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Thin small outline package

The Thin Small Outline Package (TSOP) is a compact, rectangular surface-mount (IC) package with a low profile of approximately 1.0 mm in thickness and lead counts typically ranging from 20 to 48, designed for high-density mounting on printed circuit boards (PCBs). It features gull-wing shaped leads with tight pitches (as low as 0.5 mm) extending from two opposite sides of the package body, enabling efficient space utilization and compatibility with automated (SMT) assembly processes. TSOPs are available in two primary variants based on lead placement: Type I, where leads protrude from the shorter edges of the package (e.g., dimensions around 12 mm × 18.4 mm for a 48-lead version with 0.5 mm pitch), and Type II, where leads extend from the longer edges (e.g., 10.16 mm × 22.22 mm for a 66-lead version with 0.65 mm pitch). These configurations adhere to standards like for interoperability, with maximum heights up to 1.20 mm and materials often including copper leads for enhanced reliability and thermal dissipation. Commonly employed in memory ICs such as , (including and NOR types), , and , TSOPs support applications in portable like mobile phones and players, as well as including laptops, graphics cards, motherboards, and memory cards (e.g., PCMCIA/JEIDA standards). Their key advantages include superior space efficiency—reducing overall assembly volume by one-third to one-half compared to earlier packages—lightweight construction for portable devices, and effective thermal performance through lead-based heat transfer, making them ideal for firmware storage and high-density environments.

Overview

Definition and characteristics

The Thin Small Outline Package (TSOP) is a rectangular, surface-mount integrated circuit (IC) package characterized by its low profile, typically measuring 1.0 mm in thickness, which facilitates high-density mounting on printed circuit boards (PCBs). This design emphasizes compactness, making it suitable for space-constrained applications such as memory devices. Key structural features of the TSOP include a molded body with gull-wing style leads extending from two opposite sides—with placement on the shorter sides for Type I or longer sides for Type II variants—supporting lead counts typically ranging from 20 to 48. The leads feature tight spacing with pitches as low as 0.5 mm (e.g., for Type I) or 0.65 mm (for some Type II), enabling automated surface-mount assembly processes while maintaining electrical and thermal performance. The rectangular has dimensions varying by variant and lead count, ensuring compatibility with standards for reliability and manufacturability. Among its primary advantages, the TSOP's minimal height allows for double-sided population of PCBs, enhancing overall board density without compromising assembly efficiency. It is also cost-effective for medium pin-count , offering a balance of performance and production yield in high-volume electronics manufacturing.

Applications and usage

The thin small outline package (TSOP) is primarily utilized in memory devices, including (DRAM), (SRAM), and modules, due to its compact that supports high-density integration in space-constrained applications. This packaging has been common in such as laptops, mobile phones, and digital cameras since the , where its low-profile design enables efficient stacking and portability without compromising device thinness. In specific usage scenarios, TSOP plays an integral role in PCMCIA and JEIDA memory cards for portable computing, allowing double-sided board mounting within the 3.3 mm height constraint of these standards and facilitating easy expansion in early notebook systems. It is also employed in networking equipment for reliable, compact memory solutions and in automotive electronics to meet stringent space requirements for data storage in control units. TSOP supports high-speed data access in memory-intensive applications through its lead configuration, which minimizes and enables efficient operations; for instance, standard implementations often feature 48 pins to handle address and data lines effectively for storage tasks. As of 2025, TSOP remains relevant in legacy systems and cost-sensitive designs, such as older modules and low-end portable devices, where its simplicity and lower costs provide advantages over more complex alternatives. However, its adoption has declined in favor of (BGA) packaging for newer high-performance , as BGA offers superior pin density, thermal dissipation, and suitability for advanced stacking in modern electronics.

