Patent Publication Number: US-11390005-B2

Title: Continuous extrusion method for manufacturing a Z-directed component for insertion into a mounting hole in a printed circuit board

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     This patent application is a continuation application of U.S. patent application Ser. No. 15/397,829, filed Jan. 4, 2017, now U.S. Pat. No. 10,160,151, entitled “Continuous Extrusion Method for Manufacturing a Z-Directed Component for Insertion into a Mounting Hole in a Printed Circuit Board,” which is a divisional application of U.S. patent application Ser. No. 14/574,903, filed Dec. 18, 2014, now U.S. Pat. No. 9,564,272, issued Feb. 7, 2017, entitled “Continuous Extrusion Method for Manufacturing a Z-Directed Component for Insertion into a Mounting Hole in a Printed Circuit Board,” which is a divisional application of U.S. patent application Ser. No. 13/284,084, filed Oct. 28, 2011, now U.S. Pat. No. 8,943,684, issued Feb. 3, 2015, entitled “Continuous Extrusion Process for Manufacturing a Z-Directed Component for a Printed Circuit Board.” This patent application is related to U.S. patent application Ser. No. 13/222,748, filed Aug. 31, 2011, entitled “Die Press Process for Manufacturing a Z-Directed Component for a Printed Circuit Board,” U.S. patent application Ser. No. 13/222,418, filed Aug. 31, 2011, entitled “Screening Process for Manufacturing a Z-Directed Component for a Printed Circuit Board,” U.S. patent application Ser. No. 13/222,376, filed Aug. 31, 2011, entitled “Spin Coat Process for Manufacturing a Z-Directed Component for a Printed Circuit Board,” and U.S. patent application Ser. No. 13/250,812, filed Sep. 30, 2011, entitled “Extrusion Process for Manufacturing a Z-Directed Component for a Printed Circuit Board,” which are assigned to the assignee of the present application. 
    
    
     BACKGROUND 
     1. Field of the Disclosure 
     The present invention relates generally to processes for manufacturing printed circuit board components and more particularly to a continuous extrusion process for manufacturing a Z-directed component for a printed circuit board. 
     2. Description of the Related Art 
     The following co-pending United States patent applications, which are assigned to the assignee of the present application, describe various “Z-directed” components that are intended to be embedded or inserted into a printed circuit board (“PCB”): Ser. No. 12/508,131 entitled “Z-Directed Components for Printed Circuit Boards,” Ser. No. 12/508,145 entitled “Z-Directed Pass-Through Components for Printed Circuit Boards,” Ser. No. 12/508,158 entitled “Z-Directed Capacitor Components for Printed Circuit Boards,” Ser. No. 12/508,188 entitled “Z-Directed Delay Line Components for Printed Circuit Boards,” Ser. No. 12/508,199 entitled “Z-Directed Filter Components for Printed Circuit Boards,” Ser. No. 12/508,204 entitled “Z-Directed Ferrite Bead Components for Printed Circuit Boards,” Ser. No. 12/508,215 entitled “Z-Directed Switch Components for Printed Circuit Boards,” Ser. No. 12/508,236 entitled “Z-Directed Connector Components for Printed Circuit Boards,” and Ser. No. 12/508,248 entitled “Z-Directed Variable Value Components for Printed Circuit Boards.” 
     As densities of components for printed circuit boards have increased and higher frequencies of operation are used, some circuits&#39; designs have become very difficult to achieve. The Z-directed components described in the foregoing patent applications are designed to improve the component densities and frequencies of operation. The Z-directed components occupy less space on the surface of a PCB and for high frequency circuits, e.g. clock rates greater than 1 GHz, allow for higher frequency of operation. The foregoing patent applications describe various types of Z-directed components including, but not limited to, capacitors, delay lines, transistors, switches, and connectors. A process that permits mass production of these components on a commercial scale is desired. 
     SUMMARY 
     A method for manufacturing a Z-directed component for insertion into a mounting hole in a printed circuit board according to one example embodiment includes simultaneously extruding a plurality of materials according to the structure of the Z-directed component to form an extruded object and forming the Z-directed component from the extruded object. 
     A method for manufacturing a plurality of Z-directed components each for insertion into a respective mounting hole in a printed circuit board according to another example embodiment includes continuously extruding a plurality of materials in a lengthwise direction according to the structure of the Z-directed component to form an extruded object. The extruded object is divided into individual Z-directed components and each Z-directed component is cured. 
     A method for manufacturing a Z-directed component for insertion into a mounting hole in a printed circuit board according to another example embodiment includes simultaneously extruding a plurality of materials according to the structure of the Z-directed component to form an extruded object. The timing of extrusion between predetermined sections of one of the materials is varied in order to stagger the sections in the extruded object. The Z-directed component is formed from the extruded object. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above-mentioned and other features and advantages of the various embodiments, and the manner of attaining them, will become more apparent and will be better understood by reference to the accompanying drawings. 
         FIG. 1  is a perspective view of a Z-directed component according to one example embodiment. 
         FIG. 2  is a transparent perspective view of the Z-directed component shown in  FIG. 1  illustrating the internal arrangement of elements of the Z-directed component. 
         FIGS. 3A-3F  are perspective views showing various example shapes for the body of a Z-directed component. 
         FIGS. 4A-4C  are perspective views showing various example side channel configurations for a Z-directed component. 
         FIGS. 5A-5H  are perspective views showing various example channel configurations for the body of a Z-directed component. 
         FIG. 6A  is a perspective view of a Z-directed component having O-rings for connecting to internal layers of a PCB and having a body having regions comprised of similar and/or dissimilar materials according to one example embodiment. 
         FIG. 6B  is a top plan view of the Z-directed component shown in  FIG. 6A . 
         FIG. 6C  is a schematic side elevation view of the Z-directed component shown in  FIG. 6A . 
         FIG. 7  is a schematic illustration of various example elements or electronic components that may be provided within the body of a Z-directed component in series with a conductive channel. 
         FIG. 8  is a schematic cross-sectional view of a Z-directed component flush mounted in a PCB showing conductive traces and connections to the Z-directed component according to one example embodiment. 
         FIG. 9  is a top plan view of the Z-directed component and PCB shown in  FIG. 8 . 
         FIG. 10  is a schematic cross-sectional view of a Z-directed component flush mounted in a PCB showing ground loops for the Z-directed component with the Z-directed component further having a decoupling capacitor within its body according to one example embodiment. 
         FIG. 11  is a schematic cross-sectional view of a Z-directed component flush mounted in a PCB showing a Z-directed component for transferring a signal trace from one internal layer of a PCB to another internal layer of that PCB according to one example embodiment. 
         FIG. 12  is a perspective view of a Z-directed capacitor having semi-cylindrical sheets according to one example embodiment. 
         FIG. 13  is an exploded view of another embodiment of a Z-directed capacitor having stacked discs according to one example embodiment. 
         FIG. 14  is a schematic view of an extrusion die for forming a Z-directed component according to one example embodiment. 
         FIG. 15  is a cross-sectional view of the extrusion die shown in  FIG. 14  showing a plurality of channels therein. 
         FIG. 16  is a perspective view of a series of blades for dividing an extruded object formed from the extrusion die shown in  FIG. 14  into individual Z-directed components according to one example embodiment. 
         FIG. 17  is a top plan view of a Z-directed capacitor formed from the extrusion die shown in  FIG. 14 . 
         FIG. 18  is a top plan view of a Z-directed capacitor according to another example embodiment. 
         FIG. 19  is a perspective view of a Z-directed capacitor having a pair of radial conductive traces that extend lengthwise through the part according to one example embodiment. 
         FIG. 20  is a perspective view of a Z-directed capacitor having a thin film insulator applied to a top surface thereof and a conductive trace applied on top of the thin film insulator according to one example embodiment. 
         FIG. 21  is a cross-sectional view of an extrusion die for forming a Z-directed transmission line or delay line according to one example embodiment. 
         FIG. 22  is a top plan view of a Z-directed differential transmission line formed from the extrusion die shown in  FIG. 21 . 
         FIG. 23A  is a perspective view of a spiral tool having spiraling projections that extend from an inner surface thereof according to one example embodiment. 
         FIG. 23B  is a cutaway view of the spiral tool shown in  FIG. 23A  further illustrating one of the spiraling projections. 
         FIG. 24  is a cross-sectional view of an extrusion die for forming a Z-directed resistor according to one example embodiment. 
         FIG. 25  is a top plan view of a Z-directed resistor formed from the extrusion die shown in  FIG. 24 . 
         FIG. 26  is a perspective view of an extrusion die for forming a Z-directed alternating plate capacitor according to one example embodiment. 
         FIG. 27  is a perspective view of the extrusion die shown in  FIG. 26  schematically depicting a delivery system for delivering materials to the extrusion die. 
         FIG. 28  is a transparent perspective view of a Z-directed alternating plate capacitor formed from the extrusion die shown in  FIGS. 26 and 27 . 
         FIG. 29A  is a perspective view of a Z-directed component having a dome formed on an end thereof according to one example embodiment. 
         FIG. 29B  is a perspective view of a Z-directed component having a chamfered end according to one example embodiment. 
         FIG. 30  is a perspective view of a plug for forming a taper in an end of a Z-directed component according to one example embodiment. 
         FIG. 31  is a perspective view of a bottom surface of a PCB having an adhesive applied thereto in contact with a side surface of a Z-directed component inserted into a mounting hole in the PCB according to one example embodiment. 
         FIG. 32A  is a perspective view of a Z-directed component inserted into a mounting hole in a PCB, the Z-directed component having a conductive strip applied to a side surface thereof according to one example embodiment. 
