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TO-5

The TO-5 is a standardized hermetically sealed metal can package for transistors and other semiconductor devices, defined under the Joint Electron Device Engineering Council (JEDEC) transistor outline specifications. Characterized by its cylindrical steel or alloy body with axial leads on a 0.200-inch (5.08 mm) pin circle diameter, it provides robust protection and thermal management for components in demanding environments. The package typically measures about 0.315 inches (8 mm) in body diameter and 0.260 inches (6.6 mm) in height, making it suitable for through-hole mounting on printed circuit boards. Commonly available in configurations with 3 to 10 leads, the TO-5 supports a range of applications requiring high reliability, such as general-purpose , switching, and . Its construction, often featuring glass-to-metal seals for hermeticity with moisture levels below 5000 , ensures durability in high-frequency RF and systems, industrial controls, and optical devices like diodes and photodiodes. The TO-5's design emphasizes excellent thermal conductivity and process stability for and die attachment, contributing to its use in , , and equipment where environmental resilience is critical.

History and Development

Origins in Early Transistor Technology

The TO-5 package emerged in the late 1950s as a key advancement in semiconductor encapsulation, developed to house early transistors during the transition from germanium-based devices. introduced one of the first instances of the TO-5 in 1957 with its 2N332 series of silicon NPN transistors, marking a shift toward standardized metal-can designs capable of supporting higher-performance silicon dies compared to prior packages. However, played a pivotal role in popularizing the package through its 1958 release of the 2N696 and 2N697 silicon mesa transistors, the first commercially produced silicon devices from , which utilized the TO-5 for and demonstrated superior switching speeds for computer applications. These transistors, initially supplied to at $150 each, addressed the growing demand for reliable silicon components in early digital systems. The TO-5 design drew inspiration from earlier metal-can packages like the TO-1, which had been used for transistors since the mid-1950s, but it offered enhancements tailored to 's properties, including improved sealing via glass-to-metal bonds to protect against and oxidation, and better heat dissipation through its robust metal construction. Initial dimensions were standardized around an 8.9 mm base diameter to accommodate expanding die sizes in planar processes, allowing for three to six leads while maintaining a compact footprint suitable for emerging and . This package facilitated the replacement of vacuum tubes in applications such as radios, early computers like IBM's systems, and equipment, where transistors enabled miniaturization and increased reliability. Early production of TO-5 packaged devices faced challenges, particularly with achieving consistent glass-to-metal seals, as mismatches in coefficients between the alloy base and could lead to cracks or leaks during high-temperature assembly processes. Fairchild's implementation for the 2N696 and 2N697 overcame initial yield issues by refining diffusion and etching techniques for mesa structures, enabling hermetic encapsulation that supported the transistors' operation up to 40 V and 150 mA, critical for high-speed switching in 1950s-era circuits. These advancements solidified the TO-5's role in pioneering the silicon era, paving the way for broader adoption in electronics by the early 1960s.

Standardization and Industry Adoption

The TO-5 package was formally registered by the Joint Electron Device Engineering Council () as TO-205AA in the late , establishing it as a for medium-power s and promoting uniformity in the burgeoning . This registration aligned with 's formation in 1958 to standardize solid-state devices, including transistor outlines, under the auspices of the (). Major manufacturers rapidly adopted the TO-5, with introducing the first commercial silicon transistors in this package, such as the 2N332 series in 1957, which helped drive its acceptance as an industry benchmark. followed suit in the early 1960s, further solidifying its prevalence across production lines. By the early 1960s, the package's design tolerances were refined through collaborative efforts involving EIA and the (IEC), ensuring compatibility and easing global interchangeability. A pivotal milestone occurred in 1965 with the TO-5's integration into military specifications (MIL-SPEC), enabling its use in ruggedized applications for defense and enhancing reliability standards for high-stakes environments. In the late , adoption expanded beyond transistors to early integrated circuits, including operational amplifiers like the μA741, which leveraged the package's thermal and hermetic properties for . This versatility accelerated .

