supplies to connect through the capacitor blades near the periphery of the interposer.

While this exemplary embodiment is illustrated with capacitor blades310, it should be understood that the capacitor blades310may be replaced by two capacitor modules300. The exemplary embodiments of the capacitor block or module300described above may be integrated or incorporated into the interposer50.

FIG. 27illustrates a further exemplary embodiment in which the capacitor block or module300is provided in the substrate200rather than the interposer50. While the embodiment will be described using the capacitor blades310as an example, it should be appreciated that the capacitor module300may be used in addition or instead of the capacitor blades310. As shown inFIG. 27, conductive bumps121, for example solder bumps, may connect features110on the chip100both to features235-1on the substrate and to the conductive paths312of the capacitor blades310. In addition, bumps221may connect features235-2on the substrate200and on the conductive paths312of the capacitor blades310to features on the PCB700. The features110,235-1,235-2may be landing pads or other features. Moreover, another conductive medium (e.g., conductive adhesive, anisotropic conductive film, a bumpless technology), or a direct connection, may be used instead of the bumps121,221. According to this embodiment, the interposer may be omitted if desired. Alternatively, the substrate200and the capacitor blades310may be connected to an interposer.

FIG. 28illustrates the exemplary embodiment of the substrate200shown inFIG. 27from below. As shown, multiple capacitor blades310are aligned in the substrate200. The blades310may be secured to the substrate200using one or more of several techniques, such as alignment ribs, clips, a tray, tabs, ultrasonic welding, and/or adhesives.

FIG. 29illustrates a further exemplary embodiment of a substrate200with a chip or die100mounted thereto.FIG. 30illustrates the substrate200shown inFIG. 29with the chip100removed.FIGS. 31 and 32illustrate exploded views of the substrate200and chip100.FIG. 33illustrates a close-up of a capacitor blade tray240and capacitor blades310in accordance with the exemplary embodiment shown inFIG. 30.FIGS. 34 and 35illustrate views of the exemplary substrate200from the bottom.FIG. 36illustrates the exemplary substrate200from the top.FIGS. 37–39illustrate cross sections of the substrate200with a chip100mounted thereto.

As shown inFIG. 30, an insulating body230, landings or pads235-1, a capacitor blade tray240, and capacitors blades310are provided. The insulating body230may be made from one or more layers231of dielectric or insulative material, however it is also possible to make the body from one piece of insulative material. As noted above, conductive paths or traces may run through the insulating body230. Landings235-1are provided on a first side232of the insulating body. The landings235-1are arranged and adapted to connect to corresponding landings or pads110on the die100, either directly or indirectly via an electrically-conductive medium, such as solder balls. As described in greater detail below, the capacitor blade tray240holds one or more capacitor blades310, such as those described above. The blades310include conductive paths312that form virtual pins sized and spaced for connection to the chip100, either directly or indirectly, as described above. In the example shown inFIG. 30, the conductive paths312have a pitch that is about twice the pitch of the landings235-1. It should be appreciated that the pitch of the conductive paths312may be selected based on several factors and could be the same as the pitch of the landings235-1or a different pitch.

FIGS. 31 and 32provide exploded views of the substrate200and chip100from different perspectives. The tray240fits within a hole234provided through the insulative body230. The tray240may include extensions242that interface with the sides of the insulating body230at or in the hole234to position and/or retain the tray240. Of course, other or additional mechanisms may be provided to position or retain the tray240. For example, mechanical techniques, such as clips, hooks, snaps, stakes, interference fits, etc., may be used, and/or adhesives, and/or welding or brazing. The tray240includes slots244for receiving capacitor blades310. In addition, the tray240may include alignment ribs246similar to the ribs514described above. The tray240may be fixed to the insulative body230or may be removable therefrom, for example, to permit repair, reconfiguration, or for substitution of the tray240and/or the insulative body230.

As shown inFIG. 32, chip100includes landings or pads110. As described above, landings235-1of body230are adapted to connect (directly or indirectly) to pads110of the chip100. The insulating body includes a second side233having landings or pads235-2. Conductive paths within insulating body230connect landings235-1on the first side232of insulating body to landings235-2on the second side233. Landings235-2are adapted to connect (directly or indirectly) to landings or pads on a circuit board (not shown). Accordingly, signals may be coupled between the chip100and the circuit board via the substrate200.