         FIG. 32B  is a side cutaway view of the Z-directed component and PCB shown in  FIG. 32A . 
     
    
    
     DETAILED DESCRIPTION 
     The following description and drawings illustrate embodiments sufficiently to enable those skilled in the art to practice the present invention. It is to be understood that the disclosure is not limited to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. For example, other embodiments may incorporate structural, chronological, electrical, process, and other changes. Examples merely typify possible variations. Individual components and functions are optional unless explicitly required, and the sequence of operations may vary. Portions and features of some embodiments may be included in or substituted for those of others. The scope of the application encompasses the appended claims and all available equivalents. The following description is, therefore, not to be taken in a limited sense and the scope of the present invention is defined by the appended claims. 
     Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings. 
     Overview of Z-Directed Components 
     An X-Y-Z frame of reference is used herein. The X and Y axes describe the plane defined by the face of a printed circuit board. The Z-axis describes a direction perpendicular to the plane of the circuit board. The top surface of the PCB has a zero Z-value. A component with a negative Z-direction value indicates that the component is inserted into the top surface of the PCB. Such a component may be above (extend past), flush with, or recessed below either the top surface and/or the bottom surface of the PCB. A component having both a positive and negative Z-direction value indicates that the component is partially inserted into the surface of the PCB. The Z-directed components are intended to be inserted into a hole or recess in a printed circuit board. Depending on the shape and length of the component(s), more than one Z-directed component may be inserted into a single mounting hole in the PCB, such as being stacked together or positioned side by side. The hole may be a through hole (a hole from the top surface through to the bottom surface), a blind hole (an opening or recess through either the top or bottom surface into an interior portion or internal layer of the PCB) or an internal cavity such that the Z-directed component is embedded within the PCB. 
     For a PCB having conductive traces on both external layers, one external layer is termed the top surface and the other the bottom surface. Where only one external layer has conductive traces, that external surface is referred to as the top surface. The Z-directed component is referred to as having a top surface, a bottom surface and a side surface. The references to top and bottom surfaces of the Z-directed component conform to the convention used to refer to the top and bottom surfaces of the PCB. The side surface of a Z-directed component extends between the top and bottom surfaces of the PCB and would be adjacent to the wall of the mounting hole in the PCB where the mounting hole is perpendicular to the face of the PCB. This use of top, bottom and side should not be taken as limiting how a Z-directed component may be mounted into a PCB. Although the components are described herein as being mounted in a Z-direction, this does not mean that such components are limited to being inserted into a PCB only along the Z-axis. Z-directed components may be mounted normal to the plane of the PCB from the top or bottom surfaces or both surfaces, mounted at an angle thereto or, depending on the thickness of the PCB and the dimensions of the Z-directed component, inserted into the edge of the PCB between the top and bottom surfaces of the PCB. Further, the Z-directed components may be inserted into the edge of the PCB even if the Z-directed component is wider than the PCB is tall as long as the Z-directed component is held in place. 
     The Z-directed components may be made from various combinations of materials commonly used in electronic components. The signal connection paths are made from conductors, which are materials that have high conductivity. Unless otherwise stated, reference to conductivity herein refers to electrical conductivity. Conducting materials include, but are not limited to, copper, gold, aluminum, silver, tin, lead and many others. The Z-directed components may have areas that need to be insulated from other areas by using insulator materials that have low conductivity like plastic, glass, FR4 (epoxy &amp; fiberglass), air, mica, ceramic and others. Capacitors are typically made of two conducting plates separated by an insulator material that has a high permittivity (dielectric constant). Permittivity is a parameter that shows the ability to store electric fields in the materials like ceramic, mica, tantalum and others. A Z-directed component that is constructed as a resistor requires materials that have properties that are between a conductor and insulator having a finite amount of resistivity, which is the reciprocal of conductivity. Materials like carbon, doped semiconductor, nichrome, tin-oxide and others are used for their resistive properties. Inductors are typically made of coils of wires or conductors wrapped around a material with high permeability. Permeability is a parameter that shows the ability to store magnetic fields in the material which may include iron and alloys like nickel-zinc, manganese-zinc, nickel-iron and others. Transistors such as field effect transistors (“FETs”) are electronic devices that are made from semiconductors that behave in a nonlinear fashion and are made from silicon, germanium, gallium arsenide and others. 
     Throughout the application there are references that discuss different materials, properties of materials or terminology interchangeably as currently used in the art of material science and electrical component design. Because of the flexibility in how a Z-directed component may be employed and the number of materials that may be used, it is also contemplated that Z-directed components may be constructed of materials that have not been discovered or created to date. The body of a Z-directed component will in general be comprised of an insulator material unless otherwise called out in the description for a particular design of a Z-directed component. This material may possess a desired permittivity, e.g., the body of a capacitor will typically be comprised of an insulator material having a relatively high dielectric constant. 
     PCBs using a Z-directed component may be constructed to have a single conductive layer or multiple conductive layers as is known. The PCB may have conductive traces on the top surface only, on the bottom surface only, or on both the top and bottom surfaces. In addition, one or more intermediate internal conductive trace layers may also be present in the PCB. 
     Connections between a Z-directed component and the traces in or on a PCB may be accomplished by soldering techniques, screening techniques, extruding techniques or plating techniques known in the art. Depending on the application, solder pastes and conductive adhesives may be used. In some configurations, compressive conductive members may be used to interconnect a Z-directed component to conductive traces found on the PCB. 
     The most general form of a Z-directed component comprises a body having a top surface, a bottom surface and a side surface, a cross-sectional shape that is insertable into a mounting hole of a given depth D within a PCB with a portion of the body comprising an insulator material. All of the embodiments described herein for Z-directed components are based on this general form. 
       FIGS. 1 and 2  show an embodiment of a Z-directed component. In this embodiment, Z-directed component  10  includes a generally cylindrical body  12  having a top surface  12   t , a bottom surface  12   b , a side surface  12   s , and a length L generally corresponding to the depth D of the mounting hole. The length L can be less than, equal to or greater than the depth D. In the former two cases, Z-directed component  10  would in one case be below at least one of the top and bottom surfaces of the PCB and in the other it may be flush with the two surfaces of the PCB. Where length L is greater than depth D, Z-directed component  10  would not be flush mounted with at least one of the top and bottom surfaces of the PCB. However, with this non-flush mount, Z-directed component  10  would be capable of being used to interconnect to another component or another PCB that is positioned nearby. The mounting hole is typically a through-hole extending between the top and bottom surfaces of the PCB but it may also be a blind hole. When recessed below the surface of the PCB, additional resist areas may be required in the hole of the PCB to keep from plating the entire circumferential area around the hole. 
     Z-directed component  10  in one form may have at least one conductive channel  14  extending through the length of body  12 . At the top and bottom ends  14   t  and  14   b  of conductive channel  14 , top and bottom conductive traces  16   t ,  16   b  are provided on the top and bottom end surfaces  12   t ,  12   b  of body  12  and extend from respective ends of the conductive channel  14  to the edge of Z-directed component  10 . In this embodiment, body  12  comprises an insulator material. Depending on its function, body  12  of Z-directed component  10  may be made of variety of materials having different properties. These properties include being conductive, resistive, magnetic, dielectric, or semi-conductive or various combinations of properties as described herein. Examples of materials that have the properties are copper, carbon, iron, ceramic or silicon, respectively. Body  12  of Z-directed component  10  may also comprise a number of different networks needed to operate a circuit that will be discussed later. 
     One or more longitudinally extending channels or wells may be provided on the side surface of body  12  of Z-directed component  10 . The channel may extend from one of the top surface and the bottom surface of body  12  toward the opposite surface. As illustrated, two concave side wells or channels  18  and  20  are provided in the outer surface of Z-directed component  10  extending the length of body  12 . When plated or soldered, these channels allow electrical connections to be made to Z-directed component  10 , through the PCB, as well as to internal conductive layers within the PCB. The length of side channels  18  or  20  may extend less than the entire length of body  12 . 
       FIG. 2  shows the same component as in  FIG. 1  but with all the surfaces transparent. Conductive channel  14  is shown as a cylinder extending through the center of Z-directed component  10 . Other shapes may also be used for conductive channel  14 . Traces  16   t  and  16   b  can be seen extending from ends  14   t  and  14   b  of conductive channel  14 , respectively, to the edge of body  12 . While traces  16   t  and  16   b  are shown as being in alignment with one another (zero degrees apart), this is not a requirement and they may be positioned as needed for a particular design. For example, traces  16   t  and  16   b  may be 180 degrees apart or 90 degrees apart or any other increment. 
     The shape of the body of the Z-directed component may be any shape that can fit into a mounting hole in a PCB.  FIGS. 3A-3F  illustrate possible body shapes for a Z-directed component.  FIG. 3A  shows a triangular cross-sectional body  40 ;  FIG. 3B  shows a rectangular cross-sectional body  42 ;  FIG. 3C  shows a frusto-conical body  44 ;  FIG. 3D  shows an ovate cross-sectional cylindrical body  46 ; and  FIG. 3E  shows a cylindrical body  48 .  FIG. 3F  shows a stepped cylindrical body  50  where one portion  52  has a larger diameter than another portion  54 . With this arrangement, the Z-directed component may be mounted on the surface of the PCB while having a section inserted into a mounting hole provided in the PCB. The edges of the Z-directed component may be beveled to help with aligning the Z-directed component for insertion into a mounting hole in a PCB. Other shapes and combinations of those illustrated may also be used for a Z-directed component as desired. 
