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Cor_ad NASa99236

Development of Electrost_cally Clean

Solar Array Panels

Final Report

May 16, 2000

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Prepared by:

Composite Optics, Incorporated

For:

NASA / Goddard Space Flight Center

COl- TR - 1413 - 002

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Composite Optics, Inc. • 9617 Distribution Ave. • San Dieso, CA 92121Tel: 619.621.5700 • Fax: 619.621.5770 • EMail: [email protected] • Web: www.coi-world.com

https://ntrs.nasa.gov/search.jsp?R=20000073303 2018-06-17T22:08:55+00:00Z

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BackgroundCertain missions require electrostatically clean solar array (ECSA) panels to establish a

favorable environment for the operation of key scientific instruments. Current technology

solar arrays have exposed electrical circuitO, that interacts with the ambient plasma. Thisinteraction affects the floating potential and particle trajectories surrounding the spacecraft,

and so may influence scientific mission readings. Solar arrays with exposed conductors canboth introduce and absorb current from the surrounding environment, and affect the shape of

the plasma sheath that typically surrounds a solar array in earth orbit.

The exposed circuitry of a solar array comprises primarily the solar cell interconnects and celledges, although cell string terminations, panel diodes and terminal boards can also providesites for electrostatic field interactions. Typical solar cell arrays use individual cell /

eoverglass assemblies that have spacing between the cell/cover assemblies for electrical andthermomechanical reasons. If the covers use a conductive coating, the covers must be

electrically connected to each other and to the array structure to establish a ground plane.

Even so, spaces between the coverglasses still expose interconnects to interact with theambient environment. A large number of these spaces exist on a typical solar panel because ofthe relatively small size of cell / coverglass assemblies.

An electrostatically clean solar panel needs a method for covering these inter-cell and edge

areas so as to create a contiguous ground plane on the front side and edges. This would enablea panel that surrounds the solar cells with a grounded shield, since electrical conductivity is

already achieved on the array backside. The approach needs to minimize thermal mismatchstresses, use materials and processes that are qualified by similarity to existing techniques on

solar panels, and minimize cost and complexity. Reliable electrical continuity of the groundedshield and insulation of the shield from the photovoltaic electrical circuit is critical.

Objective

Approach

The objectives of this program are to design, develop and demonstrate:

• an ECSA panel with continuous grounded shield surrounding the photovoltaic circuit,which uses Standard Power Modules (SPM's are multiple cells under a single

conductively-coated coverglass),

• a Front Side Aperture (FSA) shield component that covers the areas between SPM's andaround the edges, uses space qualified materials, is compatible with established paneltechnology and manufacturing approaches, and is simple and low-cost, and

• an electrical bond between the coverglasses and the FSA shield that provides electricalcontinuity for the panel front and back sides, and insulation to assure electrical isolation

between the FSA shield and the power circuit.

To accomplish the program objectives we set up a program team using expertise from COI,

Maxwell Technologies, Inc., (MTI) and Tecstar. CO1 is to apply our knowledge in solarpanel substrates and structures and electronic packaging techniques to create a grounded

structure with appropriate shielding and grounding qualities. MTI is to apply its experienceand knowledge in analysis electrostatic cleanliness criteria by performing simple calculations

and establishing test and verification criteria. Tecstar is applying its solar cell arraymanufacturing technology and SPM design to create the basic panel photovoltaic circuit,

suitable to modification into a shielded design.

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The program approach includes the following elements:• COl completes the basic design of an FSA that meets mass and manufacturability

requirements• MTI analyzes the COl pre-design for its performance in maintaining low electrical

potentials near the panel, and to establish criteria for surface resistance that will result inmeeting the surface potential requirements of the program

• Tecstar populates and flash tests the two protoflight coupons using substmtes supplied byCOl

• CO1 fabricates and assembles the FSA onto the populated coupons, and exposes the

coupons to thermal cycling environment. Electrical testing of the coupons before andafter thermal cycling leads to an evaluation of design alternatives, and choice of the bestdesign

• CO1 and Tecstar fabricate and protoflight panel, and expose it to acoustic and thermalcycling regimes to qualify the performance and durability of the chosen design approach.

ECSA Panel Design & Analysis

ECSA Panel Design

The basic geometry of the ECSA Panel, shown in Figure 1 uses SPM's each with an ITOcoated coverglasses, and a Front-side Aperture Shield (FSA) to establish a contiguous groundplane on the panel front side surface.

ITO Coated Coverglass on SPM

FSA Grid

Edge Shield

Figure 1. Basic Geometry of an ECSA Panel Using a Front Side Aperture Grid Shield

COl developed the design for the qualification panel coupons using two different FSAbonding approaches and four different FSA-to-coverglass interconnecting schemes, one foreach SPM aperture. The design of the FSA for the qualification coupons is shown in Figure 2.

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u The two approaches used for bonding the FSA to the coverglasses are a compliant RTV bond,and a film adhesive with an imbedded copper mesh. The interconnects shown on the threc

apertures are connected to the coverglasses with conductive adhesive, using McGann NusilCV2-2646 silver-filled silicone adhesive. The fourth aperture, which is shown as blank, uses

beryllium copper contact fingers, electrically and mechanically bonded to the FSA, andspring-contacted to the coverglass. This mechanical contact approach is derived from EMIshielding gaskets used in electronic packaging applications. The circular features on thecomers of the FSA are for tooling pins to register the FSA against the SPM's during assembly

of the qualification coupons. A similar set of registration features will be used on the full-

scale prototype panel coupon.

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Figure 2. Layout of the Frontside Aperture Shield for the Qual Coupons.

ECSA Panel Analysis

Structural AnalysisA top-level structural analysis was performed on the ECSA panel design to examine the

stresses on the components of the panel associated with the modifications needed forelectrostatic cleanliness. The panel materials considered in the analysis were glass, siliconeadhesive and T300 composite 0.15ram, 0.1 nun and 0.Smm thick respectively. A finiteelement model was constructed representing four cells and constrained at each of the four

edges. Each edge is free to slide in plane, but constrained out of plane. The panel wasanalyzed using the two worst-case thermal load cases - cold soaking to -180C, and hotsoaking to +90C. These analyses considered the stress-free condition to be at an ambient

room temperature of 21C. The resulting stresses were compared with the known ultimate

capabilitiesof each material. This comparison showed large positive margins in all eases.Maximum deflections of the panel were 1.0mm under the +90C soak and 3.0mm while

subjected to the -180C cold soak.

Of particular interest for maintaining the integrity of this design is the ability of the siliconeadhesive to accommodate differential CTE stress. The maximum principal stress imposed on

the adhesive was 70 psi. This compares with the specified tensile strength of the NuSil CV2-

2506-6 at 350 psi.

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Electrostatic Analysis

MTI performed electrostatic analysis of the ECSA design, focusing on exposed voltageestablished near the panels by the photovoltaic circuit, and the potentials established on the

panels due to the charged particle environment. Detailed results for the MTI analysis are

provided as Appendix I.

MTI looked at the ECSA design to determine the voltages that might be incurred near the

panel ff the FSA does not seal the edges of the SPM's. A gap height of 20mils (0.5mm) wasused as a typical value achievable between the FSA and the SPM ff a continuous bond to theedges of the coverglass was not used. The results showed that a small voltage is established

near the gap area (<0.9V), but that this voltage dissipates rapidly with distance away from the

gap, and is in fact <lmV at a distance greater than lmm from the panel surface.

MTI's analysis of maintaining equipotential on the ECSA panel surface looked at differentITO thicknesses and resulting resistance, and determined the maximum voltage that could be

established on the coverglass under exposure to the charged particle environment. Initially,

the environmental requirements were reviewed and found to be overstated by an order ofmagnitude. This is because it is the ram ion current, rather than the electron current that will

result in charging of the panel surface. Since the ion current density is 0.1 _tA/cm 2 rather than

the 1i.tA]cm 2 specified in the requirements. As a result, NASA agreed to modify therequirements to reflect the expected environmental interaction. The results of this analysis

showed that an ITO coating with a resistivity of 3x10E+4 D/square or less would be needed

to establish a potential of <0.1V. This coating would be about 150A thick.

MTI also Performed analysis to determine what the test criteria should be for establishing thatsufficient conductivity had been achieved within the ITO coating and from the coating to the

FSA grounded structure. This analysis considered various geometric configurations shown inFigure 2, and concluded that a measurement of less than 100kohms from the center of thecoverglass to the structure would be sufficient to maintain the 0.1V requirement under space

conditions. The analysis also showed that the results would be relatively independent of thesize of the probe used to pick up the conduction path at the center of the coverglass.

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Qualification Coupon FabricationHaving established the basic design of the qualification coupons, we sought to develop themanufacturing technology on some dummy test hardware to prove out the fabrication process

without risking the populated panels. Three man-tech coupons were built to show the ability

to position and bond the FSA while limiting the unwanted exposure of adhesive. The man-tech coupons used three different FSA bonding techniques - RTV CV2566 silicone adhesive,a similar silicone provided in a beta-staged pre-form, and a film adhesive with embedded

copper mesh. Dummy coverglasses were fashioned from ordinary plate glass and mountedonto a typical solar panel substrate. The man-tech coupons showed the ability to bond the

FSA using all three adhesive systems, although the liquid RTV system was the hardest to

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maintain cleanliness. We chose to use the RTV pre-form (Coupon#002) and the film adhesive

approach (Coupons#001) for the qualification coupons.