In addition, the chip100includes landings or pads120that couple (directly or indirectly using conductive bumps or balls, etc.) to conductive paths312of the capacitor blades. An opposite end of conductive paths312couple (directly or indirectly) to landings or pads on the circuit board. Accordingly, signals (including power and/or ground) may be coupled to and/or from the circuit board and the chip100.

FIG. 33provides an exploded view of tray240and capacitor blades310. As shown, the tray240may include a series of slots244for receiving the capacitor blades310.FIGS. 34 and 35illustrates the second side233of the insulating body230. The landings235-2are shown as well as the capacitor blades310and alignment ribs246. As shown, the pitch of the landings235-2may be the same as the pitch of the conductive paths312provided by the capacitor blades310. As above, it is possible for the pitch of the conductive paths312to differ from the pitch of the landings235-2.FIG. 36illustrates the substrate200from above, showing the capacitor blades310, landings235-1, tray240, and insulative body230. The number of landings235-1on the top surface of the substrate200may equal the number of landings235-2on the bottom surface of the substrate. However, this is not required for some applications and the numbers of landings235-1and235-2may differ. For example, as shown inFIGS. 35 and 36, the substrate may have fewer landings235-1at the upper surface than landings235-2at the bottom surface. In this regard, some landings235-1may be routed to multiple landings235-2.

FIGS. 37-39illustrate cross sections of the substrate200and die100. These views illustrate the connection between the landings110and235-1and between landings120and conductive paths312. As shown in these Figs., the insulating body230may include an edge238that receives the extensions242of the tray240, thereby seating the tray242in the insulating body230.

FIG. 40illustrates a further exemplary embodiment of a device arrangement in accordance with an aspect of the present invention. As shown inFIG. 40–42, the device arrangement includes an IC chip or die100, a substrate200, capacitor block300, pins400, interposer main body500, and socket800. Features of the IC chip100, substrate200, capacitor block300, and main body500may be similar to those described above in connection with other embodiments and therefore may not be described in detail again below.

Die100mounts to substrate200, with substrate200in turn mounting to interposer main body500. As above, landings or pads on the bottom surface of die100electrically connect to landing or pads on the top surface of substrate200. The pads on the top surface of substrate200connect to pads on the bottom surface thereof. The pads on the bottom surface of substrate200connect to the tops of the virtual pins of the capacitor block300and to the pins400of interposer main body500. The interposer main body500mounts to socket800. As will be discussed in greater detail below, the pins400connect to corresponding pins820of the socket800to form an electrical connection therebetween. The socket pins820may connect to a PCB or other substrate. Accordingly, electrical connection may be made from the die to/from the PCB or other substrate via the substrate200, capacitor block300, pins400, and socket800.

As shown inFIGS. 41 and 42, the bottom surface of main body500may include an array of buttresses550. The buttresses550may be made of the same material as the main body, such as an insulative polymer (e.g., liquid crystal polymer) and may extend from the bottom surface of the main body500. The buttresses550may be integrally molded as part of the main body500, or may be formed separately and connected after the main body500is formed. It should be appreciated that the buttresses550are not required and may be omitted in some embodiments.

Each of the pins400extend through the interposer main body500and along the length of a buttress550. Clusters or groups of pins400, for example, four pins400in the illustrated example, are spaced around the circumferences of buttresses550. More particularly, the circumferences of the buttresses550may include cut-outs or indentations which receive the pins400, yet expose at least a side surface of the pins400to permit electrical connection. In the embodiment illustrated, the buttresses550have rounded outer surfaces that, together with pins400, provide a shape generally like a circular cylinder with flat surfaces corresponding to the exposed sides of the pins400. The tips of the buttresses550may be tapered, for example rounded, conic, or pyramidal, to facilitate connection to the socket800, as described below. Other shapes of the buttress and its tip are possible as well. Similarly, the tip of the pins400extending along the buttress500may be tapered. Moreover, as noted above, the buttresses550are not required, in which case the pins400would extend from the bottom surface of the main body500.