     For a Z-directed component, the channels for plating can be of various cross-sectional shapes and lengths. The only requirement is that plating or solder material make the proper connections to the Z-directed component and corresponding conductive traces in or on the PCB. Side channels  18  or  20  may have, for example, V-, C- or U-shaped cross-sections, semi-circular or elliptical cross-sections. Where more than one channel is provided, each channel may have the same or a different cross-sectional shape.  FIGS. 4A-4C  illustrate three side channel shapes. In  FIG. 4A , V-shaped side channels  60  are shown. In  FIG. 4B , U- or C-shaped side channels  62  are shown. In  FIG. 4C , wavy or irregular cross-sectional side channel shapes  65  are shown. 
     The numbers of layers in a PCB varies from being single sided to being over 22 layers and may have different overall thicknesses that range from less than 0.051 inch to over 0.093 inch or more. Where a flush mount is desired, the length of the Z-directed component will depend on the thickness of the PCB into which it is intended to be inserted. The Z-directed component&#39;s length may also vary depending on the intended function and tolerance of a process. The preferred lengths will be where the Z-directed component is either flush with the surfaces or extends slightly beyond the surface of the PCB. This would keep the plating solution from plating completely around the interior of the PCB hole that may cause a short in some cases. It is possible to add a resist material around the interior of a PCB hole to only allow plating in the desired areas. However, there are some cases where it is desired to completely plate around the interior of a PCB hole above and below the Z-directed component. For example, if the top layer of the PCB is a V CC  plane and the bottom layer is a GND plane then a decoupling capacitor would have lower impedance if the connection used a greater volume of copper to make the connection. 
     There are a number of features that can be added to a Z-directed component to create different mechanical and electrical characteristics. The number of channels or conductors can be varied from zero to any number that can maintain enough strength to take the stresses of insertion, plating, manufacturing processes and operation of the PCB in its intended environment. The outer surface of a Z-directed component may have a coating that glues it in place. Flanges or radial projections may also be used to prevent over or under insertion of a Z-directed component into the mounting hole, particularly where the mounting hole is a through-hole. A surface coating material may also be used to promote or impede migration of the plating or solder material. Various locating or orienting features may be provided such as a recess or projection, or a visual or magnetic indicator on an end surface of the Z-directed component. Further, a connecting feature such as a conductive pad, a spring loaded style pogo-pin or even a simple spring may be included to add an additional electrical connection (such as frame ground) point to a PCB. 
     A Z-directed component may take on several roles depending on the number of ports or terminals needed to make connections to the PCB. Some possibilities are shown in  FIGS. 5A-H .  FIG. 5A  is a Z-directed component configured as 0-port device  70 A used as a plug so that if a filter or a component is optional then the plug stops the hole from being plated. After the PCB has been manufactured, the 0-port device  70 A may be removed and another Z-directed component may be inserted, plated and connected to the circuit.  FIGS. 5B-5H  illustrate various configurations useful for multi-terminal devices such as resistors, diodes, transistors, and/or clock circuits.  FIG. 5B  shows a 1-port or single signal Z-directed component  70 B having a conductive channel  71  through a center portion of the component connected to top and bottom conductive traces  72   t ,  72   b .  FIG. 5C  shows a 1-port 1-channel Z-directed component  70 C where one plated side well or channel  73  is provided in addition to conductive channel  71  through the component, which is connected to top and bottom conductive traces  72   t  and  72   b .  FIG. 5D  shows a Z-directed component  70 D having two side wells  73  and  75  in addition to conductive channel  71  through the component which is connected to top and bottom traces  72   t ,  72   b . The Z-directed component  70 E of  FIG. 5E  has three side wells  73 ,  75  and  76  in addition to conductive channel  71  through the component, which is connected to top and bottom traces  72   t ,  72   b .  FIG. 5F  shows Z-directed component  70 F having two conductive channels  71  and  77  through the component each with their respective top and bottom traces  72   t ,  72   b  and  78   t ,  78   b  and no side channels or wells. Z-directed component  70 F is a two signal device to be primarily used for differential signaling.  FIG. 5G  shows a Z-directed component  70 G having one side well  73  and two conductive channels  71  and  77  each with their respective top and bottom traces  72   t ,  72   b  and  78   t ,  78   b .  FIG. 5H  shows Z-directed component  70 H having one conductive channel  71  with top and bottom traces  72   t ,  72   b  and a blind well or partial well  78  extending from the top surface along a portion of the side surface that will allow the plating material or solder to stop at a given depth. For one skilled in the art, the number of wells and signals is only limited by the space, required well or channel sizes. 
       FIGS. 6A-C  illustrate another configuration for a Z-directed component utilizing O-rings for use in a PCB having a top and bottom conductive layer and at least one internal conductive layer. Z-directed component  150  is shown having on its top surface  150   t , a locating feature  152  and a conductive top trace  154   t  extending between a conductive channel  156  and the edge of body  150   d  on its top surface  150   t . A conductive bottom trace (not shown) is provided on the bottom surface. Conductive channel  156  extends through a portion of the body  150   d  as previously described. Located on the side surface  150   s  of body  150   d  is a least one semi-circular channel or grove. As shown, a pair of axially spaced apart circumferential channels  158   a ,  158   b  is provided having O-rings  160   a ,  160   b , respectively disposed within channels  158   a ,  158   b . A portion of the O-rings  160   a ,  160   b  extend out beyond the side surface  150   s  of the body  150   d . O-rings  160   a ,  160   b  would be positioned adjacent one or more of the internal layers of the PCB to make electrical contract to one or more traces provided at that point in the mounting hole for the Z-directed component. Depending on the design employed, an O-ring would not have to be provided adjacent every internal layer. 
     O-rings  160   a ,  160   b  may be conductive or non-conductive depending on the design of the circuit in which they are used. O-rings  160   a ,  160   b  preferably would be compressive helping to secure Z-directed component  150  within the mounting hole. The region  162  of body  150   d  intermediate O-rings  160   a ,  160   b  may be comprised of different material than the regions  164  and  166  of the body  150   d  outside of the O-rings. For example, if the material of region  162  is of a resistive material and O-rings  160   a ,  160   b  are conductive then internal circuit board traces in contact with the O-rings  160   a ,  160   b  see a resistive load. 
     Regions  164  and  166  may also be comprised of a material having different properties from each other and region  162 . For example, region  164  may be resistive, region  162  capacitive and region  166  inductive. Each of these regions can be electrically connected to the adjoining layers of the PCB. Further, conductive channel  156  and traces  154   t ,  154   b  do not need to be provided. So for the illustrated construction, between the top layer of the PCB and the first internal layer from the top, a resistive element may be present in region  164 , a capacitive element between the first internal layer and the second internal layer in region  162  and an inductive element between the second internal layer and the bottom layer of the PCB in region  166 . Accordingly, for a signal transmitted from an internal trace contacting conductive O-ring  160   a  to a second internal trace contacting conductive O-ring  160   b , the signal would see an inductive load. The material for regions  162 ,  164 ,  166  may have properties selected from a group comprising conductive, resistive, magnetic, dielectric, capacitive or semi-conductive and combinations thereof. The design may be extended to circuit boards having fewer or more internal layers than that described without departing from the spirit of the invention. 
     In addition, regions  162 ,  164 ,  166  may have electronic components  167 ,  169 ,  171  embedded therein and connected as described herein. Also, as illustrated for component  171 , a component may be found within one or more regions within the body of a Z-directed component. Internal connections may be provided from embedded components to O-rings  160   a ,  160   b . Alternatively, internal connections may be provided from the embedded components to plateable pads provided on the side surface  150   s.    
     The various embodiments and features discussed for a Z-directed component are meant to be illustrative and not limiting. A Z-directed component may be made of a bulk material that performs a network function or may have other parts embedded into its body. A Z-directed component may be a multi-terminal device and, therefore, may be used to perform a variety of functions including, but not limited to: transmission lines, delay lines, T filters, decoupling capacitors, inductors, common mode chokes, resistors, differential pair pass throughs, differential ferrite beads, diodes, or ESD protection devices (varistors). Combinations of these functions may be provided within one component. 
       FIG. 7  illustrates various example configurations for a conductive channel in a Z-directed component. As shown, channel  90  has a region  92  intermediate the ends comprising a material having properties selected from a group comprising conductive, resistive, magnetic, dielectric, capacitive or semi-conductive properties and combinations thereof. These materials form a variety of components. Additionally, a component may be inserted or embedded into region  92  with portions of the conductive channel extending from the terminals of the component. A capacitor  92   a  may be provided in region  92 . Similarly, a diode  92   b , a transistor  92   c  such as a MOSFET  92   d , a zener diode  92   e , an inductor  92   f , a surge suppressor  92   g , a resistor  92   h , a diac  92   i , a varactor  92   j  and combinations of these items are further examples of materials that may be provided in region  92  of conductive channel  90 . While region  92  is shown as being centered within the conductive channel  90 , it is not limited to that location. 
     For a multi-terminal device such as transistor  92   c , MOSFET  92   d , an integrated circuit  92   k , or a transformer  921 , one portion of the conductive channel may be between the top surface trace and a first terminal of the device and the other portion of the conductive channel between the bottom surface trace and a second terminal of the device. For additional device terminals, additional conductors may be provided in the body of the Z-directed component to allow electrical connection to the remaining terminals or additional conductive traces may be provided within the body of the Z-directed component between the additional terminals and channels on the side surface of the body of a Z-directed component allowing electrical connection to an external conductive trace. Various connection configurations to a multiple terminal device may be used in a Z-directed component. 