Design and Construction

Physical Structure and Materials

The TO-5 package utilizes a robust metal construction for encapsulation of devices, primarily transistors. The base is fabricated from cold-rolled or alloy, measuring 8.9 mm in diameter, and serves dual purposes as a to dissipate from the die and as a mounting for attachment to boards or . The enclosure is completed by a metal cap, typically welded to the base via resistance welding for airtight sealing, with dimensions of 8.1 mm in diameter and 6.3 mm in height to accommodate the internal components while maintaining a compact footprint. Internally, the structure incorporates glass-to-metal or ceramic insulators to electrically isolate the leads from the conductive base, preventing short circuits while allowing axial leads arranged on a 0.200-inch (5.08 mm) pin circle. The semiconductor die is often bonded to the base using methods such as gold-silicon eutectic attachment, which provides low thermal impedance and high reliability under varying temperatures. Key performance metrics include a package weight of about 2 grams. integrity is ensured through leak testing, achieving rates below 5 × 10^{-8} atm-cc/sec to protect against moisture and contaminants.

Lead Configuration and Thermal Management

The TO-5 package employs a standard three-lead configuration for junction transistors, with pin 1 as the emitter, pin 2 as the , and pin 3 as the . The leads are arranged in an equilateral triangular pattern on a circle with a of 5.08 (0.200 inches), ensuring with standard assembly processes. A mounting on the , positioned at a 45° from pin 1, provides orientation reference and mechanical support during insertion. Some configurations include an optional fourth pin connected to the case for grounding applications. The sealing of the leads is achieved through a frit process or ceramic-to-metal bonds, providing electrical isolation and a moisture-resistant barrier that protects internal components from environmental ingress. The cap is attached via resistance welding to complete the enclosure seal. Thermal management in the TO-5 relies on the electrical and thermal connection of the case to the collector terminal (pin 3), allowing direct from the transistor die to an external heatsink or . This path minimizes thermal impedance, supporting reliable operation under moderate power conditions. The maximum is rated at 150°C in many specifications, with power dissipation capabilities up to 500 mW at a 25°C ambient without additional cooling. The junction-to-case thermal resistance, denoted as \theta_{JC}, quantifies the package's heat dissipation efficiency from the die to the case surface and is approximately 40°C/W for the TO-5. It is calculated using the formula \theta_{JC} = \frac{T_J - T_C}{P_D}, where T_J is the junction temperature in °C, T_C is the case temperature in °C, and P_D is the power dissipation in watts. This equation derives from Fourier's law of heat conduction, assuming steady-state conditions and one-dimensional heat flow through the package materials; solving for P_D enables determination of safe operating limits given cooling constraints.

Variants

Three- and Four-Pin Variants (TO-39, TO-9, TO-16, TO-42)

The three- and four-pin variants of the TO-5 package, including the TO-39, TO-9, TO-16, and TO-42, represent compact modifications that reduce overall size while preserving the essential metal can structure for reliable protection against environmental contaminants. These variants are designed for applications requiring fewer leads, emphasizing space efficiency and compatibility with standard TO-5 pin orientations where applicable, such as axial lead configurations on a 0.200-inch pin circle. All maintain the of the original TO-5 but exhibit reduced thermal capacity, limited to a maximum of 350 mW dissipation without external heatsinking at 25°C ambient, due to their smaller form factors. The TO-39 package, with its 9.53 mm height and three pins arranged in a standard emitter-base-collector layout, is commonly used for low-power audio transistors in circuits. Its leads extend to 12.7 mm in length, facilitating straightforward and mechanical stability in through-hole assemblies. This variant balances compactness with moderate performance, suitable for general-purpose switching and where power levels remain below 350 mW under ambient conditions. In contrast, the TO-9 features a flat base design with four pins, incorporating an additional grounding pin to enhance electrical isolation and reduce parasitic effects in RF applications. This configuration improves grounding efficiency, making it ideal for high-frequency operations where stable is critical. The flat base also aids in mounting to heat sinks or PCBs for better thermal contact compared to rounded variants. The TO-16 and TO-42 serve as miniaturized versions with a 6.35 diameter, both supporting three pins for simplified connectivity in space-constrained designs (note: TO-16 is an obsolete outline). These packages excel in high-frequency switching tasks, such as in RF and pulse circuits, where their reduced size minimizes while upholding the hermetic integrity essential for longevity in harsh environments. Their compact profile limits power handling to the 350 mW threshold, prioritizing speed over high dissipation.