As shown inFIG. 41for example, pins400may be exposed at the top surface of main body500for connecting (directly or indirectly, as discussed above) to the landing pads on the bottom surface of substrate200. In addition, pins400provided beneath the capacitor block300may connect, directly or indirectly, to the conductive paths312of the capacitor blades310, thereby forming an electrical connection from the top of the main body500(i.e., the top of the conductive paths312) to the lower surface of the main body (i.e., the pins400beneath the capacitor block300). While capacitor blades310are shown, it should be appreciated that the capacitor block300could be embodied as a capacitor module, for example, as illustrated inFIGS. 13–23.

Socket800includes a body810, pins820, and a cover plate830having holes835. The main body810may be formed of an insulative material, such as a polymer, for example, a liquid crystal polymer. Pins820are held in the main body810, as discussed further below. Cover plate830may be provided to cover the pins820. The cover plate830includes holes835to receive the pins400and buttresses550, if provided, of the interposer main body500.

FIG. 43illustrates the upper surfaces of the main body500with pins400and capacitor block300that couple to the substrate200and IC die100. As shown, the ends of pins400may extend from the upper surface of the main body500. The pitch of the pins400may be the same as the pitch of the conductive paths312of the capacitor blades310. However, as above, this may be useful in some applications, but is not required. Similar to the pins400, the capacitor blades310may also extend from the upper surface of body500.

FIG. 44illustrates the interposer main body500coupled to the socket800. As described above, the pins400and buttresses550of the main body500may extend through the holes835in the cover plate830of socket800. While not shown inFIG. 44, the pins400engage corresponding pins820of the socket to form an electrical connection.

FIG. 45provides a close-up view of the upper surface of main body500, showing the array of pins400and the capacitor block300. The capacitor block300includes multiple capacitor blades310made up of multiple individual capacitors320as described above. The capacitor blades310may be disposed in a capacitor blade tray240seated in the main body500.

FIG. 46illustrates a cross section of the interposer main body500and the socket800during connection.FIGS. 47 and 48also provide cross sectional views during connection. As shown in these Figs., pins400and the conductive paths312of capacitor block300may be exposed at the top surface of main body500for coupling (directly or indirectly, as discussed above) to the landing pads on the bottom surface of substrate200. In addition, pins400provided beneath the capacitor block300may connect, directly or indirectly, to the bottom of conductive paths312of the capacitor blades310, thereby forming an electrical connection.

The opposite ends of pins400extend from the bottom surface of the interposer main body500along the sides of buttresses550. As shown, the pins400may include a stabilization portion404and a contact portion406. The stabilization portion404may held within holes of the main body500, for example, using a frictional fit and/or adhesives. The stabilization portion404may be thicker than the contact portion406to provide, among other things, stable engagement with the main body500. The contact portion406may be narrower that the stabilization portion404. The contact portion406includes a flat surface407for contact to the pins820of the socket and a tapered lead-in portion408. The tapered lead-in portion408is designed to initially engage a pin820and to flex the pin820as it slides along the tapered portion408.

Similarly, the pins820of the socket800include a stabilization portion824and a contact portion826. As above, the stabilization portion824may be held within holes in the main body820using a frictional fit and/or adhesive. As shown, the stabilization portion824may be thicker than the contact portion826. The contact portion826may be angled relative to the stabilization portion824when not flexed. The contact portion826may include a flexible beam portion827and a lead-in portion828that may be wedge-shaped. The flexible beam portion827is designed to flex upon engagement with the pins400, making the lead800straighter. The flexure produces a normal force between the pin820and the pin400to provide a good electrical connection. In addition, the flexure enables the pin820to wipe the surface of pin400, again facilitating good electrical connection. Lead-in portion828engages lead-in portion408to facilitate sliding contact of the portions826and406and to initiate flexing the pin820.

FIGS. 46–48additionally show the cross section of the cover plate830. As shown, the edges of the holes835may be angled inward to facilitate alignment of the buttresses550and leads400during insertion. In addition, the undersurface of the cover plate830may include extensions832that may serve to separate adjacent clusters of pins820. The extensions832may form a grid-like or honeycomb-like pattern on the bottom surface of the cover plate830. Of course, the pattern formed by the extensions832may be circular, hexagonal, rectangular, or other shape.