     Accordingly, those skilled in the art will appreciate that various types of Z-directed components may be utilized including, but not limited to, capacitors, delay lines, transistors, switches, and connectors. For example,  FIGS. 8 and 9  illustrate a Z-directed component termed a signal pass-through that is used for passing a signal trace from the top surface of a PCB to the bottom surface. 
     Z-Directed Signal Pass-Through Component 
       FIG. 8  shows a sectional view taken along line  8 - 8  in  FIG. 9  of a PCB  200  having 4 conductive planes or layers comprising, from top to bottom, a ground (GND) plane or trace  202 , a voltage supply plane V CC    204 , a second ground GND plane  206  and a third ground GND plane or trace  208  separated by nonconductive material such as a phenolic plastic such as FR4 which is widely used as is known in the art. PCB  200  may be used for high frequency signals. The top and bottom ground planes or traces  202  and  208 , respectively, on the top and bottom surfaces  212  and  214 , respectively, of PCB  200  are connected to conductive traces leading up to Z-directed component  220 . A mounting hole  216  having a depth D in a negative Z direction is provided in PCB  200  for the flush mounting of Z-directed component  220 . Here depth D corresponds to the thickness of PCB  200 ; however, depth D may be less than the thickness of PCB  200  creating a blind hole therein. Mounting hole  216 , as illustrated, is a through-hole that is round in cross-section to accommodate Z-directed component  220  but may have cross sections to accommodate the insertion of Z-directed components having other body configurations. In other words, mounting holes are sized so that Z-directed components are insertable therein. For example, a Z-directed component having a cylindrical shape may be inserted into a square mounting hole and vice versa. In the cases where Z-directed component does not make a tight fit, resist materials will have to be added to the areas of the component and PCB where copper plating is not desired. 
     Z-directed component  220  is illustrated as a three lead component that is flush mounted with respect to both the top surface  212  and bottom surface  214  of PCB  200 . Z-directed component  220  is illustrated as having a generally cylindrical body  222  of a length L. A center conductive channel or lead  224 , illustrated as being cylindrical, is shown extending the length of body  222 . Two concave side wells or channels  226  and  228 , which define the other two leads, are provided on the side surface of Z-directed component  220  extending the length of body  222 . Side channels  226  and  228  are plated for making electrical connections to Z-directed component  220  from various layers of PCB  200 . As shown, the ground plane traces on layers  202 ,  206 , and  208  of PCB  100  are electrically connected to side channels  226  and  228 . V CC  plane  204  does not connect to Z-directed component  220  as shown by the gap  219  between V CC  plane  204  and wall  217  of mounting hole  216 . 
       FIG. 9  illustrates a top view of Z-directed component  220  in PCB  200 . Three conductive traces  250 ,  252  and  254  lead up to the edge of wall  217  of mounting hole  216 . As illustrated, trace  252  serves as a high-frequency signal trace to be passed from the top surface  212  to the bottom surface  214  of PCB  200  via Z-directed component  220 . Conductive traces  250  and  254  serve as ground nets. Center lead or conductive channel  224  is electrically connected to trace  252  on the top surface  212  of PCB  200  by a top trace  245  and plating bridge  230 . Top trace  245  on the top surface of Z-directed component  220  extends from the top end  224   t  of conductive channel  224  to the edge of Z-directed component  220 . Although not shown, the bottom side of Z-directed component  220  and bottom surface  214  of PCB  200  is configured in a similar arrangement of traces as shown on top surface  212  of PCB  200  illustrated in  FIG. 12 . A bottom trace on the bottom surface of Z-directed component  220  extends from bottom of conductive channel  224  to the edge of Z-directed component  220 . A plating bridge is used to make the electrical connection between the bottom trace and another high frequency signal trace provided on the bottom surface of PCB  200 . The transmission line impedance of the Z-directed component can be adjusted to match the PCB trace impedance by controlling the conductor sizes and distances between each conductor which improves the high speed performance of the PCB. 
     During the plating process, wells  256  and  258  formed between wall  217  of mounting hole  216  and side channels  226  and  228  allow plating material or solder pass from the top surface  212  to the bottom surface  214  electrically interconnecting traces  250  and  254 , respectively to side channels  226  and  228 , respectively, of Z-directed component  220  and also to similarly situated traces provided on the bottom surface  214  of PCB  200  interconnecting ground planes or traces  202 ,  206  and  208 . The plating is not shown for purposes of illustrating the structure. In this embodiment, V CC  plane  204  does not connect to Z-directed component  220 . 
     One of the challenges for high frequency signal speeds is the reflections and discontinuities due to signal trace transmission line impedance changes. Many PCB layouts try to keep high frequency signals on one layer because of these discontinuities caused by the routing of signal traces through the PCB. Standard vias through a PCB have to be spaced some distance apart which creates high impedance between the signal via and the return signal via or ground via. As illustrated in  FIGS. 8 and 9 , the Z-directed component and the return ground or signals have a very close and controlled proximity that allow essentially constant impedance from the top surface  212  to the bottom surface  214  of PCB  200 . 
     A Z-directed signal pass through component may also comprise a decoupling capacitor that will allow the reference plane of a signal to switch from a ground plane, designated GND, to a voltage supply plane, designated V CC , without having a high frequency discontinuity.  FIG. 10  shows a cross-sectional view of a typical 4-layer PCB  300  with a signal trace  302  transferring between the top layer  304  and the bottom layer  306 . Z-directed component  310 , similar to that shown in  FIG. 5D , having body  312  connects signal trace  302  through center conductive channel  314 . Z-directed component  310  also comprises plated side channels  316  and  318  extending along the side surface  312   s  of the body  312 . The top  314   t  and bottom  314   b  of conductive channel  314  are connected to conductive traces  318   t  and  318   b  on the top  312   t  and bottom  312   b  of body  312 . These, in turn, are connected to signal trace  302  via top and bottom plating bridges  330   t  and  330   b . Side channels  316  and  318  are plated to GND plane  332  and V CC  plane  334 , respectively. Connection points  336  and  338 , respectively, illustrate this electrical connection. Schematically illustrated decoupling capacitor  350  is internal to body  312  and is connected between side channels  316  and  318 . Decoupling capacitor  350  may be a separate capacitor integrated into the body  312  of Z-directed component  310  or it can be formed by fabricating a portion of the body  312  of Z-directed component  310  from the required materials with dielectric properties between conductive surfaces. 
     The path for signal trace  302  is illustrated with diagonal hatching and can be seen to run from top layer  304  to bottom layer  306 . GND plane  332  and side channel  316  are electrically connected at  336  with the signal path return indicated by the dark stippling  362 . V CC  plane  334  and side channel  318  are electrically connected at  338  with the signal path return indicated by the light stippling  364 . As is known in the art, where a signal plane or trace is not to be connected to the inserted part, those portions are spaced apart from the component as shown at  370 . Where a signal plane or trace is to be connected to an inserted component, the signal plane or trace is provided at the wall or edge of the opening to allow the plating material or solder to bridge therebetween as illustrated at points  330   t ,  330   b ,  336 , and  338 . 
     The vertically hatched portion  380  shows the high speed loop area between the signal trace and return current path described by the signal trace  302  and the GND plane  332  or V CC  plane  334 . The signal trace  302  on the bottom surface  306  is referenced to power plane V CC    334  that is coupled to the GND plane  332  through decoupling capacitor  350 . This coupling between the two planes will keep the high frequency impedance close to constant for the transition from one return plane to another plane of a different DC voltage. 
     Internally mounting Z-directed components in a PCB greatly facilitates the PCB technique of using outer ground planes for EMI reduction. With this technique, signals are routed on the inner layers as much as possible.  FIG. 11  illustrates one embodiment of this technique. PCB  400  is comprised of, from top to bottom, top ground layer  402 , internal signal layer  404 , internal signal layer  406  and bottom ground layer  408 . Ground layers  402  and  408  are on the top and bottom surfaces  400   t  and  400   b  of PCB  400 . A mounting hole  410 , shown as a through-hole, extends between the top and bottom surfaces  400   t  and  400   b . Z-directed component  420  is shown flush mounted in PCB  400 . Z-directed component  420  comprises body  422  having a center region  424  intermediate the top  422   t  and bottom  422   b  of body  422  and two side channels  425  and  427  on side surface  422   s.    
     Side channels  425  and  427  and wall  411  of hole  410  form plating wells  413  and  415  respectively. Center region  424  is positioned within body  422  and extends a distance approximately equal to the distance separating the two internal signal layers  404  and  406 . Side channel  425  extends from the bottom surface  422   b  of body  422  to internal signal level  406  while side channel  427  extends from top surface  422   t  of body  422  to internal signal level  404 . Here, side channels  425  and  427  extend only along a portion of side surface  422   s  of body  422 . Conductive channel  426  extends through center region  424  but does not extend to the top and bottom surfaces  422   t ,  422   b  of body  422 .  FIG. 5H  illustrates a partial channel similar to side channel  427 . Conductive channel  426  has conductive traces  428   t  and  428   b  extending from the top  426   t  and bottom  426   b  of conductive channel  426  to side channels  427  and  425 , respectively. While illustrated as separate elements, conductive channel  426  and traces  428   t ,  428   b  may be one integrated conductor electrically interconnecting side channels  425 ,  427 . As shown, conductive trace  428   b  is connected to internal signal layer  406  via plated side channel  425  and well  413  while trace  428   t  connects to internal signal level  404  via side channel  427  and well  415 . Ground layers  402  and  408  are not connected to Z-directed component  420  and are spaced away from mounting hole  410  as previously described for  FIGS. 8 and 10 . As shown by double headed dashed arrow  430 , a signal on signal layer  406  can be via′d to signal layer  404  (or vice versa) via Z-directed component  420  through a path extending from well  413 , side channel  425 , trace  428   b , conductive channel  426 , trace  428   t , side channel  427 , and well  415  to allow the signal to remain on the inner layers of PCB  400  with ground layers  402  and  408  providing shielding. 