Two qualification coupons were fabricated. Each used four SPM's, where each SPM used twosolar cells and a single coverglass. Redundant wiring was soldered to the solar cell

interconnect pads at the edge of the panel, requiring that some of the FSA be trimmed away toprevent mechanical interference. One of the two qualification coupons is shown in Figure 3.

Figure 3. Qualification coupon using four coverglass interconnect approaches

Qualification Coupon TestsElectrical I-V and resistance tests were performed on the qualification coupons prior to

thermal cycling. Table 1 shows the values that were achieved on the two qualificationcoupons. Resistance readings were difficult to measure because an anti-reflection coating

exists on top of the ITO coating on the coverglass. We had to scratch through the AR coatingto get a reading. Conductive pads could also be used, but required some pressure to be appliedin order to get consistent readings.

Table 1. Resistance values (in kilo-ohms) measured on the qualification coupons prior to

thermal cycling.

Interconnect type Qual coupon #1 Qual coupon #2Slant i0 33

Serpentine 93 98Diamond 5 23

Be-Cu Contact Fin_er 8 27Electrical measurements taken on the qualification coupons before and after bonding of theFSA showed an efficiency reduction of about 4% on S/N 001 and 6% on S/N 002. Resistance

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from the PV circuit to the structure was open on both coupons initially. Because a couple of

the interconnects on coupon #002 had poor fillets on the conductive adhesive bond, wetouched them up prior to thermal cycling by adding additional adhesive. Unfortunately, some

squeeze-out into the solar cell area caused a resistive short from the structure to the solar cell

string, initially measured at > 1M.O.

The coupons were thermal cycled from -180C to 35C for 200 cycles, and re-measured, thenthermal cycled from -90 to 90C for 1000 cycles and re-measured. The results of thesemeasurements are shown in Tables 2 and 3. After the initial 200 cycles, it was observed thatthe film adhesive bond between the FSA and the SPM for coupon #001 failed almost

completely, lifting the FSA away from the surface, and pulling up the serpentine interconnectswith it. As a result, no conductivity reading is seen for the serpentine or Be-Cu contact finger

for coupon #001 after thermal cycling. Some separation of the bond-line around the area ofthe beryllium contact finger on Coupon #002 was also observed. In addition, the shunting

resistance in Coupon #002 had decreased to <300ohms.

Table 2. Resistance values (in kf).) measured on the qualification coupons after 200 cycles

from 180 to 35C.

Interconnect type Qual coupon # 1 Qual coupon #2Slant 20 12

Serpentine open 26Diamond 6 7

Be-Cu Contact Fin_er open 8

Table 3. Resistance values (in k_) measured on the qualification coupons after 1,000 cycles

from -90 to 90(7.

Interconnect type Quai coupon # 1 Qual coupon #2Slant 31 50

serpentine open 97Diamond 50 20

Be-Cu Contact Fin_er open 52

Qualification Coupon Analysis

Qualification coupon #002 represents a design that appears to have the ability to meet allprogram requirements. The RTV pre-form bond appears to be solid after thermal cycling, andthe conductive adhesive also maintained bond integrity. Although all four interconnect

approaches appear to work, the diamond interconnect configuration gave consistently lowerresistances. The effectiveness of the diamond interconnect configuration may be due to

maximiTJng continuous fibers within the interconnect. Also contributing may be the dualconductive path from the contact point of the coverglass, through the two legs of the diamond,

to the FSA body structure.

The use of a film adhesive with an imbedded copper-mesh does not provide sufficient bond

strength to maintain mechanical connection in a thermal cycling environment. There may beseveral contributing causes to this, including the stiffness of the film adhesive, its relatively

high CTE, stress applied by the beryllium-copper contact finger which may have increasedwith temperature, and possibly the bond-ability of the AR coating surface.

Given the successful measurement of the key parameter of coverglass conductivity to

structure on Coupon #002, especially for the diamond interconnect geometry, werecommended that the protoflight panel use that design exclusively.

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Based on the results of the qualification coupons, a prototype panel was fabricated that

incorporated the diamond coverglass interconnect approach on a larger scale. The prototype panelused a total of 48 Standard Power Modules (SPM), with each SPM comprising two solar cells, a

series interconnect between the cells, as a single coverglass covering both cells.

The layout of the solar cells was coordinated with Tecstar to allow appropriate spacing betweeneach SPM, based on achieving a minimum structural bond-line width between the FSA edges and

the coverglasses of 0.75mm (0.030"). A section of this layout pattern is shown in the drawing of

Figure 4. Tecstar assembled the SPM's, interconnected them to form 4 series connected strings of12 SPM's (i.e., 24 cells) each, and laid them down onto the COI supplied substrate to the pattern

described by the layout drawing.

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Figure 4. Cell layout drawing used to provide appropriate spacing for the FSA.

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We then completed the assembly of the ECSA panel,using a single-piece FSA fabricated fromT300 graphite fiber reinforced composite fabric, along with some Z-clips to close out the edges ofthe FSA to the edges of the substrate. As with the qualification coupons, this provided a complete

and continuous grounded enclosure for the active solar cell components. Finally, we usedconductive adhesive to bond the diamond interconnects to the coverglasses. The resulting panel is

shown in the photographs of Figure 5. A listing of the parts and materials used in constructing this

prototype panel is provided as Appendix 2.

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Figure 5. Completed prototype ECSA panel.

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The overall size of the prototype panel, including the extra edge area (edge distances were notoptimized) is 0.532 X 0.585m Its mass properties are shown in Table 4.

Table 4. Mass properties of the prototype panel.

Component ,. Mass$ ubstrate 711

Panel withoutEC compo_nts (FSA, ec_e clips,and structuraland conductiveadtw,sives) 1055_

Completedprototypepanel 1118g

Based on these mass properties, we observe that the components needed to provide electrostatic

cleanliness add approximately 6% to the mass of a typical high performance solar panel. This doesnot include any mass added as a result of extra spacing between the solar cells needed toaccommodate the FSA.

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Prototype Panel Functional Tests and Environmental Exposures

The prototype panel was put through a set of functional tests and environmental exposures in

the following order:

• Functional / Electrical testing

J Acoustic Testing

• Functional / Electrical Testing

• Thermal Cycling

• Functional / Electrical Testing

Each functional test included panel photovoltaic performance and electrical isolation andgrounding. Functional testing was performed prior to and subsequent to each environmental

exposure.

The photovoltaic performance testing was performed at Tecstar evaluated by taking I-V

curves at room temperatmx. _and at 70C. 70C data was taken in a hot-box with Lexan window,with compensation for window transmission loss accomplished by using a referencecalibrated solar cell. For the discussion in this section, we present the summary of the room

temperature data, but complete data sets are provided in Appendix 3. No unusual effects wereobserved in the 70C data either before or after environmental exposures.

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Figure 6. Electrical isolation/grounding test setups

Electrical isolation and grounding performed at COl, i.e. isolation between the photovoltaiccircuit and the panel ground/structure, resistance between each coverglass and ground. Thetest setup is illustrated in Figure 6. All isolation measurements were made with photovoltaic

circuit leads shorted to each other to prevent the possibility of electrical damage.

Initial photovoltaic electrical testing of the prototype panel prior to application of the FSA

component is summar/zed in Table 6. The results summarize the performance with all fourcircuits tied together in parallel. Although this was not a required measurement for this

program, we wanted to understand how aperture blockage by the FSA affected the paneloutput.

The panel performance after final assembly, prior to acoustic testing is summarized in Table7. From these results, we can see a current decrease of 7% with an equivalent decrease inefficiency performance. A slight drop in fill factor can be attributed to small additional

mismatch in maximum power current between the various cells resulting from differences inblockage by the FSA and its associated bonds. The panel was also tested electrically for

circuit isolation from ground and resistance from each coverglass to the panel substrate. Theresults of these tests are summarized in Table 8.

Table 6. Photovoltaic performance of the prototype panel at room temperature prior to application ofmodifications for electrostatic cleanliness.

Parameter Value

Voc 58.78V

Isc 1.49A

Pmax 69.42W

Vmp 49.37V

t,,.,e L41AFF 79.1%

Efficiency 21.98°/o

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u Table 7. Baseline photovoltaic performance of the assembled prototype panel at room temperature shows a7% decrease in current compared to a bare panel resulting from the expected FSA blockage.

Parameter Value

Voc 58.61V

Isc 1.40A

Pmax 64.33W

Vmp 49.26V

Imp 1.31AFF 78.2%

Efficiency 20.37%

Table 8. Results of electrical continuity and isolation tests for the prototype panel pre- environmentalexposure.

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Acoustic testing was performed at Wyle Laboratories to the environment specified in theStatement of Work and Specification for the Development of Electrostatically Clean Solar

Panels. The panel was placed in a net and exposed to an acoustic environment exceeding142.5dB for a period of 60 seconds. The Wyle test report is included as Appendix 4.

After this exposure, panel photovoltaic and electrical measurements were completed. Theseresults, as exhibited in Tables 9 and 10, indicate no change in photovoltaic performance (<1%

variation in all parameters), but some increase in the number of coverglasses that exceed the

maximum resistance requirement. After acoustic testing the number of coverglasses that didnot have a resistance to ground of less than 100kohm was 11 compared to 4 out of 48 prior to

acoustic testing. Visual inspection of the bonds did not indicate any obvious cause for thisloss of continuity.

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Table 9. Photovoltaic performance of the prototype panel at room temperature after acoustic.

ParameterVoc

Isc

Pmax

Vmp

ImpFF

Efficiency

Value58.66V

1.40A

64.78W

49.31V

1.31A

78.9%

20.51%

Table 10. Results of electrical continuity and isolation testing for the prototype panel after acoustic test.