When the interposer500mates with socket800, pins400and buttresses550extend through holes835through the cover plate830of the socket800. In the illustrated embodiment, each buttress550and cluster of pins400extends through one of the holes835. However, it is possible for multiple buttresses550and clusters of pins400to pass through a hole835. The pins400engage pins820of the socket800establishing electrical connection.

FIG. 49shows the upper surface of the interposer main body500with capacitor block300and pins400.FIG. 50shows a close-up view of the capacitor block300. As shown, the capacitor blades310are arranged parallel to each other in a blade tray240. The blade tray240is seated in the main body500.FIGS. 51 and 52provide exploded views of the capacitor blades310and the blade tray240. The tray240may be made from an insulative material. As shown, the blade tray240includes rows of slots244for receiving individual blades310. As best shown inFIG. 52, the bottom of the tray240may include alignment ribs246for engaging the alignment notches314of the blades310.

FIG. 53shows a cross section view taken through the interposer main body500at the bottom of the capacitor block300. In accordance withFIG. 53, the conductive paths312of the capacitor blades310are exposed and available for connection to leads400(not shown) extending through the main body500beneath the capacitor block300.

FIG. 54illustrates the bottom of the socket800. The leads820may extend from the bottom surface of the main body810in an array pattern. The leads820may connect to a substrate, such as a PCB, for example. The bottom of main body810may be provided with pegs, as described above, for example, to aid in mounting, alignment, and/or positioning.

As noted above, the capacitor blades310may be replaced by a capacitor module, such as shown inFIGS. 13–23. In such case, the pins340,345of the capacitor module may interface (directly or indirectly) with the pins400to permit electrical connection between the substrate or chip and the socket800.

FIG. 55illustrates an exploded view of an exemplary device arrangement in accordance with a further embodiment of the invention. Similar to the embodiment ofFIG. 3, the device arrangement includes a chip100, a substrate200, a capacitor block300, pins400, and an interposer main body500. Pins400are provided in pin modules440, as described in greater detail below. The chip100, substrate200, capacitor block300, and interposer main body500are similar to those described above. It should be noted that, while capacitor block300is shown to have multiple capacitor blades310, a capacitor module, such as that shown inFIG. 13, may be provided instead.

FIG. 56illustrates an close-up view of the exemplary pin and capacitor blade arrangement in accordance withFIG. 55.FIG. 57illustrates a further exploded view of the exemplary device arrangement ofFIG. 55.FIG. 58illustrates an exemplary interposer arrangement consistent withFIG. 55.FIG. 59illustrates the interposer arrangement ofFIG. 58from above.FIGS. 60 and 61illustrate the interposer arrangement ofFIG. 58from below.FIGS. 62,63, and64illustrate cross sectional view of the interposer arrangement ofFIG. 58.FIG. 65illustrates a top view of the main body500.FIG. 66illustrates the lower surface of the substrate200, which includes landing pads235-2,235-3for connection to pins400and to the conductive paths312of the capacitor blades310. WhileFIG. 66shows that the landing pads235-2,235-3may be differently sized, these pads may be the same size.

As shown, the pins400are provided as part of pin modules440.FIG. 67illustrates a pin module440andFIG. 68illustrates an exploded view of the pin module440ofFIG. 67. Each of the pin modules440may include a plurality of pins400. In the example, four pins400are provided for each module440. But it should be appreciated that another number of pins400may be provided per module440, such as 2, 3, or 5 or more pins.

The pins400are held in an insulative material444, such as a polymer material. For example, the insulative material444may be polytetrafluoroethelyne or a liquid crystal polymer. The outer side surfaces of the insulative material444may be plated with an electrically-conductive material446, such as copper or gold, for example. As shown inFIG. 67, the plating446may extend entirely around the side surfaces of the insulative material444. The pins400may extend vertically (i.e., from the perspective shown inFIG. 55or67) beyond the conductive plating446. Alternatively, the plating446may extend the same distance as the pins400, or even longer, to enable the plating446to form one or more electrical connections to an electrical potential, e.g., to ground potential. As an alternative, or in addition, to plating446, a conductive material may be provided at hole520of the main body. For example, the surface that defines hole520may be plated with a conductive material, thereby surrounding the pin module440inserted into hole520. As above, the plating may extend the same length as pins400, or longer or shorter than pins400, depending on the desired arrangement.