     Z-Directed Decoupling Capacitors 
       FIGS. 12 and 13  illustrate two additional example Z-directed components in the form of decoupling capacitors. In  FIG. 12 , a Z-directed capacitor  500  is shown with a body  502  having a conductive channel  504  and two side channels  506  and  508  extending along its length similar to those previously described. Conductive channel  504  is shown connected to a signal  526 . Vertically oriented interleaved partial cylindrical sheets  510 ,  512  to forming the plates of Z-directed capacitor  500  are connected to reference voltages such as voltage V CC  and ground (or any other signals requiring capacitance) and are used with intervening layers of dielectric material (not shown). Partial cylindrical sheet  510  is connected to plated channel  506  which is connected to ground  520 . Partial cylindrical sheet  512  is connected to plated channel  508  which is connected to supply voltage V CC    522 . Sheets  510 ,  512  may be formed of copper, aluminum or other material with high conductivity. The material between the partial cylindrical sheets is a material with dielectric properties. Only one partial cylindrical sheet is shown connected to each of V CC    522  and ground  520 ; however, additional partial cylindrical sheets may be provided to achieve the desired capacitance/voltage rating. 
     Another embodiment of a Z-directed capacitor is shown in  FIG. 13  using stacked support members connected to voltage V CC  or ground. Z-directed capacitor  600  is comprised of center conductive channel  601  and a body  605  comprised of a top member  605   t , a bottom member  605   b , and a plurality of support members  610  (illustrated as disks) between the top and bottom members  605   t ,  605   b.    
     Center conductive channel  601  extends through openings  615  in the assembled Z-directed capacitor  600  and openings  602   t  and  602   b , all of which are sized to closely receive the center conductor. Center conductive channel  601  is electrically connectable to conductive traces  603   t  and  603   b  on the top and bottom portions  605   t ,  605   b  forming a signal path for signal  626 . This connection is made by plating or soldering. Center conductive channel  601  is connected to signal  626  via conductive trace  603   t . The bottom end of conductive channel  601  is connected in a similar fashion to a signal trace (not shown) via conductive trace  603   b.    
     Opposed openings  607   t  and  608   t  are provided at the edge of top portion  605   t . Bottom portion  605   b  is of similar construction as top portion  605   t  having opposed openings  607   b  and  608   b  provided at the edge. Between top and bottom portions  605   t ,  605   b  are a plurality of support members  610 , which provide the capacitive feature. Support members  610  each have at least one opening  613  at their outer edge and an inner hole  615  allowing for passage of conductive channel  601  therethrough. As shown, two opposed openings  613  are provided in each support member  610 . When assembled, the opposed openings  607   t ,  607   b ,  608   t ,  608   b , and  613  align to form opposed side channels  604  and  608  extending along the side surface of Z-directed capacitor  600 . Side channel  604  is shown connected to reference voltage such as ground  620  and side channel  606  to another reference voltage such as V CC    622 . Support members  610  may be fabricated from a dielectric material and may be all of the same or varying thickness allowing for choice in designing the desired properties for Z-directed capacitor  600 . 
     Annular plating  617  is provided on one of top and bottom surfaces of support member  610  or, if desired, on both surfaces. Annular plating is shown on the top surface of each support member but location of the annular plating can vary from support member to support member. Annular plating  617  generally conforms to the shape of the support member and extends from one of the edge openings  613  toward the other if an additional opening is provided. The annular plate  617  is of a diameter or dimension or overall size that is less than the diameter, dimension or overall size of support member  610  on which it is affixed. While the plate  617  is described as annular, other shapes may also be used provided that the plating does not contact the center conductive channel or extend to the edge of the support member on which it is plated or otherwise affixed. The annular plate does contact one of the edge openings  613  but is spaced apart from the other openings if more than one channel is present in the side surface of the body of Z-directed capacitor  600 . Also, there is an opening  619  in annular plate  617  having a larger diameter than opening  615  in annular plate  617  through which conductive channel  601  passes. Opening  619  has a larger diameter than that of conductive channel  601  leaving annular plate  617  spaced apart from conductive channel  601 . 
     As illustrated, the support members  610  are substantially identical except that when stacked, alternate members are rotated 180 degrees with respect to the member above or below it. This may be referred to as a 1-1 configuration. In this way, alternate members will be connected to one or the other of the two side channels. As shown in  FIG. 13 , the annular plating on the upper one of the two support members  610  is connected to side channel  608  and voltage V CC    622  while the annular plating on the lower one of the two support members  610  is connected to side channel  604  and ground  620 . Other support member arrangements may also be used such as having two adjacent members connected to the same channel with the next support member being connected to the opposite channel which may be referred to as a 2-1 configuration. Other configurations may include 2-2, 3-1 and are a matter of design choice. The desired capacitance or voltage rating determines the number of support members that are inserted between top and bottom portions  605   t ,  605   b . Although not shown, dielectric members comprised of dielectric material and similarly shaped to support members  610  may be interleaved with support members  610 . Based on design choice, only a single channel may be used or more channels may be provided and/or the annular plating may be brought into contact with the center conductive channel and not in contact with the side channels. Again, the embodiments for Z-directed capacitors are for purposes of illustration and are not meant to be limiting. 
     With either design for a Z-directed capacitor, a second conductive channel may be provided in parallel with the first conductive channel that is disposed within the conductive plates to create a differential decoupling capacitor. Another embodiment of a Z-directed capacitor can be constructed from  FIG. 12  or  FIG. 13  by connecting the center conductive channel to one of the reference voltages at each support member that also has its annular plating connected to the same reference voltage. This may be accomplished simply by connecting the conductive channel to the annular plating as schematically illustrated by the jumper  621 . In practice, the annular opening  619  in the annular plate  617  would be sized so that the annular plate and conductive channel  601  would be electrically connected. This component may be placed directly below a power pin or ball of an integrated circuit or other surface mounted component for optimum decoupling placement. 
     Again, the Z-directed signal pass-through components illustrated in  FIGS. 8-11  and the Z-directed decoupling capacitors illustrated in  FIGS. 12 and 13  provide merely a few example applications of a Z-directed component. Those skilled in the art will appreciate that various other types of Z-directed components may be utilized including, but not limited to, transmission lines, delay lines, T filters, decoupling capacitors, inductors, common mode chokes, resistors, differential pair pass throughs, differential ferrite beads, diodes, or ESD protection devices (varistors). 
     Continuous Extrusion Process for Manufacturing a Z-Directed Component 
     A continuous extrusion process for manufacturing the Z-directed components on a commercial scale is provided. In the continuous extrusion process, at least two different materials are extruded simultaneously to form the Z-directed component. This process is particularly useful where the materials forming the Z-directed component extend in a lengthwise direction within the component. As discussed above, a variety of different Z-directed components are contemplated herein. Accordingly, it will be appreciated that the specific materials used will depend on the Z-directed component desired. Signal paths will be formed from a conductive material. Resistive materials may also be used as desired. A dielectric material may be used that has a relative permittivity from about 3, e.g., polymers, to over 10,000, e.g., barium titanate (BaTiO 3 ). For example, a material with a relatively high dielectric value may be used in a Z-directed decoupling capacitor and a material with a relatively low dielectric value may be used in a Z-directed signal pass-through component. If a Z-directed component is desired to have an inductive function or a delay line then a ferrite material may be selected that has a low or high relative permeability with a range of about 1 to about 50,000. 
     With reference to  FIG. 14 , an extrusion die  700  for forming a Z-directed component in the form of a decoupling capacitor according to one example embodiment is illustrated. The Z-directed capacitor formed from extrusion die  700  is composed of conductive material and dielectric material. As needed, a binder material may also be included as is known in the art. Extrusion die  700  includes a chamber  702  having an inlet  704  and an outlet  706  for passing material therethrough. Chamber  702  is divided into a plurality of channels  708  that are separated from one another by one or more barriers  710  to permit simultaneous extrusion of multiple materials. The channels  708  are arranged in predetermined positions that define the structure of the Z-directed component. In the example embodiment illustrated, a chamber  702  having a circular cross-section is used to form a generally cylindrical Z-directed component; however, as discussed above, many different shapes may be used. 
     The Z-directed component is formed by simultaneously forcing the desired materials into their corresponding channels  708  at inlet  704  of extrusion die  700 , which causes the materials to take on the respective shapes of channels  708 . The materials may be pressed into channels  708  using a ram, injection press or extruder screw (not shown). For example, a direct extrusion process may be used where extrusion die  700  is held stationary and the ram is moved towards it or an indirect extrusion process may be used where the ram is held stationary and extrusion die  700  is moved towards it. A combination of the two may be also used where the ram and die  700  are moved towards each other. A hydrostatic extrusion process may also be used where fluid pressure forces the materials through die  700 . Extrusion die  700  may be oriented horizontally, vertically or at any suitable angle thereto. Any conventional drive may be applied to provide the extruding force including a mechanical or hydraulic drive. The desired materials are forced through die  700  in a continuous manner so that substantially an entire component (or more than one component) is extruded at once. Where more than one component is extruded at once, the extruded object exiting chamber  702  may then be divided into individual components as discussed in greater detail below. 
