Editorial Technical Reference

Molded Package

This page explains how Molded Package is classified within Computer, Electronic and Optical Product Manufacturing. Technical values and manufacturer relationships are research references; confirm the current specification and supplier evidence for each order.

Technical Definition & Core Assembly

A protective housing for photocoupler components formed through injection molding processes.

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Product Specifications

Technical details and manufacturing context for Molded Package

Definition
The molded package is the protective enclosure within a photocoupler assembly that houses and insulates the light-emitting diode (LED) and photodetector components. It provides electrical isolation, mechanical protection, and environmental sealing while allowing optical transmission between the internal components. Manufactured using injection molding techniques, thermoplastic or thermosetting materials such as epoxy resin, silicone, or polycarbonate are heated, injected into precision molds, and cooled to form the housing. The package maintains precise optical alignment between the LED and photodetector, ensuring reliable signal transfer. It also provides electrical insulation and protection against moisture, dust, and mechanical stress. Typical package dimensions for a standard DIP configuration include a length of 4.4–5.2 mm, width of 3.5–4.0 mm, and height of 2.0–2.5 mm. Lead pitch is 2.54 mm per IEC 60194, with lead width and length ranging from 0.4–0.5 mm and 3.0–3.5 mm, respectively. The operating temperature range is -40 to 85 °C (IEC 60068-2-1), storage temperature -40 to 100 °C (IEC 60068-2-2), and humidity 5–95% RH non-condensing (IEC 60068-2-78). Insulation resistance is at least 10^10 Ω at 500 V DC (IEC 60250), dielectric strength is 5 kV AC 50 Hz for 1 minute (IEC 60243-1), creepage distance is at least 7 mm, and clearance distance at least 5 mm for reinforced insulation per IEC 60664-1. Typical package weight is 0.3–0.5 g. These values are reference ranges and must be verified for the specific model and application with the legal manufacturer or supplier. The molded package is a critical component in photocouplers used for signal isolation in industrial electronics, power supplies, and control systems.
Working Principle
The molded package is manufactured using injection molding techniques where thermoplastic or thermosetting materials are heated, injected into precision molds, and cooled to form the protective housing. It maintains precise optical alignment between the LED and photodetector while providing electrical insulation and environmental protection. The molding process ensures dimensional accuracy and repeatability, which is essential for consistent optical performance. The package design includes lead frames that provide electrical connections while maintaining isolation between input and output sides. The material selection (e.g., epoxy resin, silicone, polycarbonate) influences thermal, mechanical, and optical properties. During operation, the package must withstand temperature variations, humidity, and mechanical stress without degrading its insulating or optical properties. Verification of package integrity involves checking for cracks, delamination, or discoloration, which could indicate material degradation or moisture ingress. The package's electrical isolation is validated through insulation resistance and dielectric strength tests. Proper handling and storage conditions are necessary to prevent damage before assembly.
Common Materials
Epoxy resin, Silicone, Polycarbonate
Technical Parameters
ParameterTypical rangeNotes & selection driver
Package Length4.4–5.2 mmStandard DIP package dimensions
Package Width3.5–4.0 mmStandard DIP package dimensions
Package Height2.0–2.5 mmStandard DIP package dimensions
Lead Pitch2.54 mmStandard DIP lead spacingIEC 60194
Lead Width0.4–0.5 mmTypical lead width
Lead Length3.0–3.5 mmTypical lead length
Operating Temperature-40–85 °CExtended temperature rangeIEC 60068-2-1
Storage Temperature-40–100 °CNon-operating storageIEC 60068-2-2
Humidity5–95 % RHNon-condensingIEC 60068-2-78
Insulation Resistance≥10^10 ΩAt 500 V DCIEC 60250
Dielectric Strength5 kVAC 50 Hz, 1 minIEC 60243-1
Creepage Distance≥7 mmFor reinforced insulationIEC 60664-1
Clearance Distance≥5 mmFor reinforced insulationIEC 60664-1
Weight0.3–0.5 gTypical package weight

Ranges are indicative industry figures for RFQ preparation, not a supplier commitment. Confirm every value and standard with the legal manufacturer before ordering.