History

Origins and development

The Thin Small Outline Package (TSOP) emerged in the early 1990s as a response to the growing demand for compact, low-profile integrated circuit packaging in portable computing devices. Developed primarily by Intel Corporation and other semiconductor manufacturers, TSOP addressed the height limitations imposed by emerging standards for mobile electronics, particularly following the introduction of the PCMCIA (Personal Computer Memory Card International Association) specification in 1990, which mandated a maximum card thickness of 3.3 mm to enable slim form factors for memory expansion in laptops and palmtops. Key engineering motivations centered on replacing bulkier through-hole packages like Dual In-line Packages (DIP) and taller surface-mount options such as Small Outline Integrated Circuits (SOIC), which exceeded the height constraints of portable applications while offering improved surface-mount efficiency and higher lead densities. In June 1990, pioneered early TSOP adoption by packaging its 1 Mb and 2 Mb devices in this format, utilizing the 1-micron II process to achieve access times of 200 ns and 150 ns, respectively, thereby enabling non-volatile storage in space-constrained environments. Initial TSOP designs targeted a package thickness of approximately 1.0–1.2 mm with a 0.5 mm lead to facilitate double-sided board mounting within the PCMCIA , prioritizing gull-wing leads for reliable joints in automated . Early prototypes emphasized integration with high-density , exemplified by Intel's 1994 introduction of a 32 Mb (dual 16 Mb die) in a 56-lead TSOP optimized for Type I PCMCIA cards, marking a significant milestone in scaling non-volatile storage for portable systems. Standardization efforts culminated in the late 1990s through the , with outlines registered under MO-135 for Type I and MO-142 for Type II configurations to ensure across manufacturers. Intel's 1999 Packaging Databook further formalized these dimensions, specifying lead counts from 32 to 56, a nominal body thickness of 1.0 mm, and compliance with JEDEC Publication 95 for consistent mechanical and thermal performance in memory applications.

Adoption and evolution

The Thin Small Outline Package (TSOP) gained significant traction in the late 1990s as a preferred solution for chips, particularly in personal digital assistants (PDAs) and early mobile phones, where its low-profile design enabled compact device architectures compatible with standards like PCMCIA cards. By the early 2000s, TSOP had become a standard for (DRAM) modules, with and others advancing its use in high-volume production, supporting the rapid growth of and computing applications during that era. Key evolutions in TSOP design addressed demands for even slimmer profiles and environmental compliance; thinner variants emerged in the early to accommodate higher-density memory requirements in portable devices. Following the European Union's Restriction of Hazardous Substances () directive in , manufacturers transitioned to lead-free TSOP configurations, replacing traditional tin-lead plating with alternatives like pure tin or matte tin to ensure compliance while maintaining reliability in processes. TSOP reached its peak usage between 2000 and 2010, dominating consumer memory packaging for applications in laptops, digital cameras, and , with major production volumes driven by leading firms including for and Samsung for . During this period, its surface-mount compatibility and cost-effectiveness made it integral to high-volume assembly lines, facilitating the miniaturization of portable consumer products. From the mid-2010s onward, TSOP experienced a decline as (BGA) and (LGA) packages supplanted it in mainstream memory applications, offering superior thermal dissipation and higher pin density for advanced stacking and integration needs. As of 2025, TSOP persists in low-cost, legacy embedded systems and niche markets where and simplicity outweigh the benefits of newer formats.

Design and variants

Type I configuration

The Type I configuration of the Thin Small Outline Package (TSOP) employs gull-wing leads positioned on the two shorter sides of the rectangular package body, enabling a dual-in-line that optimizes space on narrower printed circuit boards (PCBs). For instance, the TSOP48 variant features 24 leads per short side, supporting lead counts such as 32, 40, 48, or 56 in total. Standard dimensions for Type I TSOP packages include a body width of 12 mm, length of 18.4 mm, height of 1.0 mm, and a lead pitch of 0.5 mm, which collectively contribute to its low-profile design suitable for surface-mount applications. These specifications allow for efficient integration in space-constrained environments, such as memory modules. Key structural features include symmetric lead placement on opposing short sides, which promotes balanced mechanical stress and uniform during assembly. The package body is formed from molded resin that encapsulates the internal components, with the die secured via die attach material to provide robust protection against environmental factors and mechanical damage. This configuration is particularly preferred for applications demanding lengthwise board space efficiency, such as linear memory arrays in or devices, where the elongated body aligns well with sequential layouts. In contrast to the Type II variant, which places leads on the longer sides to support higher pin counts, Type I prioritizes width compactness.

Type II configuration

The Type II configuration of the thin small outline package (TSOP) distinguishes itself by placing gull-wing leads along the two longer sides of the rectangular package body, facilitating higher pin density for applications requiring increased I/O connections. This contrasts with the Type I variant, which positions leads on the shorter sides to prioritize width reduction. Typical dimensions for Type II TSOP include a body width of 10.16 mm, length of 22.22 mm, height of 1.0 mm, and lead pitch of 0.8 mm, supporting an elongated suitable for accommodating more leads without expanding the overall footprint excessively. For instance, the TSOP54 variant features 27 leads per long side, enabling configurations up to 54 total pins for devices with elevated connectivity needs. Structural elements of the Type II design incorporate gull-wing leads with intentional offsets in their positioning to minimize the risk of bridging during surface-mount assembly processes. Internally, the die is connected via to the leadframe, ensuring reliable electrical pathways within the compact, low-profile enclosure. This configuration proves particularly advantageous for scenarios demanding denser pin arrangements, such as in memory controllers or multi-port interfaces, where space efficiency and pin count are critical.