       FIG. 15  shows a cross section of extrusion die  700  taken near inlet  704 . In  FIG. 15 , the channels  708  that are filled with conductive material are indicated with a medium cross hatched fill and the channels  708  that are filled with dielectric material are indicated with a light dotted fill. Barriers  710  of extrusion die  700  are shown in cross-section without a fill. The small circles  712  shown in  FIG. 15  indicate locations at inlet  704  where the desired materials may be pressed into chamber  702 . The size and number of inlet ports  712  are selected to provide predetermined volumetric material flow rates through chamber  702 . In the example embodiment illustrated, a center conductive channel in the Z-directed capacitor is formed in channel  708   a . Channel  708   a  can also be used to form a signal trace, as desired. Two concentric conductive plates that surround the center conductive channel are formed in channels  708   b  and  708   c . The conductive layers are isolated from each other by three layers of dielectric material. The dielectric layers are formed around each of the conductive layers in channels  708   d ,  708   e  and  708   f  As discussed in greater detail below, a dielectric divider is formed in each of the concentric conductive plates to make a bridge path that will be used to connect alternating conductive traces on the top and/or bottom of the component. The dielectric dividers are formed by channels  708   g  and  708   h  in extrusion die  700 . 
     As shown in  FIG. 14 , the diameter of chamber  702  reduces from inlet  704  to outlet  706 . Each of the barriers  710  correspondingly tapers from inlet  704  to outlet  706  such that at a location near inlet  704  (shown in  FIG. 15 ), barriers  710  are thicker than they are near outlet  706  (shown in  FIG. 14 ). In this manner, the various materials are isolated from one another by barriers  710  when they are first introduced into chamber  702 . Laminar flow is desired through chamber  702  in order to fill each channel  708  and form a substantially uniform part that is free of air gaps or other irregularities. The reduction in diameter of chamber  702  and the corresponding taper of barriers  710  cause the materials to fill their respective channels  708  and promote laminar flow therethrough. The reduction in diameter of chamber  702  and the corresponding taper of barriers  710  also urge the materials in the various channels  708  toward each other near outlet  706  to form a unitary part composed of multiple materials. After the various materials are combined (at the downstream end of barriers  710 ), in one embodiment, any remaining length of chamber  702  prior to outlet  706  has a constant diameter (as shown in dashed lines in  FIG. 14 ) in order to maintain the shape of the extruded object and the relative positions of the various materials therein. Alternatively, the diameter of chamber  702  may continue to narrow in order to shrink the component to its final dimensions so long as the positioning of the various materials making up the component relative to each other is not disturbed. A movable element, such as a plug or rod, may be used to support the downstream end of the extruded object as it advances to help prevent it from losing its shape. For instance, where the extrusion process is performed in a vertically downward direction, a plug that lowers according to the speed of extrusion may be used to support the extruded object from below to maintain the shape of the extruded object. 
     After the materials have been extruded to form the desired shape and configuration of the Z-directed component, if desired, before proceeding with any remaining steps the extruded object can be partially fired in order to improve the strength of the materials and to ensure that the component will remain intact. Moderate heat may also be applied to cure the binder material. Heating elements can be embedded into the walls of a chamber downstream from the extrusion output, which may either be attached to the extrusion die or form a unitary part of the extrusion die, in order to supply a desired temperature profile to the extruded object. Alternatively, rather than applying moderate heat to cure the binder material or partially fire the extruded object, a full firing process may be performed at this time. 
     After extrusion, in one embodiment, the extruded object is divided into individual Z-directed components according to the desired length(s) of the Z-directed component(s).  FIG. 16  shows a segment of an extruded object  720  ready to be cut. One option is to use a series of blades  722  spaced according to the desired component lengths. In one embodiment, the components range in length from about 0.5 mil to about 62 mil (about 0.0127 mm to about 1.57 mm), including all increments and values therebetween, depending on the PCB used and the desired mounting position of the Z-directed component. Another option is to cut the extruded object  720  using multiple passes of a single blade. In this embodiment, the length of each component is determined by controlling the timing of each pass of the blade. Each component may have substantially the same length or different lengths may be used. A feedback mechanism may be used to adjust the timing of the cuts in order to account for parameters that may change with blade usage, such as the kerf of the blade. The extruded object may be in an unfired, a partially fired or a fully fired state when it is divided into separate components. It will be appreciated that a partially fired state is preferred. When extruded object  720  is cut in an unfired state, it may be difficult to ensure that extruded object  720  will retain its shape. When extruded object  720  is fully fired when it is cut, it will take more force to perform the cut with a very hard cutting tool such as, for example, a diamond cutting tool as is known in the art. As an alternative to extruding the components in bulk and then dividing the extruded object into individual components, each Z-directed component may be extruded individually. However, this may still require each extruded component to be cut to its precise length. 
       FIG. 17  shows a top plan view of a Z-directed capacitor  730  formed using the example extrusion die  700  shown in  FIGS. 14 and 15 . In  FIG. 17 , the diagonal hatching indicates those areas that are composed of conductive material. The remainder of the component is composed of dielectric material. Capacitor  730  includes a center conductor  732  running lengthwise through the part that is formed by channel  708   a . Capacitor  730  also includes a pair of concentric conductive plates  734 ,  736  spaced radially from conductor  732  running lengthwise through the part that are formed by channels  708   b ,  708   c , respectively. Three concentric layers  738 ,  740 ,  742  of dielectric formed by channels  708   d ,  708   e ,  708   f , respectively, isolate conductors  732 ,  734 ,  736  from each other. After the component is cut from the extruded object, a conductive trace  744  is added to a top and/or bottom surface of capacitor  730  that connects center conductor  732  to outer conductive plate  736  and to an edge of the part to provide a connection with a corresponding trace on the PCB. Trace  744  passes through a dielectric divider  748  formed by channel  708   g  in order to avoid connection with middle conductive plate  734 . Similarly, a conductive trace  746  is added to connect middle conductive plate  734  to an edge of the capacitor  730  to provide a connection with another trace on the PCB. Trace  746  passes through a dielectric divider  750  formed by channel  708   f  in order to avoid connection with outer conductive plate  736 . In one embodiment, center conductor  732  and outer conductive plate  736  are connected to a supply voltage V CC  and middle conductive plate  734  is connected to ground voltage GND although this configuration can be reversed as desired. Traces  744 ,  746  can be applied when the Z-directed component is fabricated or after the Z-directed component is inserted into the mounting hole in the PCB when the PCB is plated. 
     It will be appreciated that the Z-directed capacitor may have any number of conductive plates depending on the desired capacitance of the part. For example,  FIG. 18  shows a Z-directed capacitor  800  having a center conductor  802  and four concentric conductive plates  804 ,  806 ,  808 ,  810  spaced outwardly therefrom. Trace  812  is formed on a top surface of capacitor  800  that connects center conductor  802  and conductive plates  806  and  810  to an edge of the part for connection with a trace on the PCB. Trace  814  is formed on the top surface of capacitor  800  that connects conductive plates  804  and  808  to an edge of capacitor  800  for connection with the PCB. As discussed above with respect to  FIG. 17 , dielectric material isolates center conductor  802  and conductive plates  804 ,  806 ,  808 ,  810  from each other and creates a bridge for traces  812 ,  814 . It will be appreciated that the number and arrangement of conductive and dielectric layers may be altered simply by changing the configuration of the extrusion die used. 
     In another alternative, the conductive connections to the PCB, such as traces  744 ,  746  shown in  FIG. 17  or traces  812 ,  814  shown in  FIG. 18 , are extruded within the part. For example,  FIG. 19  shows a Z-directed capacitor  900  that has a similar layout to Z-directed capacitor  700  shown in  FIG. 17  except that radial conductive traces  902 ,  904  extend through the length of the part. In this embodiment, traces  902 ,  904  are formed by altering the configuration of the channels in the extrusion die so that traces  902 ,  904  are extruded within the part. Traces  902 ,  904  are each positioned in a respective side channel  906 ,  908  in capacitor  900 . In order to form side channels  906 ,  908 , an extrusion die that features a corresponding pair of inwardly projecting scalloped portions is used instead of a cylindrical die. As shown in  FIG. 19 , traces  902 ,  904  are exposed on a side surface  900   s  of capacitor  900  along the entire length of the part. As a result, traces  902 ,  904  may be used to establish a connection not only with the top or bottom surface of the PCB but also an intermediate layer of the PCB as desired. By extruding the conductive connections to the PCB within the component, in some embodiments, a separate step adding conductive traces for connection to the PCB may be eliminated. 
     In some embodiments, a thin film resist layer is added to a top and/or bottom surface of the component in order to prevent plating material from interfering with the conductive paths present on the top or bottom surface of the Z-directed component when the PCB is plated. In this configuration, the connection between the component and the PCB may be made by plating side channels, such as side channels  906 ,  908 , of the Z-directed component and connecting them to a trace on the PCB rather than using a trace on the top or bottom surface of the component. 