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Following this evaluation, the prototype panel was bagged and placed in a thermal cycle

chamber, and exposed to thermal cycle environments of 200 cycles from -180 to 35Cfollowed by I000 cycles from -90 to 90C. Test tolerances for each thermal cycle environmentlimits were +/-5C.

Inspection of the panel after thermal cycling showed no observable physical effects. Therewas no warping of the panel or the FSA, and all structural bonds appeared intact. The results

of photovoltaic and electrical testing are provided in Tables 11 and 12. Photovoltaic testingshowed no change in performance (<1% difference in all values). Electrical isolation was still

good, but continuity testing did indicate 8 additional failures of coverglass-to-FSA bonds. Atotal of 19 out of 48 coverglasses did not meet the continuity requirement after all

environmental exposures. A failure analysis was performed on the coverglass continuity andis described in the next section.

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Table 11. Photovoltaic performance of the prototype panel at room temperature after thermal

cycling in simulated LEO and GEO environments.

Parameter Value

Voc 58.66V

Isc 1.40A

Pmax 64.57W

49.29VVmp

ImpFF

Efficiency

1.31A

78.9%

20.45%

Table 12. Results of electrical continuity testing for the prototype panel after thermal cycling exposure.

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Prototype Panel Evaluation and Failure AnalysisThe prototype panel was evaluated to determine its ability to meet the requirements of thisprogram. The photovoltaic performance, electrical continuity, and visual inspection of the

panel before and after environmental exposures demonstrated the following key attributes:

• A composite FSA can be used as an electrostatic shield with a small performance andcost penalty, and is structurally robust in acoustic and thermal cycling environment.

Beyond the shadowing of solar cells from the FSA, the performance of the solar panel,

and its response to acoustic and thermal cycling environment, is not impacted by additionof electrostatically clean features.

A continuous grounded enclosure that would result in less than 0. IV of potential between

any two points on a solar panel can be assembled using 1TO coated coverglasses, the FSAand conductive adhesive providing a connection between the two through a stress-relieved interconnect.

The ability to maintain grounding continuity to the SPM's after environmental exposure wasnot demonstrated because of failure of the conductively bonded_ joints. The direct cause of thefailure was loss of adhesion at the interface between the glass and the conductive adhesive,

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which we determined by measuring resistances across the FSA, and between the coverglassesand the FSA on the failed SPM's.

We performed a failure analysis to determine the root cause of the loss of bond adhesion tothe covcrglasses, using the "fish-bone" failure analysis technique. The fishbone approach

correlates observations from inspection and non-destructive testing to possible failure modes.

It is especially useful when multiple causes may be involved, and limited diagnostic test dataare available.

The root cause fishbone for the bond adhesion failure is shown in Figure 7. Additionaldiagnostics were performed to support the fishbone analysis - measurement of surface

resistance within each coverglass, evaluation of conductive adhesive bond size and filletshape, and evaluation of position of the failures. The results are summ_ed in Table 12, and

the plot of the coverglass resistances as a function of position shown in Figure 8. The analysisof the likelihood of root cause based on the possibilities presented in the fishbone diagram is

provided in Table 13.

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FSAtoostiff _ Sir¢one

aC?o_eSsf_exceeds J . . / contaminalion

adhesiveorcoatin_ ;_=quate surfac_

I I IFigure 7. Root cause failure analysis fishbone diagram

Failureofbondbetweencoverglass&conductiveadhesive

Table 12. Additional NDE performed for fishbone evaluation. Failed bonds are shaded.

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ECSA Coverglass Continuity Post-Thermal Cycle

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$3 [] 60.0-80.0

$4 [] 40.0-60.0• 20.O-40.0

$5 [] 0.0-20.0

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Figure 8. Correlation between areas of marginal and failed continuity with position on thepanel.

Table 13. Root cause analysis based onfishbone diagram.

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Categoric Possible Cause Likelihood Rationale

Adhesive Material

Adhesive Geometry

Not the best material for this application

Ol&'bad batch of material

Too little adhesive

Too much adhesive

Bad fillet shape

CTE stresses exceeds allowable

FSA too stiff

Design

Bonding Surface Coverglass coating inconsistency

Inadequate surface prep

Silicone or other contamination

Very Unlikely

Unlikely

Possible Contributor



Unlikely

Unlikely/


Likely Contributor

Likely Contributor

This material qualified for flight coverglass ESD bond

Material controlled to R&D standards

Some correlation

Some correlation

Some evidence

Based on stress analysis results

Based on material selection and stress analysis

Correlation between inconsistent coverglass surface resistance

Minimal prep was used to prevent coating erosion

Groupin 6 of failures and hitcher bond resistance areas

Based on the analysis summarized in Table 13, the most likely root cause appears to be acombination of contamination and inadequate surface preparation. We had discussions with

OCLI and Tecstar about how silicone squeeze-out is cleaned during the lay-down process, thepotential for silicone contamination on the glass surface, and how we should have preparedthe surfaces for bonding. The conclusion of this discussion is that there was a high likelihoodof some level of silicone contamination on the coverglasses, which should have been removedby cleaning the surface prior to adhesive application.

The grouping of failures is further evidence of local area contamination, and the differences incovergiass surface resistance may be evidence of either contamination or inconsistent coatingthickness. Our lack of experience in bonding to coated glass surfaces led us to be overlycautious in preparing the glass surface. The coverglass coating, comprising ITO with MgF ARovercoat is more durable than we had assumed, and should be cleaned thoroughly with

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acetone and alcohol prior to applying the conductive adhesive. The structural analysis, whichindicates a relatively low load on the conductive bond joint, and the extensive heritage around

bonding grounding wires to coverglasses using this adhesive, make the risk of the correctiveaction for this developmental failure low. Implementation of this corrective action anddemonstration of its effectiveness can be accomplished as part of the initial ECSA flight

application qualificaiton.

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This development program has developed a design with the ability to meet the statedrequirements of this program. The following technical goals and requirements, taken from the

program Statement of Work and Specification, were demonstrated by analysis or tests on the

prototype panel:

Demonstrated the ability to establish equi-potential solar array surface (<100mV) by

bonding the FSA to conductively coated coverglasses, establishing the method formaintaining that electrical continuity through the panel life-cycle, and through analysis of

the panel geometry.

Demonstrated the ability to prevent exposure of voltage produced by the solar cell, and

panel insulators to the charged particle environment through encapsulation of inter-cellareas using a grounded conductive shield. This was shown by MTI's analysis in this

program to result in negligible electric potentials from being established even lcm awayfrom the panel. The FSA, which provides this function, was demonstrated for structural

integrity in launch and space environments.

Minimization of the number of parts used to achieve electrostatic cleanliness wasachieved. The prototype panel used a single FSA and four edge clips, a total of five parts

(plus two kinds of adhesive), which minimizes cost and complexity.

Established small and consistent current and associated power reduction from

incorporation of electrostatically clean components, at about 7%. We also established

stability of solar panel performance in acoustic and thermal cycling environment with

these components incorporated.

• Established that the mass penalty for achieving electrostatic cleanliness is small, on theorder of 6%.

The cost delta associated with achieving electrostatic cleanliness is small. For the

prototype panel, the cost for fabricating the FSA and edge clips, and bonding thesecomponents structurally and electrically, added -5% to the cost of the panel.

The design of the prototype panel is compatible with any thickness coverglass, any typeof solar cell, standard spacecraft outgassing requirements, and standard solar arraymaterials and assembly processes. The design uses no magnetic parts.

The ECSA technology that was developed in this program has demonstrated the capability tomeet all of the goals and requirements of this program, and should be qualified for flight on

an intended application. In implementing a new solar panel technology, materialcharacterization testing, the fabrication of Design Evaluation Test (DET) coupons and a

qualification panel are often standard practice. In addition, it is advisable (and standardpractice at COl) to establish allowables for bonded joints in a flight configuration for anystructural bond, whenever new material and adhesive combinations are involved.

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We recommend that a bonded joint characterization program be implemented as part of the

solar panel qualification for the first mission to use this technology. The characteriTationwould establish allowable ultimate tensile stress for a bond between graphite fiber reinforced

composite and coated glass. Structural analysis can then use these allowables to establish themargin of safety for this adhesive bond joint. The use of DET coupons for thermal cyclingand other environmental tests will demonstrate the corrective action to resolve any remaining

questions regarding the robustness of the ECSA design. Finally, the implementation of thedesign on a full-scale qualification panel should remove any uncertainties associated withscale-up of the technology.

A further recommendation for implementation of this technology relates to rework and repairof individual solar cells. Typically such a process is necessary to account for cell cracking orother failures that can occur during array acceptance testing. We recommend that a removeand replace procedure be developed for ECSA panels that account for the removal andreplacement of part of the FSA and edge clips, if necessary, as well as the solar cells. Whilewe don't anticipate this to be a major effort, since the FSA and edge clips are thin and can bereadily cut and removed with an razor blade, it is nonetheless a process which would need tobe worked out for the eventual application.

Finally, the performance of the ECSA components should be optimized as part of theengineering development and qualification of a flight panel design. The reduction of panelperformance by shadowing and cell spacing can be minimized by reducing the width of theindividual elements of the FSA, and by maximizing the size of each SPM. If the width ofeach member of the FSA were reduced from 0.5 l cm to 0.25cm, and the number of cells perSPM were increased from 2 to 4, this would reduce the degradation in packing factor from 7%

to 2%, and the shadow factor from 7% to 4%. The net result would be a reduction inperformance penalty for electrostatic cleanliness by more than half, to about 6%. This wouldalso reduce the mass associated with the components used for electrostatic cleanliness whilehaving a negligible impact on cost. By using a flight application to optimize and demonstratethis approach, these recommendations will bring a higher performance Electrostatically CleanSolar Array panel concept to a state of flight readiness.

