would this add up to more power consumptions, a 5w difference per chip is negligible, however if you have a 1000 chip or even a few hundred chip the power bill will shoots up? 1000 chip x 5w = 5000w
You're looking at a break-trough improvement. As said, we're able to fit 16 cores into a 130nm process, outputting 5 GH at 2.7W/GHash.
The 65nm 500mhz design will output 450~500MH at 0.7~0.8~1W so it's definitely a great improvement.
EDIT : Also, the 65nm chip is more suitable for an USB miner device, not for mass deployment of hashing power as multi-core communication have yet to be ironed out.
We think the best choice right now is going for mass production and deployment of the 130nm design with 16 cores, and consider the production of USB miners for re-sale as well.