A column448may be provided among the pins400, for example, separating each from another or all others. The insulative material444may separate the pins400from the column448. The column448may, for example, may have a cross-shaped cross section, as shown in FIG.56. However, the column448may have other cross-sectional shapes. The column448may be made of an insulative material, such as a polymer, or a conductive material, such as copper, nickel, aluminum, or steel. If made of an insulative material, the column448may be plated with a conductive material449, such as copper. The column448can function as a support or structural element and/or as a shield or additional contact.

As shown inFIG. 58, for example, the pin modules440may be inserted into and held within holes520formed in the main body500. The modules440may be held within the holes520using a mechanical mechanism, such as friction, a snap, stake, ledge, protrusion, clip and/or notch, for example, and/or using an adhesive or weld. One of the advantages of modules440is that they may be used with packages having different numbers of inputs/outputs.

FIGS. 69–70illustrate a further exemplary embodiment of pin module440according to the present invention. The module440shown inFIG. 69–70may be used with a device arrangement similar to that ofFIGS. 55–68. In the example ofFIGS. 69–70, the pin module440includes four pins400, insulative material444, and plating446-2similar to that of the embodiment inFIGS. 67–68. In contrast, the column448inFIGS. 69–70has a rectangular cross-section. The column448separates two pins400of a module440from the other two pins400of the module. As above, the column448may be made from an insulative material, a conductive material, or a plated insulative material. Using a conductive material or a plated insulative material, the column448may shield one pair of pins400from the other pair of pins of the module440. According to this arrangement, the adjacent pairs of pins400may be operated to carry differential signal pairs.

FIGS. 71–74illustrate a further embodiment similar to those ofFIGS. 55–70.FIG. 71illustrates an alternative design for a pin module440.FIG. 72illustrates an exploded view of the pin module440illustrated inFIG. 71. As shown inFIGS. 71 and 72, the pin module440includes two pins400. The pins400are separated from each other by insulative material444. The insulative material444may be, for example, a solid material, such as a polymer (e.g., a liquid crystal polymer or polytetraflouroethylene). The outer side surfaces of the insulative material444may be plated with a conductive material446-3, for example, copper, as noted above. WhileFIG. 71shows that the pins400extend vertically beyond the plating446-3, it is possible for the plating446-3to extend the same distance or greater than the pins440, as noted above.FIG. 73illustrates an interposer main body500-2having holes520-2for receiving pin modules440and a capacitor tray240for receiving multiple capacitor blades310. As above, in addition or instead of plating446-3, a conductive material may be provided at holes520-2, in the manner described above.FIG. 74illustrates an exploded cross section of the interposer main body500-2with pins400of pin modules440ofFIG. 71.

FIGS. 75–77illustrate a further embodiment similar to those ofFIGS. 71–74.FIG. 75illustrates an alternative design for a pin module440.FIG. 76illustrates an exploded view of the pin module440illustrated inFIG. 75. As shown inFIGS. 75 and 76, the pin module440includes a single pin400with an insulative material444, such as a polymer, axially disposed around the pin400. As above, the outer side surfaces of the insulative material444may be plated with a conductive material446-4, for example, copper. Pin400may extend vertically beyond plating446-4, as shown inFIG. 75, or alternatively may extend the same or less than plating446-4. The plating446-4may be grounded or supplied with another potential. In effect, the pin module440may be similar to a co-axial arrangement.FIG. 77illustrates an interposer main body500-3having holes520-3for receiving pin modules440and a capacitor tray240for receiving multiple capacitor blades310. As above, in addition or instead of plating446-4, a conductive material may be provided at holes520-3, in the manner described above.FIG. 78illustrates an exploded cross section of the interposer main body500with pins module440ofFIG. 75.

FIG. 79illustrates the bottom pin structure of a further exemplary embodiment of the present invention.FIG. 79shows a close-up view of the bottom surface of main body500, according to an exemplary embodiment of the invention. The main body500includes holes520through which pins400protrude. The main body further includes holes524through which ends372of capacitor pins370protrude. The ends372of capacitor pins370may be bent, as shown inFIG. 79, to aid in retention and/or provide a larger area for connection. Of course, the ends372need not be bent in other embodiments. Moreover, the pins370may be retained in main body500by other means, such as friction, an interference fits, shoulders, snaps, bumps, and/or adhesives.