= =u

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Appendix I - Electrostatic Analysis Of the-ECSA Panei

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Appendix 2 - Parts and Matedals Used In Construction of The Prototype Panel

Substrate:

Faceskins - M55J/950-1, .0025" CPT, 5 plies (90,45,0,-45,90), FV=61%, RC=38%

Aluminum Honeycomb Core - CR3-5056.0015" foil, 1/4" cell, 3.4 pcf

Film Adhesive - Reticulated FM73U, .030pcf

Insulator - Kapton, .002" FPC

Solar Cell Blanket:

Solar Cells - Tecstar DuaI-Bandgap High Efficiency Solar Cell

Coverglass - OCLI ITO and AR-Coated CMG

Laydown Adhesive - Nusil CV-2566

Coverglass Adhesive - DC93-500

Electrostatically Clean Components

FSA Aperture Grid - T300/RS-3 Composite fabric laminate

FSA Edge Clips - T300/RS-3 composite fabric laminate

FSA structural adhesive- NuSil CV-2506-6, B-staged silicone sheet adhesive

FSA conductive adhesive - NuSil CV-2-2646, Silver filled silicone paste adhesive

m

Appendix 3- Photovoltaic Performance _ the ECSA Prototype Panel

-w

i

ESCA _-% _ %1%1_" j0_:_,_ _ (._.

QUAL COUPON • i/_.-_._/,_ _.

STRING:A ( Tech2 cell )

Test date: 01/06/2000

PARAMETERS

Calibration 5tanOarO:

No. of Series Cells:

No. of Parallel Cells:

Area per Cell :

Target Temperature:

Volta_le Temp Coef.:

51Z-98

24

1

24.312 cm^2

28 °C

-0.24 %VOC / °C

t_

m

= =

m

=

w

m

DATA CORRECTEDTO 28°C

VOLTS AMPS POWER

59.4600

55.2960

53.5340

51.7360

49.9720

48.1580

45.7680

42.8180

29.7220

0.0000

0._

0.2653

0.3_7

0.3248

0.3347

0.3407

0.3452

0.3479

0.3542

0.3683

0.0000

14.6700

16.3118

16.8039

16.7256

16.4074

15.7991

14.8964

10.5275

0.0000

DATA CORRECTED TO

TARGET TEMPERATURE

VOLTS

59.46

55.296

53.534

51.736

49.972

48.158

45.768

42.818

29.722

0

AMPS IPOWER

0 0

0.2653 14.670029

0.3047 16.31181

0.3248 16.803853

0.3347 16.725628

0.3407 16.407431

0.3452 15.799114

0.3479 14.896382

0.3542 10.527532

0.3683 0

0.4

0.35

0.05

0

0

I I -

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:

ISC :

PMAX :

VMAX :

IMAX :

FF :

Eft :

59.460 V

0.368 A

16.804 W

51.736 V

0.325 A

76.733 %

21.285 %

.... --I

80

w

t!

ESCA

QUAL COUPON

STRING:B

w

i

w

m

Test date: 0110612000

PARAMETERSCallbratJon Standard:



Area per Cell :Target Temperature:

Voltage Temp Coef.:

512,_J8

24

1

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.523054.434052.672050.914049.152047.413045.064042.115029.2660

0.0000

0.00000.26390.31640.34630.36010.36530.36740.36900.37230.3765

0.000014.365116.665417.631517.699617.320016.556515.540410.89570.0000

DATA CORRECTED TOTARGET TEMPERATURE

VOLTS

58.52354.43452.67250.91449.15247.41345.06442.11529.266

0

AMPS

00.26390.3164!0.34630.36010.36530.36740.369

0.37230.3765

POWER

014.36513316.66542117.63151817.69963517.31996916.55651415.54043510.895732

0

• 0.4

0.35

0.2

0.15

0.1O

0.05

0 ÷ I

0 20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Eft:

58.523 V0.377 A

17.700 W49.152 V

0.360 A80.329 %22.420 %

8O

u

w ESCA

QUAL COUPON

STRING:C

Test date: 01106/2000

PARAMETERSCalibratzon Standard:



Area per Cell :Target Temperature:Voltage Temp Coef.:

512-98

24

1

24.312 cm^228 "C

-0.24 %VOC / °C

--=

m

r _

u


VOLTS AMPS POWER

58.686054.573052.811051.056049.291047.521045.204042.253029.3300

0.0000

0.00000.26170.31400.34260.35580.36100.36440.365910.369710.3740

0.000014.281816.582717.491817.537717.155116.472315.460410.84330.0000


VOLTS AMPS POWER

58.68654.57352.81151.05649.29147.52145.20442.253

29.330

00.26170.314

0.34260.35580.361

0.36440,36590.3697

O.374

014.28175416.58265417.49178617.53773817.15508116.47233815.46037310.843301

0

0.4

0.35

" 0.30.25

z 0.2

0.15

0.1u

0.05

0

20 40

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Eft :

58.686 V0.374 A

17.538 W49.291 V

0.356 A79,904 %22.215 %

60 80

ESCA

QUAL COUPON

STRING:D

B

m

Test date: 0110612000

PARAMETERScalibration Standard:



Area per Cell :Target Temperature:Voltage Temp Coef,:

5_2-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.622054.532052.768051.003049.2430:47.4770J45.119042.214029.283C0.0000

0.00000.26210.31500.34440.35920.3627:0,3651i0.36720.37170.3770

0.000014.292816.621917.565417.688117.2199 I

16.472915.501010.88450.0000


VOLTS AMPS POWER

58.62254.53252.76851.00349.24347.47745.11942.21429,283

0

00.2621

0.3150.34440.35920.36270.36510.36720.37170.377

014.292837

16.6219217.56543317.68808617.21990816.47294715.50098110.884491

0:

0.4

0.35

0.30.25

0.2

0.15

0.05

0

0 20 40 60

VOLTAGE (VOLTS)

RESULTS


58.622 V0.377 A

17.688 W49.243 V

0.359 A80.035 %22.405 %

t

8O

=_ _-

m

mr

mESCA

QUAL. COUPON

FULL

imm

m

w

mm

Test date: 0110612000

PARAMETERSCalibration _tandard:




51Z-$8

24

4

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.775054.657052.898051.128049.374047.598045.238042.310029.36900.0000

0.00001.04111.2409J1.35031.40601.42711.44001.44771.46511.4933

0.000056.903465.641169.038169.419867.927165.142761.252243.02850.0000


VOLTS AMPS POWER

58.77554.65752.89851.12849.37447.59845.23842.31

29.3690

01.04111.24091.35031.406

1.42711.44

1.44771.46511.4933

056.90340365.64112869.0381 3869.41984467.927106

65.1427261.25218743.028522

0

1.6

1.4

'1.2

< 10.8

_: 0.6

0.2

I I

0 20 40 60

VOLTAGE (VOLTS)

RESULTS


58.775 V1.493 A

69.420 W49.374 V

1.406 A79.094 %21.983 %

I

80

r _

ESCA

QUAL COUPON


POST-CUSTOMER MODIFICATION

Test date: 01/27/2000

PARAMETERScalibrauon Standard:

No, of Series Cells:



Voltage Temp Coef.:

512-98

24

1

24.312 cm^228 °C

-0.24 %VOC / oC


VOLTS AMPS POWER

59.350055.197053.436051.633049.869048.067045.713042.721029.6680

0.0100

0.00040.25400.29690.31500.32180.32590.32850.32960.33260.3468

0.023714.020015.865116.264416.047815.665015.016714.08089.86760.0035


VOLTS AMPS POWER

59.350055.197053.436051.633049.869048.067045.713042.721029.6680

0.0100

0.00040.25400.29690.31500.32180.32590.32850.32960.33260.3468

0.023714.020015.865116.264416.047815.665015.016714.08089.86760.0035

0.4000 T

0.3500

_ 0.3000_ 0.2500

0.20000.1500

e,,

0"1000 I0.0500

0.0000 = --r-- k_

0.0000 20.0000 40.0000 60.0000 80.0000

VOLTAGE (VOLTS)

VOC:

ISC :PMAX :

RESULTS

VMAX :

IMAX :

59.350 V0.347 A

16.264 W51.633 V0.315 A

79.020 %20.602 %

m

E

m

ESCA

QUAL COUPON

STRING:B


Test date: 01/27/2000

PARAMETERSCalibration Standard:




Voltage Temp Coef.:

51Z-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.129054.080052.313050.594048.828047.086044.740041.837029.06000.0000

0.00040.21090.26470.29930.31990.33330.34110.34380.34920.3534

0.023311.405513.847315.142815.620115.693815.260814.383610.14780.0000


VOLTS AMPS POWER

58.12954.08

52.31350.59448.82847.08644.74

41.83729.06

0

0.00040.21090.26470.29930.31990.33330.34110.34380.34920.3534

0.023251611.40547213.84725115.14278415.62007715.69376415,26081414.38356110.147752

0

0.4

0.35

0.30.25

0.05

0 20 40 60 80

VOLTAGE (VOLTS)

RESULTS

voc: 58.129 vISC : 0.353 APMAX : 15.694 WVMAX : 47.086 VIMAX : 0.333 AFF : 76.395 %Eft: 19.879 %

z :

w

Test date:

ESCA

QUAL COUPON

STRING:C


01/27/2000

m

w

PARAMETERScalibration Standard:




512-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.384054.286052.563050.801049.035047.303044,953042.046029.18900.0015

0.00030.2403;0.280110.30460.32170.33220.33840.34100.34600.351,_

0,017513.944914.722915.474015.774615.714115.212114.337710.09940.0005


VOLTS AMPS POWER

58.38454.28652.56350.80149.03547.30344.95342.04629.1890.0015

0.00030.24030.28010.30460.32170.33220.3384

0.3410.346

0,3512

0.017515;13.04492614.72289615.473985

15.7745615.71405715.21209514.33768610.0993940.0005268

0.4

0.35

" 0.30.25

_z 0.2

0.15

0.05

0

: I

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Eft' :

58.384 V0.351 A

15.775 W49.035 V0.322 A

76.932 %19.981 %

m

Test date:

ESCA

QUAL COUPON

STRING:D


01/27/2000





Voltage Temp Coef.:

512-96

24

1

24.312 cm^228 °C

-0.24 %VOC / °C

u

DATA CORRECTEDTO 28=C

VOLTS AMPS POWER

58.380054.316052.550050.792049.069047.283044.938042.031029.1820

0.0000

0.00020.24640.29480.32070.33200.33880.34110.34230.34610.3530

0.011713,383515,491716.289016,290916,019515.328414.387210.09990.0000


VOLTS AMPS POWER

58.3854.31652.55

50.79249.06947.28344.93842.03129.182

0

0.00020.24640.29480.3207

0.3320.33880.34110.34230.3461

0.353

0.01167613.383462

15.4917416.28899416.290908

16.0194815.32835214.387211

10.099890

0.4

0.35

0.2

0.15

0.10

0.05

0

20 40 60

VOLTAGE (VOLTS)

RESULTS


58.380 V0.353 A

16.291 W49.069 V

0.332 A79.051 %20.636 %

t

8O

Testdate:

ESCA

QUAL COUPON


FULL PANEL

01/27/2000






512-98

24

4

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.608054.515052.752050.990049.262047.502045.136042.204029.3030

0.0000

-0.00150.96941.15411.25301.30591.33251.34861.357511.37371.4035

-0.087952.846860.881163.890564.331263.296460.870457.291940.25350.0000


VOLTS AMPS POWER

58.60854.51552.752:50.99

49.26247.50245.13642.20429.303

0

-0.00150.96941.1541

1.2531.30591.33251.34861.35751.37371.4035

-0.08791252.84684160.881083

63.8904764.33124663.296415

60.8704157.29193

40.2535310

1.6

1.4 _

1.21tg_0.8

_ 0.6

0.2

I t t

0 20 40 60

VOLTAGE (VOLTS)

RESULTSVOC:ISC :F)MAX :/MAX :IMAX :FF :Eft:

58.608 V1.404 A

64.331 W49.262 V

1.306 A78.208 %20.372 %

8O

m

Test date:

ESCA

PRE-HOT FLASH TEST INSIDE THE HOT BOX WITH COVER @ 28°C

QUAL COUPON


CKT:A01/27/2000

PARAMETERSCaI,Drat|on Standard:




Voltage Temp Coef.:

512-98

24

1

24.312 cm^228 "C

-0.24 %VOC / "C


VOLTS AMPS POWER

58.879054.759052.995051.236049.471047.705045.348042.406029.4300

0.0019

0.00010.20400.23040.24040.24520.24840.25060.25170.25370.2630

0.005911.170812o210012.317112.130311.849911.364210.67367.46640.0005


VOLTS

58.8790 0.000154.7590 0.204052.9950 0.230451.2360 0.240449.4710 0.245247.705045.348042.406029.4300

0.0019

AMPS POWER

0.005911.170812.210012.317112.1303

0.2484 11.849g0.2506 11.3642

0.2517 10.67360.2537 7.46640.2630 0.0005

0.3000

_" 0.2500

0.2000

Z_ 0.1500gJ

0.1000

O 0.0500

0.0000 -- _-_--}- :

0.0000 20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE (VOLTS)

RESULTS

VOC: 58.8790 VISC : 0.2630 APMAX : 12.3171 WVMAX : 51.2360 VIMAX : 0.2404 AFF : 79.5415 %Eft : 15.6020 %

w

U •

)

Test date:

ESCA


QUAL COUPON


CKT:B01/27/2000

PARAMETERScald)ratmn Standard:




Voltage Temp Coef.:

512-98

24

1

24.312 cm^228 =C

-0.24 %VOC / °C

= =

w

w

= =

m


VOLTS AMPS POWER

57.8140;53.7890i52.056050.298048.556046.8350]44.519041.618028.9220

0.0000

0.00000.20120.23620.25240.25680.25820.25930.26020.26360.2664

0.000010, 822312.295612.695212.469212.092811.543810.82907.62380.0000


VOLTS AMPS POWER

57.814053.789052.056050.298048.556046.835044.5190

41.618028.9220

0.0000

0.00000.20120.23620.25240.25680.25820.2593

0.26020.26360.2664

0.000010.822312.295612.695212.469212.092811.5438

10.82907.62380.0000

0.3000

_, 0.2500

0.2000

0.1500

0.1000

o 0.0500

0.0000

0.0000 20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE (VOLTS)

RESULTS


57.8140 V0.2664 A

12.6952 W50.2980 V0.2524 A

82.4276 %16.0809 %

Testdate:

ESCA

PRE-HOTFLASHTEST INSIDE THE HOT BOX WITH COVER (_ 28°C

QUAL COUPON


CKT:C0112712000

PARAMETERSCal,bration Standard: 512-98





24

1

24.312 cm^228 °C

-0.24 %VOC / °C

w

-i


VOLTS AMPS POWER

57.828053.786052.073050.307O48.572O46.849044.529041.629028.8910

0.0150

0.00000.17800.20980.23140.24480.25190.25600.25760.26190.2653

0.00009.5739

10.924911.641011.890411.801311.399410.72367.56660.0040


VOLTS AMPS POWER

57.828053.786052.073050.307048.572046.649044.5290

41.629028.8910

0.0150

0.00000.17800.20980.23140.24480.25190.2560

0.25760.26190.2653

0.00009.5739

10.924911.641011.890411.801311.3994

10.72367.56660.0040

0.3000

_, 0.2500

0.2000

0.1500

0.1000

o 0.0500

0.0000

0.0000

L+.... t _--

20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE(VOLTS)

RESULTS

VOC: 57.8280 VISC : 0.2653 APMAX : 11.8904 WVMAX : 48.5720 VIMAX : 0.2448 AFF : 77.5036 %Eft: 15.0615 %

Test date:

ESCA


QUAL COUPON


CKT:D01/27/2000

PARAMETERSC_tlzbratlon Standard:




Voltage Temp Coef.:

512-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C

m

w


VOLTS AMPS POWER

57.914053.892052,122050.399048.665046.903044.586041.689028.94900.0000

0.00000.19700.22790.24300.25160.25530.25700,25820.26070.2652

0.000010.616711.878612.247012.244111.974311.458610.76417.54700.0000


VOLTS AMPS POWER

57.914053.892052.122050.399O48.665046.903044.5860

41.689028.94900.009O

0.00000.19700.22790.24300.25160.25530.2570

0.25820.26070.2652

0.000010.616711.878612.247012.244111.974311.4586

10.76417.54700.0000

0.3000

_, 0.2500

0.1500tM

0.1000

U 0.0500

0.0000

0.0000 20.000 40.000 60,000 80,0000 0 0 0

VOLTAGE (VOLTS)

RESULTS

VOC: 57.9140 VISC : 0.2652 APMAX : 12.2470 WVMAX : 50.3990 VIMAX : 0.2430 AFF : 79.7391 %Eft: 15.5131 %

ESCA

HOT-FLASH TESTQUALCOUPON

CKT:A

Test date: 01/27/2000

m

= =

u

PARAMETERScalibration standard:



Area per Cell :Target Temperature:Voltage Temp Coef.:Current Temp Coef:

|in

TEST TEMPERATURE70 °C

VOLTS AMPS POWER

53.9680 0.000050.2120 0.195948.5710 0.230546.9570 0.245745.3410' 0.251443.69801 0.254441.5440 0.256638.7990! 0.257826.9480 0.25960.0781 0.2689

0.00009.8365

11.195611.537311.398711.116810.660210.00246.99570.0210


VOLTS )ER53.96850.21248.57148.95745.34143.69841.54438.79926.9480.0781

00.195910.23050.24570.25140.25440.25660.25780.25980.2689

09.836530811.19561611.53733511.39872711.11677110.66019

10.0023826.99570080.0210011

512-9I!