     It will be appreciated that any number of isolated conductors could be extruded to make through board connections of a PCB. For example, in the example Z-directed capacitor shown in  FIG. 19 , it may be desired to pass a signal through a center conductor  912  rather than supply voltage V CC  or ground GND. In order to accomplish this, a layer of thin film insulator may be screened on the top and/or bottom surface of the Z-directed component. For example,  FIG. 20  illustrates a Z-directed capacitor  1000  having a thin film insulator  1002  screened across a top surface thereof. In the example embodiment illustrated, the film is screened such that a small hole  1004  is provided in insulator  1002  in order to permit plating to a center conductor  1006  that extends the length of capacitor  1000 . A conductive trace  1008  is applied across insulator  1002  that connects center conductor  1006  to an edge of the part. Trace  1008  from center conductor  1006  can be applied when the Z-directed component is fabricated or after the Z-directed component is inserted into the mounting hole in the PCB when the PCB is plated. Capacitor  1000  also includes a pair of concentric conductive plates  1010 ,  1012  extruded through the part. In this embodiment, center conductor  1006  is isolated from concentric conductive plates  1010 ,  1012  by dielectric material. Conductive traces  1014 ,  1016  also extend through the length of the part and are exposed along a side surface  1000   s  of capacitor  1000  in side channels  1018 ,  1020 , respectively. Traces  1014 ,  1016  extend radially from and connect conductive plates  1010 ,  1012 , respectively, to an edge of the component. Conductive plates  1010 ,  1012  and the radial portions of traces  1014 ,  1016  are covered on the top surface of the part by insulator  1002  and are therefore shown in dashed lines. In this manner, insulator  1002  prevents the signal (Signal) sent to center conductor  1006  via trace  1008  from shorting either the supply voltage (V CC ) or the ground (GND). Trace  1008  can be connected to a corresponding trace on a top surface of the PCB and traces  1014 ,  1016  can be connected to the PCB anywhere along side surface  1000   s  of capacitor  1000 . 
       FIG. 21  illustrates a cross-section of another example extrusion die  1100  for forming a Z-directed transmission line or delay line. Die  1100  includes a plurality of channels  1108  therein separated by barriers  1110 . The same fill convention used in  FIG. 14  is used in  FIG. 21 . Specifically, the channels  1108  that are filled with conductive material are indicated with a medium cross hatched fill and the channels  1108  that are filled with dielectric material are indicated with a light dotted fill. Barriers  1110  of extrusion die  1100  are shown without a fill. The small circles  1112  shown in  FIG. 21  indicate locations where the desired materials may be pressed into a chamber  1102  of die  1100 . In this embodiment, die  1100  includes a pair of inwardly projecting scalloped portions  1112 ,  1114  for forming a corresponding pair of side channels in the component. Die  1100  includes a channel  1108   a  for forming a conductor through the length of the component that includes a circular portion having radial connections to each of the side channels. Die  1100  also includes a pair of channels  1108   b ,  1108   c  for forming a corresponding pair of conductors through the Z-directed component. 
       FIG. 22  shows a top plan view of a Z-directed differential transmission line  1120  formed using extrusion die  1100  shown in  FIG. 21 . The same fill convention used in  FIG. 17  is used in  FIG. 22 . The diagonal hatching in  FIG. 22  indicates those areas that are composed of conductive material. The remainder of the component is composed of dielectric material. Transmission line  1120  includes a pair of conductors  1122 ,  1124  formed from channels  1108   b ,  1108   c , respectively, that run lengthwise through the part. Transmission line  1120  also includes a ground (or reference) conductor  1126  having a circular portion  1126   a  and a pair of radial extensions  1126   b ,  1126   c  that connect to corresponding side channels  1128 ,  1130  in the part. Conductor  1126  is formed by channel  1108   a  of extrusion die  1100 . Side channels  1128 ,  1130  are formed by scalloped portions  1112 ,  1114 , respectively. Conductors  1122 ,  1124 ,  1126  are separated from each other by a dielectric material  1132  such as ceramic. Conductive traces  1134 ,  1136  are applied to the top surface of the component to provide a connection for conductor  1122 ,  1124 . Conductors  1122 ,  1124  form a differential pair. Since transmission line  1120  includes a reference conductor  1126 , the two differential signals are not highly coupled. However, conductor  1126  could be replaced with the dielectric material and the differential signals would become highly coupled. 
     With reference to  FIGS. 23A and 23B , if it is desired to delay the signals through transmission line  1120 , the extruded object may be forced through a spiral tool  1150  that lengthens the path of conductors  1122 ,  1124  relative to the length of the component. Spiral tool  1150  includes a pair of spiraling projections  1152  that extend from an inner surface  1150   s  thereof.  FIG. 23B  illustrates a cross-section of spiral tool  1150  that more to clearly illustrates one of the projections  1152  therein. As the extruded object is forced through spiral tool  1150 , projections  1152  form corresponding side channels in the component and cause the extruded object to twist as it advances. This causes conductors  1122 ,  1124  to twist into a double helix configuration. Again, center conductor  1126  can be omitted as desired. 
     Spiral tool  1150  can be used to alter the relative positions of corresponding traces on the top and bottom surfaces of the component such that a trace on the top surface of the component can be angled with respect to a corresponding trace on the bottom surface of the component. It will be appreciated that spiral tool  1150  can also be used to create an inductor. For instance, a single conductor, such as conductor  1122  or conductor  1124  can be formed in a twisted pattern that can be used as a single wire inductor. In this embodiment, the remainder of the Z-directed component will be composed of a material having a relatively high permeability. Where two conductors, such as conductors  1122 ,  1124 , are used in a double helix configuration, a transformer can be formed. In this embodiment, by driving current through one of the conductors  1122  or  1124  (the primary coil), energy is magnetically coupled to the second conductor (the secondary coil) as an output. 
       FIG. 24  illustrates a cross-section of another example extrusion die  1200  for forming a Z-directed resistor. Die  1200  includes a plurality of channels  1208  therein separated by barriers  1210 . The same fill convention used in  FIGS. 14 and 21  is used in  FIG. 24 . Specifically, the channel  1208  that is filled with dielectric material is indicated with a light dotted fill. The channel  1208  that is filled with resistive material is indicated with a heavy cross hatched fill. Barriers  1210  of extrusion die  1200  are shown without a fill. The small circles  1212  shown in  FIG. 24  indicate locations where the desired materials may be pressed into a chamber  1202  of die  1200 . Die  1200  includes a channel  1208   a  for forming a resistive path through the length of the component and a channel  1208   b  for providing dielectric material around the resistive path. 
       FIG. 25  shows a top plan view of a Z-directed resistor  1220  formed using extrusion die  1200  shown in  FIG. 24 . The same fill convention used in  FIGS. 17 and 22  is used in  FIG. 25 . The diagonal hatching in  FIG. 22  indicates those areas that are composed of conductive material. The heavy crossed hatching indicates those areas that are composed of resistive material. The remainder of the component is composed of dielectric material. Resistor  1220  includes a resistive path  1222  that runs lengthwise through the part formed by channel  1208   a . Dielectric material  1224 , such as ceramic, formed by channel  1208   b  surrounds resistive path  1222 . Conductive trace  1226  is applied to the top and/or bottom surface of the component to provide a connection to resistive path  1222 . It will be appreciated that the resistance imparted by resistor  1220  may be altered as desired by changing the diameter of channel  1208   a  in die  1200  in order to correspondingly alter the diameter of resistive path  1222 . 
     With reference to  FIGS. 26 and 27 , an extrusion die  1300  for forming an alternating plate capacitor according to one example embodiment is shown. In this embodiment, the timing of extrusion of the various materials is varied in order to stagger them within the Z-directed component. Extrusion die  1300  includes a chamber  1302  having an inlet  1304  and an outlet (not shown). A plurality of slats  1306  are positioned at inlet  1304  or downstream therefrom. Each slat  1306  includes an inlet  1308  that receives material from a supply source through a corresponding pipe or tube  1332 . Each slat  1306  also includes an outlet  1310  that emits material into die  1300  in the downstream direction of extrusion, which is downward in the embodiment shown in  FIGS. 26 and 27 . One or more materials is supplied to the inlet  1308  of each slat  1306  by a delivery system  1330  that includes a switch to control which material is being emitted by a particular slat  1306 . 
       FIG. 28  shows a Z-directed alternating plate capacitor  1320  formed using the example extrusion die  1300  shown in  FIGS. 26 and 27  as discussed in greater detail below. In order to more clearly illustrate the internal structure of capacitor  1320 , capacitor  1320  is shown with a transparent body in  FIG. 28 . Capacitor  1320  includes a plurality of conductive plates  1322  extending lengthwise within the component. Plates  1322  are divided into two sets  1322   a ,  1322   b  that are spaced from each other in an alternating relationship. Each of the first set  1322   a  of plates  1322  extends to a bottom surface  1320   b  of capacitor  1320  but is spaced from a top surface  1320   t  thereof. Conversely, each of the second set  1322   b  of plates  1322  extends to top surface  1320   t  but is spaced from bottom surface  1320   b . The body of capacitor  1320  is formed from dielectric material. Capacitor  1320  includes a first conductive trace  1324  along bottom surface  1320   b  that connects with each of the first set  1322   a  of plates  1322  but not the second set  1322   b  of plates  1322  and a second conductive trace  1326  along top surface  1320   t  that connects with each of the second set  1322   b  of plates  1322  but not the first set  1322   a  of plates  1322 . In one embodiment, trace  1324  and first set  1322   a  of plates  1322  are connected to a supply voltage V CC  and trace  1326  and second set  1322   b  of plates  1322  are connected to ground voltage GND although this configuration can be reversed as desired. 