FIG. 80illustrates the top pin structure of the embodiment ofFIG. 79. As shown, the opposite ends of pins400protrude from holes520in the main body500. The main body500may includes an insulative cover526having holes528. The opposite ends374of capacitor pins370protrude from the holes528. As above, the ends374may be bent over adjacent to or on the surface of cover526.

FIGS. 81 and 82illustrate the top pin structure of the embodiment ofFIG. 80prior to finishing, according to an exemplary embodiment of the present invention. In particular,FIG. 81illustrates the main body500with the cover plate526removed and prior to bending the ends374of capacitor pins370. As shown inFIG. 81, the capacitor pins370couple between individual capacitors or individual capacitor modules of capacitor blades310. For example, the capacitor pins370may connect to the conductive paths312between capacitors. Accordingly, the capacitor pins370serve as the electrical connection region for the capacitor blades310. Each of the capacitor pins370in a column of pins370(e.g., between different capacitor blades310) may be connected together in some embodiments. However, this is not required. One or more of the capacitor pins370in a column may be electrically insulated from the other pins370in the column.

As shown inFIG. 81, the ends374of capacitor pins370extend vertically.FIG. 82shows the arrangement once cover plate526is provided. The cover plate526may be attached to the main body500using one or more of several expedients, such as clips, welding, staking, and adhesives. After placement of the cover plate528, the ends374of the pins may be bent down toward the cover plate528. Alternatively, the ends374may be kept straight. The length of the ends374above the surface of the main body500may be the same as pins400, or a different length, for example, if the pins370and400are intended for connection at different levels.

FIG. 83illustrates an embodiment of a reel segment910of a take-up reel of capacitor pins370according to an exemplary embodiment of the invention. The reel segment910may be part of a reel of pins370used for automated fabrication of the capacitor blades310. The reel segment910may be made from a conductive material, such as copper, and may be plated, in whole or in part, with a conductive material, such as gold. The reel may be formed by punching or stamping out portions of a metal strip. The strip may be plated either before or after this punching or stamping operation, preferably after, to increase the area of plating. The reel segment910includes holes912that may interface with a feeder mechanism to feed the reel and/or measure the length of fed material. The portion of the reel segment910that connects to the ends of the capacitor pins370may be narrowed or scored to facilitate removal of the pins370from the reel, e.g., by punching.

FIG. 84illustrates an exemplary capacitor blade310with attached pins370according to an exemplary embodiment of the present invention. As shown inFIG. 84, the pins370may be attached to the capacitor blade310along the conductive paths312of the blade. The attachment may be made, for example, using solder or a conductive paste. As shown, the ends372,374(which are shown bent in this embodiment) may be narrower than the remainder of the pins370. In this arrangement, the pins370provide electrical connection between the capacitor blade segments.

FIG. 85illustrates an exemplary capacitor blade310attached to the capacitor pins370that are still attached to a reel segment910of capacitor pins according to an exemplary embodiment of the present invention. As above, the blade310may be connected to the leads370using solder or a conductive paste.

FIGS. 86–88illustrate an exemplary method of manufacturing a capacitor blade with capacitor pins using a soldering tray650according to an exemplary embodiment of the present invention. The soldering tray650includes features660for positioning the reel segment910and capacitor blade310in a stable manner for soldering. As shown inFIG. 86, the reel segment910is positioned on the soldering tray650. A solder or conductive paste may be applied to portions of the reel segment910. The capacitor blade310may then be positioned relative to the reel segment910. The soldering tray650may then be heated in an oven or otherwise subjected to heat treatment, for example, to cause reflow of the solder or conductive paste, thereby electrically and physically connecting the pins370to the blade310. The reel910may then be removed from the soldering tray650. The exemplary capacitor blade310with capacitor pins370and mounted to the reel segment910is shown inFIG. 89.

FIG. 90illustrates an exemplary capacitor blade310with capacitor pins370in accordance with an embodiment of the invention. For example, the arrangement ofFIG. 90may be obtained by removing the reel910from the embodiment shown inFIG. 89, e.g., with a punch or cutting tool.