Components / BOM
  • Molded Body Part
    Main protective housing that encapsulates the internal components
    Material: Epoxy resin or silicone
  • Lead Frame Part
    Metal structure that provides electrical connections and mechanical support
    Material: Copper alloy
  • Optical Window Part
    Transparent section that allows light transmission between LED and photodetector
    Material: Clear epoxy or polycarbonate
  • Internal Cavity Part
    Space within the package that houses the LED and photodetector chips
    Material: Air or inert gas

Applied To / Applications

This component is essential for the following industrial systems and equipment:

Industrial Ecosystem & Supply Chain Structure

Complementary Systems
Downstream Applications
Specialized Tooling

Application Fit & Sizing Matrix

Operational Limits
pressure: Atmospheric to 1.5 bar (molded package structural limits)
other spec: Mold flow index: 10-50 g/10min (for injection molding process compatibility)
temperature: -40°C to +125°C (operational range for typical photocoupler applications)
Media Compatibility
✓ Epoxy resin encapsulation ✓ Silicon-based potting compounds ✓ Clean room assembly environments
Unsuitable: High-vibration industrial machinery (due to potential for mechanical stress on molded joints)
Sizing Data Required
  • Photocoupler component dimensions (LxWxH)
  • Required creepage/clearance distances for electrical isolation
  • Number of pins/pads and their pitch/spacing

Reliability & Engineering Risk Analysis

Failure Mode & Root Cause
Cracking or fracture
Cause: Thermal cycling stress exceeding material fatigue limits, often due to rapid temperature changes during operation or environmental exposure.
Delamination or bond failure
Cause: Moisture ingress or contamination at interfaces, combined with mechanical stress, compromising adhesive or molded bonds.
Maintenance Indicators
  • Visible cracks, crazing, or discoloration on the package surface
  • Audible creaking or popping sounds during thermal cycles, indicating internal stress relief
Engineering Tips
  • Implement controlled thermal ramp rates during operation and maintenance to minimize thermal shock stress on the package material.
  • Apply conformal coatings or sealants at vulnerable interfaces and regularly inspect for moisture ingress using non-destructive testing methods.

Indicative industry ranges for design and RFQ preparation. Confirm the exact figures and applicable standard with the manufacturer before specifying.

Compliance & Manufacturing Standards

Applicable Standards
ASTM D3641 - Standard Practice for Injection Molding Test Specimens of Thermoplastic Molding and Extrusion Materials CE Marking - EU Directive 2001/95/EC on General Product Safety

Quoted from the published standard.

Manufacturing Precision
  • Wall Thickness: +/-0.1mm
  • Dimensional Stability: +/-0.05% of nominal dimension
Quality Inspection
  • Dimensional Verification with CMM (Coordinate Measuring Machine)
  • Visual Inspection for Surface Defects and Flash

Manufacturers of Molded Package

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Frequently Asked Questions

What materials are commonly used for molded packages?

Common materials include epoxy resin, silicone, and polycarbonate. These are selected for their insulating properties, thermal stability, and ability to be molded precisely. The specific material grade should be confirmed with the manufacturer for the intended application.

What are the typical dimensions of a molded package?

For a standard DIP package, the length is typically 4.4–5.2 mm, width 3.5–4.0 mm, and height 2.0–2.5 mm. Lead pitch is 2.54 mm, lead width 0.4–0.5 mm, and lead length 3.0–3.5 mm. These are reference ranges; actual dimensions may vary by model.

How is electrical isolation ensured in a molded package?

Electrical isolation is achieved through the insulating properties of the molding material and the package design. It is verified by insulation resistance (≥10^10 Ω at 500 V DC) and dielectric strength (5 kV AC for 1 minute) tests per IEC standards. Always verify these parameters for the specific product.

What environmental conditions can a molded package withstand?

Typical operating temperature is -40 to 85 °C, storage temperature -40 to 100 °C, and humidity 5–95% RH non-condensing. These are based on IEC standards. For extreme conditions, consult the manufacturer for derating or special versions.

Data Basis

Editorial classification, named public sources where available, and source-reviewed manufacturer records.

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