HTSOP variant

The HTSOP (Heat Sink Thin Small Outline Package) is a heat sink-enhanced small outline package similar to TSOP, featuring an exposed metal pad on the bottom surface to facilitate direct heat dissipation to the (). This structural adaptation addresses thermal limitations in compact devices by providing a low-resistance path for from the die to the board. It is typically used for ICs with lower pin counts, such as 8-pin linear regulators. In terms of configuration, the HTSOP maintains gull-wing leads on opposing sides like standard small outline packages, but incorporates a central exposed die pad—typically a area measuring around 2.4 mm × 3.2 mm for 8-pin configurations—while preserving the overall package thickness of approximately 1.0 mm. This design ensures compatibility with existing small outline footprints and surface-mount assembly processes, without altering lead pitch or body dimensions significantly. offers HTSOP primarily for 8-pin devices, with related HTSSOP variants for higher pin counts up to 44. A primary feature of the HTSOP is its improved thermal conductivity, achieving junction-to-ambient thermal resistance (θ_JA) values as low as 35.6 °C/W on a 4-layer , which represents a notable enhancement over non-exposed pad small outline packages for applications demanding efficient cooling. It is particularly suited for power-sensitive integrated circuits, such as linear voltage regulators and drivers in compact , where heat management is critical to maintain performance and reliability. The HTSOP emerged in the early as a response to increasing power densities in portable and high-performance devices, though it incorporates proprietary elements.

Physical properties

Dimensions and lead specifications

The Thin Small Outline Package (TSOP) features a low-profile body with a maximum height of 1.2 mm, ensuring compatibility with space-constrained applications, while lead is maintained at 0.1 mm to facilitate reliable surface-mount assembly. Common package sizes include the TSOP48 Type I variant, measuring 18.4 mm in length by 12 mm in width, and the TSOP54 Type II variant, measuring approximately 22.22 mm in length by 10.16 mm in width, both adhering to standardized footprints for devices. TSOP leads are configured in a gull-wing shape, with typical thickness ranging from 0.15 mm to 0.25 mm and an extension length of 0.6 mm to 1.0 mm beyond the package body to optimize joint formation. Lead pitch varies by configuration: 0.5 mm for Type I packages, where leads protrude from the narrower ends, and 0.65–0.80 mm for Type II packages, with leads along the longer sides depending on lead count. The leadframe material is commonly Alloy 42 (42% nickel-iron) or , finished with plating such as matte tin to enhance wettability and resistance. Dimensional tolerances and package outlines are governed by standards, such as MO-142 for Type I configurations, which specify precise body and lead geometries to ensure interoperability across manufacturers. For PCB design, recommended footprints include a solder mask clearance of 0.3 mm around pads to prevent bridging while accommodating alignment variations during . Pinout conventions for TSOP packages, particularly in memory applications, follow standardized numbering starting from pin 1 at one end of the package, progressing sequentially along the leads, with () and (Vss) typically assigned to specific pins such as 1 and the opposite end for balanced electrical performance.