Five- to Eight-Pin Variants (TO-12, TO-33, TO-75, TO-76, TO-77)

The five- to eight-pin variants of the TO-5 package, such as the TO-12, TO-33, TO-75, TO-76, and TO-77, extend the original design to support increased pin density for analog integrated circuits and transistors, enabling more sophisticated and power handling in compact enclosures. These packages maintain the characteristic metal can construction with a .200-inch (5.08 mm) pin circle diameter for lead arrangement, but incorporate axial or dual-in-line lead configurations to accommodate 5 to 8 pins, facilitating applications in power and operational where additional connections are needed for , outputs, and bias. The TO-12 and TO-33 variants are configured with 5 to 6 pins and elongated leads of 38.1 mm length, optimized for power amplifiers in environments requiring flexible wiring and enhanced heat dissipation through extended lead exposure. These designs allow for direct integration into point-to-point circuits, reducing parasitic while supporting moderate power levels suitable for audio and RF stages. The TO-33, in particular, features 4 to 6 axial leads arranged on the .200-inch pin , providing a balance between pin count and the mechanical robustness of the TO-5 base. The TO-75 package supports up to 8 pins in a 6-lead axial configuration on a .200-inch (5.08 ) pin circle, with gold-plated leads for superior resistance and in military-grade applications. Measuring 38.1 in overall height, it achieves a of 1 W through its and efficient thermal path, making it ideal for rugged environments like and systems where reliability under and extremes is critical. The TO-76 and TO-77 packages feature a style with 8 axial leads on the .200-inch (5.08 ) pin circle, tailored for operational amplifiers requiring multiple connections for inputs, outputs, and power supplies. The TO-76 features 8 axial leads for broad analog IC integration, while the TO-77's 8-lead arrangement enhances board mounting and in precision circuits, as exemplified by its use in devices like the μA741 op-amp for general-purpose in early integrated . These variants prioritize sealing to protect sensitive dies from moisture and contaminants, supporting applications in instrumentation and control systems.

Ten-Plus Pin Variants (TO-78, TO-79, TO-80, TO-99, TO-74, TO-96, TO-97, TO-100, TO-73, TO-101, TO-205)

The ten-plus pin variants of the TO-5 package represent evolutionary extensions designed to support higher integration levels in integrated circuits and hybrid modules, featuring axial leads arranged in a circular pattern similar to the original TO-5's 5.08 mm pin circle diameter but scaled for additional pins. These packages maintain the metal can or ceramic construction for reliability in demanding environments, with lead pitches typically at 2.54 mm to facilitate through-hole mounting. The TO-78, TO-79, TO-80, and TO-99 packages accommodate 8 axial leads on a 0.200-inch (5.08 mm) pin circle, often employing bodies for enhanced thermal stability and sealing in early ICs and operational amplifiers. For instance, the TO-99 features a metal header with a minimum body diameter of 12.70 mm and height of 6.35 mm, numbered pins 1 through 8 in a circular configuration, and compliance with MO-002-AK standards. These variants were particularly suited for premium-quality requiring robust encapsulation, such as early logic gates and amplifiers, where the ceramic construction provided superior protection against moisture and mechanical stress. Expanding to 10 pins, the TO-74 uses a 0.200-inch pin circle, while the TO-96, TO-97, and TO-100 employ a slightly larger 0.230-inch (5.84 mm) pin circle, enabling hybrid assemblies with dimensions typically ranging from 12.7 mm to 19.05 mm in length for multi-device integration. These configurations supported transitional applications in analog-digital hybrids, prioritizing pin density without significantly altering the TO-5's cylindrical for compatibility in existing assembly processes. For power-oriented designs, the TO-73 and TO-101 variants offer up to 12 axial leads—the former on a 0.200-inch pin circle and the latter on 0.230-inch—with extended cap heights around 6.35 mm to improve heat dissipation in RF modules and high-current devices. The TO-205 family encompasses these power extensions as a header-type package, with the TO-205AA designation representing one of the larger configurations in the series for demanding applications. Overall, the TO series includes over 20 such variants, emphasizing scalability from the base TO-5 design for evolving semiconductor needs.

Applications and Uses

Historical Applications in Electronics

The TO-5 package played a pivotal role in and electronics during the and 1970s, valued for its and robustness in extreme environments. In the , the early Block I incorporated Fairchild Micrologic integrated circuits housed in TO-5 style metal can packages, enabling compact logic functions essential for reliability. These packages facilitated the transition from discrete transistors to early , with thousands of units deployed in guidance systems that demanded high performance under vibration and temperature stress. Similar applications extended to equipment, including radios, where TO-5 transistors ensured operational integrity in field conditions. In , the TO-5 became a staple for small-signal amplification and switching from the late 1950s through the 1970s, appearing in early radios, televisions, and systems. and early , such as those in the TO-5 format, powered audio amplifiers and RF stages in devices like portable radios, contributing to the of home entertainment. For example, Fairchild's pioneering 2N696 and 2N697 transistors, introduced in TO-5 packages, were integrated into consumer audio circuits for their stable performance. The package's prevalence in these applications stemmed from its compatibility with through-hole assembly techniques dominant at the time. Industrial applications in the 1970s leveraged the TO-5 for control circuitry, particularly in automation systems requiring precise regulation. The TO-5 was one of the most common packages for s during the , reflecting its widespread adoption across sectors before the advent of plastic alternatives. Its usage declined sharply in the with the rise of surface-mount devices (SMD), which offered smaller footprints and automated assembly, though TO-5 persisted in high-reliability and select high-voltage scenarios demanding hermetic protection.