     With reference to  FIGS. 27 and 28 , to form alternating plate capacitor  1320  shown in  FIG. 28 , slats  1306  are disposed relative to chamber  1302  according to the desired positions of conductive plates  1322 . Dielectric material is forced into inlet  1304  of chamber  1302  and around slats  1306 . As the dielectric material flows around slats  1306 , either conductive material or additional dielectric material is dispensed from outlets  1310  of slats  1306  depending on whether the slat  1306  corresponds with one of the first set  1322   a  of plates  1322  or the second set  1322   b  of plates  1322 . Specifically, a first set  1306   a  of slats  1306  corresponds with first set  1322   a  of plates  1322  and a second set  1306   b  of slats  1306  corresponds with second set  1322   b  of plates  1322 . 
     As shown in  FIG. 27 , tubes  1332  of delivery system  1330  are divided into two sets  1332   a ,  1332   b . For ease of illustration, first set  1332   a  of tubes  1332  is shown in dashed lines and second set  1332   b  is shown in solid lines. First set  1332   a  of tubes  1332  supplies material to first set  1306   a  of slats  1306 , which corresponds with first set  1322   a  of plates  1322 . Second set  1332   b  of tubes  1332  supplies material to second set  1306   b  of slats  1306 , which corresponds with second set  1322   b  of plates  1322 . In this embodiment, each tube  1332  has substantially the same length. Both sets  1332   a ,  1332   b  of tubes  1332  receive material from a manifold  1334 . A valve  1336 , such as a three-port valve (e.g., an L-shaped three-way ball valve), determines whether conductive material, dielectric material or neither is supplied to manifold  1334 . As shown in  FIG. 27 , each of the first set  1332   a  of tubes  1332  is connected to a portion of manifold  1334  that is upstream from the connection between manifold  1334  and second set  1332   b  of tubes  1332 . This causes first set  1332   a  of tubes  1332  to receive material before second set  1332   b  does. As a result, when valve  1336  switches from one material to another (e.g., from dielectric to conductor or vice versa), first set  1306   a  of slats  1306  receives the new material before second set  1306   b  of slats  1306  does thereby creating the desired stagger between sets  1322   a ,  1322   b  of plates  1322 . Because tubes  1332  are all the same length, first set  1306   a  of slats  1306  emits material into chamber  1302  in unison and then, after the delay that results from the respective placement of tubes  1332  on manifold  1334  expires, second set  1306   b  of slats  1306  emits the same material in unison to create the staggered pattern of plates  1322  shown in  FIG. 28 . Specifically, first set  1306   a  of slats  1306  first emits conductive material so that the corresponding first set  1322   a  of conductive plates  1322  extends to bottom surface  1320   b  of the part until the end of extrusion is near at which point first set  1306   a  of slats  1306  switches to dielectric material so that the plates  1322  are spaced from top surface  1320   t . Conversely, as a result of the delay imposed by manifold  1334 , second set  1306   b  of slats  1306  first emits dielectric material so that the corresponding second set  1322   b  of conductive plates  1322  are spaced from bottom surface  1320   b  of the part and then, when the delay expires, second set  1306   b  of slats  1306  switches to conductive material so that the plate  1322  extends to top surface  1320   t.    
     After the component is formed, conductive traces  1324 ,  1326  are added to top and bottom surfaces, respectively, as discussed above. Traces  1324 ,  1326  can be applied when the Z-directed component is fabricated or after the Z-directed component is inserted into the mounting hole in the PCB when the PCB is plated. 
     The arrangement shown in  FIG. 27  is intended to provide an example of a suitable configuration for creating the desired material delay and resulting stagger between plates  1322 . It will be appreciated that a number of different configurations of tubes  1332 , valves  1336  and manifolds  1334  may be used to facilitate material flow into each slat  1306  and that the timing of material flow and/or the lengths of the material paths may be adjusted to create the desired delay. One alternative is to use a valve  1336  and corresponding manifold  1334  specific to each set  1306   a ,  1306   b  of slats  1306 . In this embodiment, the stagger between plates  1322  can be created by setting a delay between the valve  1336  for first set  1306   a  of slats  1306  and the valve  1336  for second set  1306   b  of slats  1306 . Another option is to provide each slat  1306  with its own valve  1336  and feedpath from the sources of conductive material and dielectric material and to control each slat  1306  individually. Yet another option to create the desired stagger between plates  1322  is to position one set of slats  1306 , such as first set  1306   a , upstream from another set, such as second set  1306   b , and to dispense material from each slat at the same time. 
     In some embodiments, a chamfer, dome or other form of taper or lead-in of at least one of the top and bottom edge of the Z-directed component is desired in order to ease insertion of the Z-directed component into the mounting hole in the PCB. For example,  FIG. 29A  shows a Z-directed component  1400  having a dome  1402  formed on an end thereof.  FIG. 29B  shows a Z-directed component  1404  having a chamfered end  1406 . The dome  1402  or chamfer  1406  may be part of the component or attached thereto. In one embodiment, the dome  1402  or chamfer  1406  is a separate part that is partially inserted into the mounting hole in the PCB. In this embodiment, the Z-directed component is then inserted behind the dome  1402  or chamfer  1406  to push it through the mounting hole causing the dome  1402  or chamfer  1406  to expand the mounting hole and prevent the component from cutting or tearing the PCB. Where the dome  1402  or chamfer  1406  is attached to the Z-directed component, it may be configured to remain attached to the Z-directed component following insertion into the mounting hole in the PCB or it may be used to facilitate insertion and then removed. 
     One method for forming the desired taper as part of the Z-directed component utilizes a plug  1420  having a recess  1422  formed in an end  1424  thereof having a tapered rim  1426  around a periphery of recess  1422  as shown in  FIG. 30 . Tapered rim  1426  is chamfered in the example embodiment illustrated; however, a domed, elliptical or rounded rim may also be used depending on the shape of the taper desired. Plug  1420  is used to compress the component in a constraining plate having a cavity for retaining the component therein. When plug  1420  applies a force to an end of the component, the end of the part is reflowed to have the desired geometry and the conductive path(s) on the end of the part are allowed to continue across or through the corresponding taper formed on the end of the part. As a result, the tapered end portion of the part can then be used to facilitate board to board electrical connections in multi-PCB applications. 
     After the Z-directed component has been formed, a firing process is applied to cure the part if it has not been done so already. The firing process solidifies the part and shrinks it to its final dimensions. At this point, the Z-directed component can be tested for yield and performance and any additional processes may be performed as desired. For example, in some instances, the heating step may cause burrs to form. Accordingly, in some embodiments, the Z-directed components are tumbled with various abrasive agents to smooth the corners and edges of the part. Further, resist areas may be added to the Z-directed component to keep the conductive materials from sticking to areas that are not intended to be conductive. Glue areas may be applied to the component to assist with retaining it in the PCB. Visible markings and/or locating features may be added to the Z-directed component to assist with assembly into the PCB. 
     Once production of the Z-directed component is complete, it is ready to be inserted into the mounting hole of the PCB. As discussed above, the component may be mounted normal to the plane of the PCB from the top or bottom surfaces or both surfaces, mounted at an angle thereto or inserted into the edge of the PCB between the top and bottom surfaces of the PCB. In some embodiments, the Z-directed component is press fit into the mounting hole. This press fit may be in the form of an interference fit between the component and the mounting hole. After the Z-directed component is positioned in the mounting hole, a conductive plating bridge may be applied to connect one or more traces on the top and/or bottom surface of the component to a corresponding trace on the PCB. Further, where the Z-directed component includes side channels therein, additional conductive plating may be applied to these side channels to form the desired signal connections between the Z-directed component and the PCB. 
     With reference to  FIG. 31 , in one embodiment, after a Z-directed component  1500  is inserted into a mounting hole  1502  in a PCB  1504 , an adhesive  1506  is applied to a surface  1508  of PCB  1504  external to mounting hole  1502 . Adhesive  1506  is positioned to contact a surface of Z-directed component  1500  when it is inserted into mounting hole  1502  in order to fix the location of Z-directed component  1500  and prevent it from rotating or translating out of position. 
     With reference to  FIGS. 32A and 32B , manufacturing variations in the thickness of the PCB and the length of the Z-directed component may prevent the Z-directed component from being perfectly flush with both the top and bottom surfaces of the PCB. As a result, in one embodiment, a conductive strip  1512  is formed along a side surface  1510   s  of a Z-directed component  1510 . Conductive strip  1512  runs along side surface  1510   s  to either the top or bottom surface of Z-directed component  1510 . Conductive strip  1512  may be applied after the Z-directed component  1510  is formed. In the example embodiment illustrated, conductive strip  1512  runs along side surface  1510   s  to a top surface  1510   t  of Z-directed component  1510 . In this manner, conductive strip  1512  forms a bridge between a trace  1514  on the respective top or bottom surface of Z-directed component  1510  and a trace  1516  on a PCB  1518  when the top or bottom surface of the Z-directed component extends past the corresponding top or bottom surface of the PCB. As a result, trace  1514  on Z-directed component  1510  is able to connect to trace  1516  on PCB  1518  even if the top or bottom surface of Z-directed component  1510  is not flush with the corresponding top or bottom surface of PCB  1518 . In the example configuration illustrated in  FIG. 32B , conductive strip  1512  runs from top surface  1510   t  of Z-directed component  1510  to a point along side surface  1510   s  that is below the top surface of the PCB  1518 . In one embodiment, conductive strip  1512  extends into the side of Z-directed component  1510  both to decrease its resistance and to ensure that it is not removed if another feature such as a taper is later applied to Z-directed component  1510 . 
     The foregoing description of several embodiments has been presented for purposes of illustration. It is not intended to be exhaustive or to limit the application to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. It is understood that the invention may be practiced in ways other than as specifically set forth herein without departing from the scope of the invention. It is intended that the scope of the application be defined by the claims appended hereto.