Thermal and electrical characteristics

The thermal characteristics of the Thin Small Outline Package (TSOP) are essential for ensuring reliable operation of enclosed integrated circuits, particularly in applications with moderate levels. The junction-to-ambient thermal resistance (θJA) for standard TSOP packages typically ranges from 60–100 °C/W, depending on board layout, airflow, and pin count, as measured under JESD51 conditions with a multi-layer test board. The Heat Sink TSOP (HTSOP) variant improves this metric to approximately 30-40 °C/W through an exposed pad that enhances conduction to the , reducing overall θJA by up to 50% compared to non-exposed designs. Maximum dissipation for TSOP devices is generally limited to 0.5-1.0 W to maintain junction temperatures below 150 °C at ambient conditions of 25 °C. Heat dissipation in TSOP packages occurs primarily through the leads, which act as efficient thermal conduits to the , and secondarily via the molded body, whose low thermal conductivity (around 0.8-1.0 W/m·K) limits direct . The thermal θJA quantifies this performance and is calculated using the defining equation: \theta_{JA} = \frac{T_j - T_a}{P} where T_j is the junction temperature in °C, T_a is the ambient temperature in °C, and P is the power dissipation in watts. This formula arises from Fourier's law of heat conduction, treating heat flow analogously to electrical current, with θJA as the ; it is derived by rearranging the steady-state heat balance where the temperature rise across the package equals the product of and , validated through finite element modeling and empirical testing per standards. To arrive at the solution for a given scenario, measure or estimate T_j and T_a via thermocouples or infrared imaging, compute the difference, divide by P (from device current and voltage), and compare against datasheet to verify design margins—e.g., for T_j = 125 °C, T_a = 25 °C, and P = 0.5 W, θJA = (125 - 25) / 0.5 = 200 °C/W, indicating an oversized package or poor board thermal design if exceeding typical values. Electrically, TSOP leads provide low of approximately 1-2 nH per pin due to their short length (typically 1-2 mm beyond the package body) and gull-wing shape, which minimizes loop area and supports high by reducing voltage overshoot in switching applications. between adjacent pins is low, around 1-3 pF, arising from the close pin spacing (0.5-0.65 mm ) and thin air gap, which helps suppress and enables clean signal transmission. These attributes allow TSOP-packaged devices, such as synchronous DRAMs, to achieve data rates up to 100 MHz with burst lengths of 4 or 8 words. Reliability metrics for TSOP packages include robustness to 260 °C peak temperatures for up to 30 seconds, as classified under J-STD-020 for moisture sensitivity level 3 (MSL3) lead-free assemblies, ensuring no or popcorning during surface-mount processes. Under at 85 °C and nominal voltage, the (MTBF) exceeds 106 hours, based on exponential failure distributions observed in plastic encapsulated microcircuits with failure rates below 1 FIT (failures in 109 device-hours).

Manufacturing and assembly

Production process

The production process of thin small outline packages (TSOP) begins with wafer processing, where individual dies are prepared by the silicon wafer using a saw or to separate the integrated circuits while minimizing damage to the edges. This step ensures precise die dimensions suitable for subsequent , typically following front-end fabrication to create the functional devices. Following , the die is attached to the leadframe using , such as silver-filled , and electrical connections are established through —where thin gold wires (approximately 1.3 mils in diameter) are ultrasonically bonded to the die pads and leadframe fingers. The leadframe, commonly made from C194 for its high electrical and strength, is loaded into the assembly line prior to die placement to support the thin profile of the package. Encapsulation follows, involving the injection of thermoset resin, typically novolac-based molding compound, into a mold cavity containing the assembled leadframe and die; this occurs under controlled conditions of approximately 175°C temperature and 10 pressure to achieve a package body thickness of around 1.0 mm while ensuring void-free filling. The , characterized by properties like a temperature () of 165°C and low coefficient of , cures to form a protective body that encapsulates the die and wires. After molding, lead forming is performed by stamping and bending the extended leadframe fingers into the characteristic gull-wing shape, followed by trimming excess material (dambar removal) to define the final lead length and pitch, typically 0.5 mm. This step prepares the leads for surface-mount compatibility. throughout the process includes inspection to detect internal voids or delaminations in the encapsulation and automated electrical testing to verify continuity and functionality, with yield targets exceeding 95% commonly achieved for TSOP packages to ensure high-volume manufacturability.