Modern and Specialized Applications

In and sectors, hermetic TO-5 variants remain essential for their ability to withstand extreme conditions, including in satellites and missiles. These packages provide robust sealing that protects internal components from , thermal cycling, and , ensuring long-term reliability in space missions and guided munitions systems. For instance, radiation-tolerant optocouplers in 6-lead TO-5 configurations, such as the Skyworks OLH249, exhibit minimal degradation in current transfer ratio under gamma, , and proton bombardment, making them suitable for optical in high-reliability electronics. In RF and microwave applications, the TO-5-8 variant is employed in low-noise amplifiers, leveraging its design for shielding and thermal dissipation in high-frequency circuits up to bands. This package supports oscillators and amplifiers in environments requiring precise , where non- alternatives may fail due to or mechanical . Manufacturers like Electronic Products Inc. (EPI) produce these for custom RF modules, emphasizing or matched to maintain performance in demanding and infrastructure. TO-5 packages find continued use in devices and sensors operating in harsh environments, where their construction and —often exceeding years—outweigh size constraints. In settings like oilfield or chemical sensors, it provides protection against and . These applications prioritize the package's proven durability over modern surface-mount options, particularly in legacy upgrades or mixed-technology boards combining through-hole and SMD components for enhanced reliability. As of 2025, TO-5 production is niche and primarily custom-ordered, with global hermetic packaging supporting high-reliability sectors, driven by and demands rather than mass consumer s. This limited scale reflects a shift toward specialized fabrication, with suppliers focusing on variants tailored for radiation-hardened or high-power needs. The hermetic packaging is estimated at USD 4.23 billion in 2025.

Standards and Specifications

JEDEC and EIA Definitions

The standard TO-205AA establishes the registered outline for the TO-5 package, specifying it as a header-type configuration with axial leads arranged on a 0.200-inch (5.08 mm) pin circle diameter. This standard details the package's physical dimensions, including a nominal body diameter of 0.315 to 0.350 inches (8.00 to 8.89 mm) and a height of approximately 0.215 to 0.250 inches (5.46 to 6.35 mm), ensuring compatibility across manufacturers for through-hole mounting. Pin 1 is designated by a unique orientation feature, such as a beveled edge or tab on the package flange, positioned at a specific angular reference relative to the lead circle to facilitate consistent assembly and identification. Materials are outlined to include a alloy base (typically or cold-rolled steel) for the header, with gold-plated or solder-dipped leads for corrosion resistance and electrical performance, promoting hermetic sealing when welded with a metal lid. Updates to the standard align with environmental regulations like by specifying compatible finishes for leads, such as tin-based over nickel underplating, without altering core dimensional tolerances. Complementing 's outline specifications, EIA (now incorporated into joint standards with JEDEC and ) defines thermal and electrical testing protocols essential for TO-5 qualification, focusing on reliability under operational stresses. For thermal management, JESD22-A104 outlines temperature cycling procedures, subjecting the package to repeated exposures between -55°C and +125°C (Condition C) for up to 1,000 cycles at a rate of 2 cycles per hour, to evaluate mechanical integrity of welds, seals, and lead attachments against mismatches. Electrical testing protocols, such as those in JESD22-A117 for and JESD22-A115 for steady-state life, verify resistance (>1 GΩ at 500 VDC) and withstand voltage (up to 1.5 kV), ensuring the package maintains performance in high-reliability environments. is assessed per JESD22-B102, which mandates dip-and-look or tests on lead terminations, requiring at least 95% coverage with eutectic Sn-Pb or lead-free Sn-Ag-Cu after aging, to confirm robust assembly without voids or dewetting. These protocols collectively ensure the TO-5's robustness, with maximum lead coplanarity limited to 0.25 mm to prevent insertion issues during automated . As of November 2025, the latest revision of JESD22-A104 is F.01 (April 2023). No major revisions to the TO-205AA standard have occurred since its last update, reflecting the package's mature status and ongoing relevance in legacy and specialized applications, with reaffirmations maintaining compatibility updates.