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uA/cm^2/°C

0.3

,,.,, 0.25

o 0.05

0

0

I

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Elf:

53.9680 V0.2689 A

11.5373 W46.9570 V0.2457 A

79.5021 %14.6142 %

ESCA

HOT-F_SH TEST

QUAL COUPON

CKT:B

Test da_: 01/27/2000

i

m

m

PA_METERSCaliOraUon 5_ndard:


No. of Parallel _lls:

_ea _r Cell :Target Tem_ra_re:Vol=ge Temp Coef.:Current Temp ,Coef:


VOLTS

53.2740 0.000049.5360 0.199147.9290 0,236646.3600 0.254844.7550 0.262043.1450 0.263641.0450 0,264738.349026.64300.0791

AM_ POWER

0._009._

11.M0011.812511.725811.373010.8_

0.2658 10.19320.2692 7.17230.2720 0.0215


VOLTS AMPS POWER

53.27449.5_47.9_46._

44.75543.14541._538._926.6430.0791

00.1_10.23660.2548

0.2620._0._70.26580.2692

0.272

09._17611._0111.81252811.72_1

11.37302210._1210.1931647.17_9_0.0215152

512'b8

24

1

24.312 _^270 °C

-0.24 %V_ / °C17.1 _cm^_°C

==

0.3

0.2

0.15

0

I

20 40

VOLTAGE _OLTS)

RESULTS

53.2740 VVOC:ISC :PMAX :VMAX :IMAX :FF :Eft:

0.2720 A11.8125 W46.36OO V

0.2_ A81.51_ %14. _28 %

6O

m ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:C

Test date: 01/27/2000

m

m

m

g

PARAMETERSCal,I)ratzon 3tanOarO:





VOLTS AMPS POWER

53.289049.579047.967046.360044.756043.144041.034038.342026.6360

0.0892

0.00000,18940.22100.24090.25240.25850.26170.26290.26770.2707

0.00009.3903

10.600711.168111.296411.152710.738610.08017.13050.0241


VOLTS AMPS POWER

53.28949.57947.967

46.3644.75643.14441.03438.342i26.63610.0892

00.18940.221

0.24090.25240.25850.26170.26290.26770.2707

9.3902626!10.60070711.16812411.29641411.15272410.73859810.0801127.13045720.0241464

512-96

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uNcm^2/°C

0.3

,_, 0.25

0 20 40

VOLTAGE (VOLTS)

RESULTS

VOC:mC :PMAX :VMAX :IMAX :FF :Eft:

53.2890 V0.2707 A

11.2964 W44.7560 V

0.2524 A78.3096 %14.3091 %

60

w

ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:D

Test date: 01/27/2000

PARAMETERScalibration 5tandaro:

No. of Series Cells:lNo. of Parallel Cells:



VOLTS AMPS POWER

53.075049.345047.779046.169044.548042.994040.865038.197026.5100

0.0793'

0.00000.19490.23080.24730.25640.26050.26250.26410.26640.2708

0.00009.6173

11.027411.417611.422111.199910.727110.08787.06230.0215


VOLTS

53.07549.34547.77946.16944.54842.99440.86538.19726.51

0.0793

pOWER0 0

0.1949! 9.61734050.2308 11.0273930.2473 11,4175940.2564: 11.4221070.2605 11.1999370.26251 10.7270630.2641 10.0878280.2664 7.0822640.2708 0.0214744

512-9U

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uNcm^2/°C

i i

0.3

..... 0.25

0.2

_0.15

o 0.05

0 I I

20 40

VOLTAGE (VOLTS)

RESULTS

VOC:mC :PMAX :VMAX :IMAX :FF :Elf:

53.0750 V0.2708 A

11.4221 W44.5480 V0.2564 A

79.4708 %14.4683 %

6O

Testdate:

ESCA

HOT-FLASH TEST

CKT:A @ 70°C

Adjustment made for the lost of the lexan glass

Voltage Ratio: 1.007 Current Ratio:l.3201/27/2000

PARAMETERSCalll)ratzon :Standard:




512-98

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uA/cm^2/°C

TEST TEMPERATURE70 =C

IPOWERVOLTS AMPS

54.3458 0.000050.5635 0.258648.9110 0.304347.2857 0.324345.6584 0.331844.0039 0.335841.8348 0.338739.0706 0.340327.1366 0.3427

0.0788 0.3549

0.000013.075114.881715.335915.151614.776914.170013.29569.29900.0279


VOLTS

54.34578

50.5634848.911

47.2857

AMPS 01POWER 0

0.258588 ! 13.07511020.304261 14.88165995

0.3243241 15.3358870445.65839 0.331848 I44.00389 0.33580841.83481 0.33871239.07059 0.34029627.13664 0.342672

0.078647 0.354948

15.1516444114.7768569514.1699514913.295566529.298965331

0.027915489

0.4

0.35

0.3

0.25

0.2

0.15

0.05

0

20 40

VOLTAGE (VOLTS)

RESULTS


54.348 V0.355 A

15.338 W47.286 V

0.324 A79.502 %19.426 %

6O

Testdate:

ESCA

HOT-FLASH TEST

CKT:B (_ 70°C



PARAMETERSCalil)ratton 5tanoaro:



Area per Cell :Target Temperature:Voltage Temp Coef.:Current Tem.p.Coef:

512-98

24

1

24.312 cmA270 °C

-0.24 %VOC / °C17.1 uNcmA2/°C


POWERVOLTS AMPS

53.5404 0.000049.7837 0.262848.1686 0.312346.5918 0.336344.9788 0.345843.3607 0.348041.2502 0.349438,5407 0.350926.7762 0,3553

0.0795 0.3590

0.000013.083715.043615.670515.555515.087514.413013.52239.51480.0285


VOLTS AMPS POWER

53.54037

49.7836848.1686546.5918

44.9787843.3607341.2502338.5407526.77622

0.079496

0

0.2628120.3123120.336336

0.345840.3479520.3494040.3508560.355344

0.35904

O

13.0837485115.0436458615.6704996415.5554595515.0874509914.41299362

13.52225163 I9.514767343

0.028542064

0.4

0.35

0.30.25

0.05

0

28-

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF:E_:

53.540 V0.359 A

15.670 W46.592 V

0.336 A81.519 %19.850 %

Testdate:

ESCA

HOT-FLASH TEST

CKT:C _ 70°C



PARAMETERSCald)ratmn 3tan(lard:




bl Z-98

24

1

24.312 cmA270 °C

-0.24 %VOC / °C17.1 uhJcmA2/°C

u

ibm

L.=


POWERVOLTS AMPS

53.7686 0.000050.0252 0.250048.3987 0.291746.7772 0.318045.1588 0.333243.5323 0.341241.4033 0,345438.6871 0.347026.8757 0.3534

0.0900 0.3573

0.000012.506714.118914.874615.045514.854114.302513.42559.49690.0322


POWERVOLTS AMPS

53.7686 0

50.02521 0.25000848.3987 0.29172

46.77724 0.31798845.1588 0.33316843.5323 0.34122

41.40331 0.34544438.68708 0.34702826.87572 0.353364

0.090003 0.357324

0

12.5067029514.1188696414.8746009915.0454684114.8540900414.3025236413.4254993

9.496913336

0.032160161

0.4

0.35

0.3

< 0.25

0.05

0 20 40

VOLTAGE (VOLTS)

RESULTS


53.769 V0.357 A

15.045 W45.159 V

0.333 A78.310 %19.058 %

6O

m

Test date:

ESCA

HOT-FLASH TEST

CKT:D (_ 70°C



PARAMETERSCalibration 3tandara:




512-98

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uA/cm^2/°C

u

= :


POWERVOLTS AMPS

53.4996 0.000049.7398 0.259248.1612 0.307046.5384 0,328944.9044 0.341043.3380 0.346541.1919 0.349138.5026 0.351326.7221 0.35430.0799 0.3602

0.000012.893414.783815.306915.312915.015114.381113.52419.46800.0288


VOLTS

53.4996

49.7397648.1012_48.5383544.90438

43.3379541.1919238.5025826.72208

0.079934

AMPS0

0.2592170.3069640.3289090.3410120.3464650.3491250.3512530.354312

0.380164

POWER

0

12.8933913714.7837644215.3068828215.3129338

15.0150835414.3811290713.524145339.467953609

0.028789493

0.4

0.35

0.3< 0.25z 0.2

0.15

0.05

0

I I----

20 40

VOLTAGE (VOLTS)

RESULTS, i,

VOC: 53.500ISC :PMAX :VMAX :IMAX :FF:Elf :

V0.360 A

15.313 W44.904 V

0.341 A79.471 %19.397 %

60

85/8212888 13:_._

m

6269615291 TECSTAR PAGE 82

=

m

ii1

ESCA

QUAL COUPON


POST-ACOUSTIC TEST

Test date: 01/31/2000

_eiibratJon 3Stmnaara:


No. of Plrllltl Ceils:

Area per Cell :Target Tempera_re:

Voltage Temp CoeL:

PARAMETERS81Z-_

24

1

24.312 cmA228 "C

-0.24 %VOC I "C

DATA CORRECTEDTO :IPC

VOLTS

59.381055.244053.443oi51.680049.923048,105045.742042.771029.67600.0043

AMPS POWER

.0.0001 -O,00Sg0.2548 14.07620.29_M 15.t_810.3168 16.37220.3234 le.14510.3271 15.73510.328e 15.03080.3295 14.09300.3327 9.87320,3467 0.0015


VOLT859.381055.244O53.443O51.68OO49.923048.105045.742042.771029.6760

0.0043

_Ps _R-0.0001 -O.OOSg

0.2.548 14.07620.2986 15.95810.3168 16.37220.3234 16.14510,3271 15.73510.3260 15.03060.3295 14.09300.3327 9.87320.3447 0.001Sj

0.4000

0.3500

0.30000.2500

0.2000

I 0.! 500

_ 0.1000

0.0500

0.0000 t _ ,_ (

0.0000 20.0000 40.0000 60.0000 80.0000

VOLTAGE (VOLTS)

RESULTS

VOC: 59.381 v18c : 0.347 APMAX : 16.372 WVMAX : 51.680 VIMAX : 0.317 AFF : 79.525 %Eft: 20.739 %

85/8212888 13:33 6269615291 TECSTAR PAGE 83

ESCA

QUAL COUPON

8TRING:B

POST-ACOUSTIC TEST

Test clam: 01/31/2000

PARAMETERSCal,Of'at,_on 51an_a_rd:


No. of P_allel Ceils:

Area per Ceil :Target Temperature:Voltage Temp Coef.:

=lz- 24

1

24.312 cmA228 "C

-0.24 %VOC / "C

DATA CORRECTED

VOLTS

38.356054.285052,5e3050.796049,034047.294044.925041 998029.1810

00000

TO 2ref;owER

-0.0001 -0.00580.2508 13.61470.2997 15.75310,3265 16,58490.33MJ 16,59310.3417 16.16040.3435 15.43170.3455 14.51030,3493 10.19290.3530 0.0000


,|*

VOLTS

58.35654.28552,56356.7ge49.03447.29444.92541.99829.181

0

AMPS POWER-0.0001 "-0.005636

0.2508 13,814e780.2997 15.7531310,3265 le.S846940.3384 16.5931060,3417 le.1eo380.3435 15.4317380.3455 14.51o3o90.3493 10.192923

0.353 o

0.4

0.35

i 0.3

0.25

0.2

0.15

0.1

O.O5

0 ] I :20 40 60

VOLTAGE (VOLTS)


RESULTS

58.356 V0.353 A

18.593 W49.034 V0.338 A

80.550 %21.018 %

I

8O

_5182/288B 13.'33 G2G9615291 TECSTAR PAGE 8_

ESCA

QUAL COUPON

STRING:C

POST.ACOUSTIC TEST

Test date: 01/31/2000

PARAMETERSc.almrauon 3tanmtrd:

No. of Serkes Cells:



61241l

24

1

24.312 cm*228 *C

-0.24 %VOC ! "C

DATA CORRECTED

z.ozrcVOLTS

58.488054.4OO052.666050.9O8049.146047.362045.059042.109029.2210!

oooooi

AMPS POWER

-0.0001 -0.00580.2438 13.25100.2844 14.97820,3115 15.85780.3279 16.11500.3351 15.87100.3387 15.20150.3408 14.35070.3459 10.10750.3504 0.0000


VOLTS• ._'.488

54.452.66650.90849.14647.36245.05942.10829.221

0

AMPS

-0.00010.24360.28440.31150.32790.33510.33870.34080.34590.3504

13.2518414.97821

15.65764216.114973

15.8710061

15.2e148314.35074710.107544

0

0.4

0.35

i 0.3

0.25

0.2

0,15

0.1

0.05

0

0 20 40 60

VOLTAGE (VOLTS)

VOC:ISC :PMAX :VMAX:IMAX :FF :Eft :

RESULTS

,58.488 V0.350 X

16.115 W49.146 V0,328 A

78.632 %20.413 %

I

8O

85/82/2800_......13:__,.2,."-"-6':)69615291 TECSTAR PAGE 85

ESCA

QUAL COUPON

STRING:O

POST.ACOUSTIC TEST

Test date: 0t/31/2000

i



Arta per Cell :Target Temperature:iVoltage Tamp Coal.:

PARAMETERS

[)ATA CORRECTEDTO ZlI*C

VOLTS | N_PS

..,32oI :ooo2s4. IOI 0.24471s2.8oio I 0.293si5o 4oo o3,85i49.1150 0,329947.3310 0,337844.9710 0.340742.0770 0.342029.2250 0.34630,0000 0.3534

power

-0.0117

13.302115.438416.090918.203015.968415.321614.390310.12060.0000

DATA cORRECTED TOTARGET TEMPERATURE

VOLT8 AMPS

58,432 -0.000254.361 0.244752.601 0.293550.84 0.3165

49.115 0,329947.331 0,337844,971 0.340742.077 0.34229.225 0.3483

01 0.3534

,POWER'-0.011681513;30213?15.43039418,oeoee

10,20303915.988412

15.3318;14.39033410,12081B

0

81z-Ba

24

I

24.312 ca^228 "C

•.0.24 %VOC / "C

0.4

0.35

I 0.3

0.25

0.2

0.15

0.1

0.0_

0

0 20 40 60

VOLTAGE (VOLTS)

VOC:18C :PMAX :VMAX:IMAX :FF : "Eft:

RESULTSL

sa.4_ VO.353 A

1(5.203 W49.115 V

0.330 A78.4M %20.524 %

I

8O

ESCA

QUAL COUPON


POST-ENVIRONMENTAL

Test date: 05/01/2000

PARAMETERSCalibration _tandard:

No. of Series Ceils:


Area per Ceil :Target Temperature:

Voltage Temp Coef.:

512-96

24

1

24.312 cm^228 °C

-0,24 %VOC / °C

m

= :

w


VOLTS

59.349055.199053.437051.636049.875048.103045.708042.727029.6690,

0.0082

AMPS PowER

-0.0001 -0.00590.2548 14.06470.2974 15.89220.3166 16.34800.3235 16.13460.3262 15.69120.3278 14.98310.3293 14.07000.3329 9.87680.3460 0.0028


VOLTS AMPS POWER

59.349055.199053.437051.636049.875048.103045.708042,727029.66900.0082

-0.00010.25480.29740.31660.32350.32620.32780.32930.33290.3460

-0.005914.064715.892216.348016.134615.691214.983114.07009.87680.0028

0.4000

0.3500

0.3000

_ 0.2500

0.2000

_, 0.1500

¢_ 0.10000.0500

0.0000

0.0000 20.0000 40.0000 60.0000 80.0000

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :

59.349 V0.346 A

16.348 W51.636 V

0.317 A79.611 %20.708 %

m ESCA

QUAL COUPON

STRING:B

POST-ENVIRONMENTAL

Test date: 0510112000

PARAMETERS

Calmrauon Standard:




Voltage Temp Coef.:

512-98

24

1

24.312 crn^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

58.362054.304052.542050.782049.057047.283044.921042.016029.16800.0146

-0.00010.24890.29940.32590.33710.34070.34240.34460.34820.3516

-0.005813.516315.731116.549916.537116.109315.381014.478710.15630.0051

DATA (_ORRECTED TOTARGET TEMPERATURE

VOLTS AMPS POWER

58.36254.30452.54250.78249.05747.28344.92142.01829,1680.0148

-0.00010.24890.29940.32590.33710.34070.34240.34460.34820.3516

-0.00583613.51626615.73107516.549854116.537115:16.109318

15.3809514.47871410.1562980.0051334

0.4

0.35

_m" 0.3

_v0.25

0.2

0.15

0.05

0 20 40 60

VOLTAGE (VOLTS)

RESULTS


58.362 V0.352 A

16.550 W50.782 V0.326 A

80.652 %20.964 %

8O

Testdate: 05/01/2000

ESCA

QUAL COUPON

STRING:C

POST-ENVIRONMENTALTEST

IN PARAMETERS

alibrallon _tanaar¢l:

o. of Series Cells:No. of Parallel Cells:

512-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C

Area per Cell :

Target Temperature:ioltage Temp Coef.:

i

i


VOLTS AMPS POWER

58.494054.416052.658050.895049.171047.405045.045042.096029.2450

0.0151

-0.00010.24340.28490.31170.32710.33480.33870.33990.34460.3492

-0.005813.244915.002315.864016.083815.871215.256714.308410.07780.0053


VOLTS

58.49454.41652.65850.89549.17147.40545.04542.09629.2450.0151

AMPS POWER

-0.0001 -0.0058490.2434 13.2448540.2849 15.0022640.3117 15.8639720.3271 16.0838340,3348 15.8711940.3387 15.2567420.3399 14.308430.3446 10.0778270.3492 0.0052729

0.4

0.35

0.30.25

0.05

0 I

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Eff :

58.494 V0.349 A

16.084 W49.171 V

0.327 A78.742 %20.373 %

1

8O

n

ESCA

QUAL COUPON

STRING:D

POST-ENVIRONMENTAL TEST

Test date: 05/01/2000

PARAMETERScalibration :standard'!

No, of Series Cells:



Voltage Temp Coef,:

812-_8

24

1:

24.312 cm^228 °C

-0.24 %VOC / °C

w

m

=,m=

m


VOLTS

58.427054.342052.581050.859049.096047.316045.007042.055029.20400.0121

AMPS POWER

-0.0001 -0.00580.2445 13.28660.2916 15.33260.3126 15.89850.3282 16.11330.3364 15.91710.3396 15.28440.3407 14.32810.3456 10.09290.3518 0.0043


VOLTS

58.42754.34252.58150.85949.09647.31645,00742.05529.2040.0121

, PS .owE"-0.0001 -0.0058430.2445 13.2866190.2916 15.332620.3126 15.8985230.3282 16.1133070.3364 15.9171020.3396 15.2843770.3407 14.3281390.3456 10.0929020.3518 0.0042568

0.4

0.35

" 0.30.25

_" 0.2

0.05

0

20 40 60

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :

58.427 V0.352 A

16.113 W49.098 V

0.328 A78.393 %20.411 %

I

8O

85/02/2800 l_.Jo 6269615291 TECSTA_ .......

z_

I

ESCA

QUAL COUPON

POST.ACOUSTIC TEST

FULL PANEL

Test claW: 01/31/2000

PARAMETERS

r..anm'et, o_ =_anoaro:


No. of Plulllel Cells:

Area per Cell :Target Temperllture:Voltage Temp Coef.:

I_lZ-H " -

24

4

24.312 un'228 "C

.0.:,4 voc/'C

DATA CORRECTEDTO |$'C

VOLTS58.662054.555052.795051.067049.309047.543045.180042,238029 34200,0000

AMP8 POWDER_ Hi if

-0,0066 -0.38720.M01 $3.4e041.163S 61.42701,2608 64.38531.3137 64.77721.3382 e3,e2201.3472 60.86651.3540 57,1g031.3704 40,21031,4002 0,0000