Handling and reliability considerations

TSOP components require careful handling to prevent (ESD) damage, as they have (HBM) withstand voltages typically exceeding 2,000 V and often >4,000 V. Operators must work within an ESD-protected area (EPA) using grounded wrist straps, dissipative mats, and ESD-safe tools to minimize charge buildup during manipulation. For placement and removal, vacuum pick-up tools with ESD-protective tips are recommended to avoid bending or cracking the fragile gull-wing leads, which can occur from mechanical stress during manual handling. Storage of TSOP devices must occur in sealed moisture-barrier bags (MBBs) containing and humidity-indicator cards to maintain relative below 20% or ≤5% for extended periods, as these packages are typically rated at (MSL) 3. Floor life outside the MBB is limited to 168 hours at ≤30°C and ≤60% to prevent moisture absorption, which could lead to reliability issues during subsequent assembly. If moisture exposure exceeds limits, a bake-out process at 125°C for 24 hours is required prior to to desorb absorbed moisture and reduce weight gain to ≤0.05%. Reliability testing for TSOP packages follows JEDEC Standard 22 protocols to ensure durability under environmental stresses. Thermal cycling tests, per JESD22-A104, expose devices to -40°C to 125°C for 1,000 cycles with 30-minute dwells to evaluate interfacial integrity and solder joint fatigue from coefficient of thermal expansion mismatches. Humidity bias testing, per JESD22-A110, subjects components to 85°C and 85% RH for 1,000 hours under operational bias to assess corrosion and ionic contamination risks in non-hermetic plastic encapsulation. These tests confirm compliance with industry benchmarks, with zero failures reported in qualified lots for representative TSOP memory devices. Common failure modes in TSOP packages include lead cracking due to excessive bending during handling or insertion, which compromises electrical connectivity, and delamination at mold compound interfaces triggered by moisture-induced during reflow (known as the popcorn effect). often manifests as separation along the package sides or die paddle, accelerating under and leading to cracked joints. strategies, such as the aforementioned bake-out and ESD controls, along with avoiding mechanical overstress on leads, significantly reduce these risks; for instance, pre-reflow baking desorbs absorbed moisture to prevent . In consumer applications, TSOP components are rated for a minimum lifespan of 10 years under nominal operating conditions, assuming to maintain temperatures below specified limits. For high-temperature environments exceeding 70°C, power dissipation should be by approximately 50% relative to room-temperature ratings to account for increased thermal resistance (typically 50–100°C/W for TSOP packages) and prevent accelerated aging. This aligns with broader semiconductor reliability models that project extended (MTBF) when operating margins are observed.

Comparisons with similar packages

Key differences from SSOP and TSSOP

The Thin Small Outline Package (TSOP) differs from the Shrink Small Outline Package (SSOP) primarily in profile and lead configuration, with TSOP offering a thinner body of 1.0 mm compared to the SSOP's typical thickness of 1.75 mm (ranging from 1.65 mm to 1.85 mm), making TSOP more suitable for height-constrained applications such as portable devices. While the TSOP achieves a finer lead pitch of 0.5 mm, enabling higher pin counts within a similar footprint, the SSOP maintains a 0.65 mm pitch but features a narrower body due to its leads positioned along the longer edges, resulting in a more compact rectangular form. In comparison to the (TSSOP), which represents a further miniaturized , the TSOP has a comparable height of around 1.0 mm and similar pitches around 0.5–0.65 mm, with TSOP often at 0.5 mm for memory ICs and TSSOP typically at 0.65 mm for logic circuits, allowing the TSSOP to accommodate denser layouts in narrower bodies of 0.9–1.2 mm height. The TSOP's larger body dimensions support bigger memory dies, such as in modules, whereas the TSSOP's narrower profile suits general-purpose ICs with exposed pads in some variants for improved . Regarding pin count and form factor, TSOP packages are typically limited to 48–54 pins in a rectangular shape with leads on the narrow ends, contrasting with SSOP and TSSOP options that extend up to 56 pins in narrower body widths of 5.3 mm or less, facilitating more compact designs. In terms of cost and compatibility, TSOP remains more economical for legacy memory applications due to simpler , though it demands greater real estate than the space-efficient TSSOP layout.

Transition to modern alternatives

As the demands for higher memory density, faster data rates, and improved in applications grew in the late and early , the thin small outline package (TSOP) began transitioning to more advanced alternatives, particularly (BGA) variants such as fine-pitch BGA (FBGA) and chip-on-substrate BGA (COSBGA). This shift was driven by TSOP's limitations in handling increased (I/O) counts and high-frequency operations, where its peripheral leadframe design introduced higher parasitics and longer signal paths that degraded performance in modern and devices. BGA packages addressed these issues by utilizing an area-array of solder balls, enabling up to 3,000 I/Os compared to TSOP's maximum of under 300, while achieving roughly one-third the volume for equivalent memory capacity. For and DDR2 memory specifically, FBGA and COSBGA offered superior electrical characteristics, including reduced noise, lower insertion and , and minimal lead inductance, which improved at clock speeds exceeding those supported by TSOP Type II. Additionally, BGAs provided better thermal dissipation through direct heat spreading and self-aligning assembly during , making them preferable for high-density stacking in configurations. By the early 2010s, this transition had become widespread in and , with stacked BGAs largely replacing TSOP in applications like devices and servers to support gigabit-scale modules. While TSOP remains viable for cost-sensitive, lower-density legacy systems due to simpler manufacturing, modern high-performance ICs predominantly adopt BGA derivatives for their scalability and efficiency. Emerging alternatives like wafer-level chip-scale packages (WLCSP) further extend this evolution, offering even smaller footprints for ultra-compact designs, though BGA continues to dominate packaging as of 2025.

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