Electronics package having a self-aligning interconnect assembly and method of making same

1. An electronics package comprising:

an interconnect assembly comprising:

a first insulating substrate;

a first wiring layer formed on a lower surface of the first insulating substrate; and

at least one through hole extending through the first insulating substrate and the first wiring layer;

an electrical component assembly comprising:

an electrical component having an active surface coupled to an upper surface of the first insulating substrate opposite the lower surface, the active surface of the electrical comprising at least one metallic contact pad; and

at least one conductive stud coupled to the at least one metallic contact pad and positioned within the at least one through hole;

a conductive plug contacting the first wiring layer and extending into the at least one through hole to at least partially surround the at least one conductive stud; and

a component attach material coupling the active surface of the electrical component to the first insulating substrate.

2. The electronics package of claim 1 wherein a portion of the component attach material extends into the at least one through hole.

3. The electronics package of claim 1 wherein the electrical component assembly comprises a plurality of conductive studs and a plurality of metallic contact pads; and

wherein each of the plurality of conductive studs is coupled to a respective metallic contact pad of the plurality of metallic contact pads.

4. The electronics package of claim 1 wherein the at least one conductive stud comprises a first material; and

wherein the at least one metallic contact pad comprises a second material, different from the first material.

5. The electronics package of claim 4 wherein the first wiring layer comprises a third material, different from the first material and the second material.

6. The electronics package of claim 1 wherein the conductive plug comprises a conductive paste.

7. The electronics package of claim 1 wherein a portion of the at least one conductive stud within the at least one through hole is surrounded by an air gap.

8. The electronics package of claim 1 further comprising:

a second insulating substrate coupled to the first insulating substrate; and

a second wiring layer formed on the second insulating substrate and extending through at least one via formed therein to electrically couple with the first wiring layer.

9. The electronics package of claim 8 wherein the at least one through hole extends through the second insulating substrate and the second wiring layer; and

wherein the conductive plug is in contact with the second wiring layer.

10. A method of manufacturing an electronics package comprising:

providing a bumped component assembly comprising an electrical component and a plurality of conductive studs coupled to respective contact pads located on an active surface of the electrical component;

providing an interconnect assembly comprising a wiring layer formed on a first surface of an insulating substrate, the interconnect assembly having a plurality of through holes extending through the insulating substrate and the wiring layer;

coupling the bumped component assembly to a second surface of the insulating substrate by way of a component attach material such that the plurality of conductive studs extend into the plurality of through holes; and

forming a plurality of conductive plugs that electrically couple the contact pads of the electrical component to the wiring layer.

11. The method of claim 10 wherein forming the plurality of conductive plugs comprises dispensing an electrically conductive material into the plurality of through holes.

12. The method of claim 10 wherein forming the plurality of conductive plugs comprises surrounding at least a portion of each of the plurality of conductive studs within the plurality of through holes with a conductive material.

13. The method of claim 10 further comprising

applying a component attach material to one of the active surface of the electrical component and the second surface of the insulating substrate;

and

curing the component attach material.

14. The method of claim 10 further comprising removing a portion of each of the plurality of conductive plugs that extends beyond a surface of the wiring layer facing away from the insulating substrate.

15. An electronics package comprising:

an interconnect assembly comprising an insulating substrate having at least one wiring layer formed on a first surface thereof, the interconnect assembly having a plurality of through holes formed through the insulating substrate and the at least one wiring layer;

an electrical component having an active surface coupled to a second surface of the insulating substrate by way of a component attach material, the active surface comprising a plurality of contact pads;

a plurality of conductive studs, each of the plurality of conductive studs coupled to a respective contact pad of the plurality of contact pads and extending into a respective through hole of the plurality of through holes; and

a plurality of conductive plugs extending into the plurality of through holes to electrically couple the plurality of conductive studs to the at least one wiring layer.

16. The electronics package of claim 15 wherein the at least one wiring layer comprises a first wiring layer formed on the first surface of the insulating substrate and a second wiring layer;

wherein the interconnect assembly further comprises a second insulating substrate positioned between the first wiring layer and the second wiring layer; and

wherein the plurality of through holes extend through the insulating substrate, the second insulating substrate, and the first and second wiring layers.

17. The electronics package of claim 16 wherein a conductive plug of the plurality of conductive plugs is electrically coupled to the first wiring layer and the second wiring layer within a respective through hole of the plurality of through holes.

18. The electronics package of claim 15 wherein each of the plurality of conductive plugs surrounds at least a portion of a respective conductive stud within a respective through hole.

19. The electronics package of claim 15 wherein a portion of the component attach material extends into the plurality of through holes.