International Equivalents and Variations

The TO-5 package, originally defined by standards in , is adapted internationally through dimension specifications to support manufacturing and . Internationally, equivalents often involve direct conversions of dimensions, such as a nominal body diameter of 8.0 to 9.0 mm and pin circle diameter of 5.08 mm, without unique designation codes in standards like IEC 60747 (which focuses on device characteristics rather than outlines). Regional standards such as German DIN, Japanese EIAJ, Russian , British BS, and Chinese GB/T typically reference or adapt outlines with mm-based tolerances for local fabrication, emphasizing hermetic sealing in industrial applications. across these systems is facilitated by IPC-7351 guidelines for footprints, which provide standardized land patterns in units to ensure reliable assembly.

Advantages, Disadvantages, and Comparisons

Key Benefits and Limitations

The TO-5 package offers excellent sealing, typically achieving leak rates below 5 × 10^{-8} atm-cc/sec , which protects internal components from moisture and contaminants over extended periods. This sealing enables a lifespan exceeding 20 years in sealed conditions, as demonstrated by calculations showing moisture ingress times of up to 24.5 years for packages with leak rates around 4.4 × 10^{-10} atm-cm³/sec air under standard environmental assumptions. Its metal can construction provides superior thermal dissipation, supporting power handling up to approximately 1 W depending on the device and mounting, with junction-to-ambient thermal resistance around 158 °C/W derived from factors in representative integrated circuits. The robust base and resistance-welded lid also confer mechanical ruggedness, making it suitable for vibration-prone environments through enhanced structural integrity compared to non-metal enclosures. However, the TO-5's bulky size, with a of approximately 8 mm (0.315 inches) and height around 6.6 mm (0.260 inches), limits its use in high-density layouts where space is constrained. Through-hole mounting requires additional assembly steps like drilling and manual or , increasing time relative to surface-mount alternatives. Furthermore, the metal construction results in higher costs, often $0.50 or more per unit for components in this package, compared to pennies for equivalent SMD types, due to specialized materials and sealing processes. Non-lead-free versions with pure tin plating on leads are susceptible to tin whisker growth, potentially causing short circuits over time in high-reliability applications.

Comparisons with Modern Package Types

The TO-5 package provides better thermal management than smaller through-hole and surface-mount alternatives like the and SOT-23, primarily due to its metal can design that allows direct attachment to heatsinks for enhanced heat dissipation. For instance, the TO-5 supports power dissipation of up to 800 mW at an ambient of 25°C to 200°C, and 3.0 W at a case of 25°C. In contrast, the typically handles 500-625 mW under similar ambient conditions, while the SOT-23 is limited to around 200-300 mW due to its compact plastic encapsulation and reliance on traces for cooling. However, the TO-5's , with an 8 mm diameter body, is approximately 10 times larger in area than the SOT-23's 1.3 mm × 2.9 mm dimensions, making it preferable for applications exceeding 200 mW where board space is available but thermal performance is critical, such as in legacy power amplification circuits. Compared to high-density modern packages like QFN and BGA, the TO-5 lags in integration scale, supporting only 3 to 8 pins versus the 32+ pins in a typical QFN or hundreds in a BGA, limiting its use in complex assemblies requiring high I/O counts. Nonetheless, the TO-5 excels in reliability for harsh environments, with an operational temperature range of -65°C to 200°C enabled by its metal construction, surpassing the standard -40°C to 125°C limits of non- plastic QFN and BGA packages that are more susceptible to moisture and thermal cycling failures. This durability positions the TO-5 in niche high-reliability sectors like , where density is secondary to robustness. The TO-5 offers comparable hermeticity to flat-packs, both providing sealed protection for sensitive components, but at lower cost for medium-power devices due to simpler over ceramic processing. While flat-packs maintain favor in ultra-high-reliability applications, TO-5 adoption has waned since the early 2000s amid the shift to surface-mount technologies for and automated assembly, compounded by directives favoring lead-free materials—though many TO-5 variants now comply with exemptions for high-melt . As of 2025, trends indicate hybrid integration, where TO-5 persists for power-handling elements alongside SMD components in mixed-signal boards for automotive and industrial systems, balancing legacy compatibility with modern density needs. A key differentiator is the TO-5's effective thermal conductivity of approximately 50 W/m·K for bodies or 17 W/m·K for bodies, versus 0.2-1 W/m·K for typical SMD encapsulants, enabling superior spreading without additional substrates.

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