FIG. 91illustrates a cross section of an exemplary interposer in accordance with the present invention.FIG. 92illustrates a close-up view of the cross section ofFIG. 91. The cross sections shown inFIGS. 91 and 92are take through the main body500through multiple rows of capacitor blades310. As shown in these Figs., the capacitor pin370extends from the top to the bottom of the main body500, similar to that of the pins400. The pins370electrically connect to the corresponding capacitor blade310, but not in this arrangement to adjacent capacitor blades310.

FIG. 93illustrates a cross section similar to that inFIGS. 91 and 92, however, with the capacitor pins370omitted to show the arrangement of the capacitor blades310. The capacitor blades310are seated in trenches or slots510in the main body500. Walls between the trenches510insulate one capacitor blade310from an adjacent blade310. The trenches510have sufficient width to accommodate the capacitor pins370. Hole524opens into the trench510, as shown. Of course, the trenches may be formed by a capacitor tray that is connected to the main body500and forms a portion thereof.

Cover526having holes528fits over the trench area of the main body500to retain the capacitor blades310. The cover526may have a smooth upper surface and a lower surface with segments527that may engage the trench walls.

FIG. 94illustrates an exemplary method of providing an interposer50with a capacitor blade310and reel segment910of capacitor pins370according to an exemplary embodiment of the present invention. The capacitor blade310may be inserted into the trench510of the main body500with the capacitor pins370still attached to the reel segment910. Following insertion, pins370(and the capacitor blade310) may be removed from the remainder of the reel segment910. Of course, the blade310and pins370may be inserted into the trench510after removing the pins370from the segment910.

When inserting the blade310into the trench510, the ends372of the pins370may be inserted through the holes524in the bottom of the main body500and protrude therefrom. Moreover, the ends374of the pins370will extend upward from the main body500. The cover526may then be provided over the blades310so that the ends374penetrate through the holes528in the cover526. If desired, the ends372and/or374may be bent down.

FIG. 95illustrates an exemplary capacitor blade310and reel segment910of capacitor pins370according to an exemplary embodiment of the present invention. The arrangement is similar to that shown inFIG. 85, for example, except that the reel segment910includes only a top portion912. In this case, the capacitor blade310may be attached to a reel segment910having only a top portion912. Otherwise, the bottom portion of the reel segment910may be removed after the capacitor blade is attached.

FIG. 96illustrates a further embodiment of a reel segment910of capacitor pins370according to an exemplary embodiment of the invention. As shown inFIG. 96, the reel segment910only includes a top portion912. In addition, in the embodiment ofFIG. 96, the capacitor pins370include tapered bottom portions372and top portions374and protrusions375. The protrusions375may be used to retain the pins370, either alone or together with an adhesive or other expedient, in the main body500. In this case, the end372,374may remain straight as they project through the holes524,528in the main body500following assembly. Moreover, the pins370may have, if desired, the same length extension from the main body surface as the pins400.

FIG. 97illustrates a view of a further exemplary embodiment of a capacitor blade310in accordance with the present invention.FIGS. 98 and 99illustrate top and side views, respectively, of the exemplary capacitor blade ofFIG. 97. The capacitor blade310is made up of multiple capacitors320, with two of the capacitors320-1and320-2having different dimension, in this case, a different height. Of course, the different dimension may be height, width, and/or length. The different sizes of the capacitors320-1,320-2define the alignment notches314, of which two notches314are provided in the capacitor blade310by way of example. As above, another number and/or arrangement of notches may be provided.

In the embodiment ofFIGS. 97–99, the individual capacitors320are joined together by, for example, joining alternating layers of dielectric or insulator material316and conductive material318. The dielectric or insulator material316may be, for example, a ceramic material, an oxide, a nitride or other suitable material, or combination of the foregoing. The conductive material318may be, for example, a metal, such as aluminum, copper, gold, silver, steel, or other suitable metal or metal alloy. The capacitors320may be joined using a lamination process, for example, with a layer of dielectric or insulative material being formed or applied, followed by a layer of conductive material, etc. The capacitor blade310can be used in a substrate or a interposer, for example, as described above.