OATA CORRECTED TOTARGET TEMPERATURE

VOLTS

58,66254.5,_552.79551.0e74g.30947.5431

45.1842.23829.342

0

AldP$ • POWER

-0.0064 .,0,3871690.9801 53.41893M1.1635 61.4269831.2608 64.3852741,3137 64.7772331.3382 83.6220431.3472 eO.M64981.3Sd_, 57.190252

1.3704 40.21027_1.4002

1.6

1.4A

0.0

O.e

0.2

0

I

20 40 60

VOLTAGE (VOLTS)

I

8O

, m

VOC:ISC :PMAX :VMAX :IMAX :FF :

Eft:

RESULTSsi.=i2 v

1.400 A64.777 W49.3O9 V

1,314 A78.M3 %

20:513 %

ESCA

QUAL COUPON

POST-ENVIRONMENTAL

FULL PANEL

Test date: 05/01/2000

PARAMETERSc;aI,Dratmn Btandara:




512-96

24

4

24,312 cm^228 °C

-0.24 %VOC / °C

w

w


VOLTS AMPS POWER

58.661054.581052.815051.052049.291047.528045.166042.229029.32700.0000

-0.00560.97811.16111.25801.30991.33381.34581.35271.36691.3952

-0.328553.385761.323564.223464.566363.392860.784457.123240.0871

0.0000


VOLTS AMPS POWER

58.66154.56152.8151

51.05249.291i47.528;45.16642.22929.327

0

-0.00560.97811.18111.258

1.30991.33381.34581.35271.36691.3952

-0.32850253.38567861.32349764.22341864.56628163.39284660.78440357.1231684O.087076

0

1.6

1.4

1.2

0.6

0.4O

0.2

0

20 40 60

VOLTAGE (VOLTS)

Ii IOc:SC :

RESULTS

PMAX :VMAX :IMAX :

58.661 V1.395 A

64.566 W49.291 V

1.310 A78.890 %20.446 %

t

8O

Testdate:

ESCA


QUAL COUPON


CKT:A05/01/2000

PARAMETERScalibralzon Standard:




Voltage Temp Coef.:

5'12.-96

24

1

24.312 cm^228 °C

-0.24 %VOC / "C

r

=,._,

DATA CORI_ECTEDTO 28°C

VOLTS AMPS POWER

58.925054.814053.042051.290049.517047.744045.389042.414029.47600.0096

0.00000.20670.23520.24570,24980.25200,25350.25450.25690,2654

0.000011.330112.475512.602012.369312.031511.506110.79447.57240.0025


,r.

VOLTS AMPS POWER

58.925054.814053.042051.290049.517047.744045.3890

42.414029.4760

0.0096

0.00000.2_70.23520.24570.24_0.25200.2535

0.25450.2_90._54

0,000011.330112.475512.602012.369312.031511.5061

10.79447.57240.0025

0.3000

_" 0.2500

0.2O00

0.1500

0.1000

-"t

o 0.0500

0.0000 -- _---_ ,_ I

0.0000 20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE (VOLTS)

RESULTS


u

Test date:

ESCA


QUAL COUPON


CKT:B05/01/2000



No. of Parallel Ceils:


Voltage Temp Coef,:

512-98

24

1

24.312 cm^228 "C

-0.24 %VOC / °C


VOLTS AMPS POWER

57.832053.808052.068050.328048.589046.825044.508041.653028.9110

0.0000

0.00000.20250.23870.25460,25910.26050.26160.26270.26600.2687

0.000010.896112.428612.813512.589412.197911.643310.94227.69030.0000


VOLTS AMPS LPOWER

57.832053.808052.068050.328048,589046,825044.5080

41.653028.91100.0000

0.00000.2O250.23870.25460.25910.26050.2616

0.26270.26600.268?

0.0O0010.896112.428612.813512.589412.1979l11.6433

10.94227.69030.0000

0.300O

_, 0.2500

0.2000<

0.1500I¢1

0.1000::)o 0.0500

0.0000 --

0.0000

A A--v

20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE (VOLTS)

RESULTS


57.8320 V0.2667 A

12.8135 W50.3280 V

0.2546 A82.4579 %16.2307 %

Test date:

ESCA


QUAL COUPON


CKT:C

0510112000

PARAMETERScalibration _tandard:





b12-gU

24

1

24.312 cm^228 °C

-0.24 %VOC / °C

w

=

m

m


VOLTS AMPS POWER

57.964053.933052.164050.439048.712O46.9430]44.624041.731028.9920

0.0000

-0.00010.19190.22340.24380.25320.25760.25930,26040.26450.2676

-0.005810.349711.653412.297012.333912.092511.571010.86687.66840.0000


VOLTS AMPS POWER

57.9640 -0.000153.9330 0.191952.1640 0.223450.4390 0.243848.7120 0.253246.9430 0.257644.6240 0.2593

41.7310 0.260428.9920 0.2645

0.0000 0.2676

-0.003810.349711.653412.297012.333912.092511.5710

10.86687.66840.0000

:=U

0.3000

0.2500

0.2000

0.1500

0.1000

0.0500

0.0000

-0.050_'

----i_---I -- H ------_

)00 20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE(VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX:IMAX :FF :Elf:

57.9640 V0.2676 A

12.3339 W48.7120 V0.2532 A

79.5161 %15.6232 %

_ =

w

Test date:

ESCA

PRE-HOT FLASH TEST INSIDE THE HOT BOX WITH COVER

QUAL COUPON


CKT:D

o5/0112000

28°C

PARAMETERSCal#Drat_on _tandarcl:


_1o.of Parallel Cells:

_d'ea per Cell :Target Temperature:

Voltage Temp Coef.:

b12-98

24

1

24.312 cm^228 °C

-0.24 %VOC / °C


VOLTS AMPS POWER

57.881053.858052.078050.351048.628046.900044.578041.692028.94800.0000

-0.00010.19670.22360.24150.25270.25700.25860.25990.26310.2672

-0.005810.593911.644612.159812.288312.053311.527910.83587.61620.0000


VOLTS AMPS POWER 1m

57.881053.858052.078050.351048.628046.900044.5780

41.692028.94800.0000

-0.0001 -0.00580.1967 10.59390.2236 11.64460.2415 12.15980.2527 12.28830.2570 12.05330.2586 11.5279

0.2599 10.83580.2631 7.61620.2672 0.0000

==¢J

0.3000

0.2500

0.2000

0.1500

0.1000

0.0500

0.0000

-0.050_

voc:

ISC :PMAX :

:)00 20.000 40.000 60.000 80.0000 0 0 0

VOLTAGE (VOLTS)

RESULTS57.8810 V0.2672 A

12.2883 W48.6280 V0.2527 A

79,4546 %15.5655 %

ii

w

m

m

Test date: 05/01/2000

ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:A


PARAMETERSCald)ratton Gtandarcl:




512-98

24

1

24.312 cm^270 °C

-0,24 %VOC / °C17.1 u_cm^2J°C


VOLTS POWER

54.040050.263048.646047.034045.387043.780041.625038.895026.9910

0.0783

AMPS

0.00000.19930.2346;0.25070.25680.25950.26110.26200.26440,2728

0.000010.017411.412411.791411.655411.360910.868310.19057.13640.0214


PqOWERVOLTS AMPS

54.04 050.263 0.199348.646 0.234647.034 0.250745.387 0.256843.78 0.2595

41.625 0.261138.895 0.26226.991 0.26440.0783 0.2728

010.01741611.41 235211.79142411.655382

11.3609110.86828810.19049

7.13642O40.0213602

0.3

I1.

0.2

0.15ILl

0.1

o 0.05

0

A

v ¢ C_I _

I I

20 4O

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Elf :

54.0400 V0.2728 A

11.7914 W47.0340 V

0.2507 A79.9846 %14.9361 %


ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:B







VOLTS AMPS POWER

53.279049.554047.969046.358044.755043.151041.035038.357026,6360

0.0776

0.00000.20250.23970.25920.26610.26790.26900.26990.27330.2761

0.000010.034711.498212.016011.909311,560211.038410.35267.27960.0214


VOLTS AMPS POWER

053.279

49.55447.96946.35844.75543.15141.03538.35726.6360.0776

00.20250.23970.25920.2661O.2679

0.2690.26990.27330.2761

10.03468511.49816912.01599411.90930e11.56015311.03841510.3525547.27961880.0214254

b12-9_

24

I

24.312Cm^2

70 °C

-0.24 %VOC / °C17.1 uA/cm^2/°C

0.3

0.25

0.2

Z_ 0.15

0.1

0.05

0

0 20 40

VOLTAGE (VOLTS)

60

RESULTS


53.2790 V0.2761 A

12.0160 W46.3580 V

0.2592 A81.6840 %15.2205 %


ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:C


u

r_

w

PARAMETERSCalibration :Standard:





VOLTS AMPS POWER

53.323049.579047.974046.408044.799043.170041.076038.388026.6430

0.0893

0.00000.19680.23220.24930.25930,26400.26610.26710.27170.2748

0.00009.7571

11.139611.569511.616411.396910.930310.25347.23890.0245

DATA CORRECTED TOTARGETTEMPERATURE

VOLTS AMPS

53.323 049,579 0.196847.974 0.232246.408 0.249344.799 0.259343.17 0.264

41.076 0.266138.388 0.267126.643 0.27170,0893 0.2748

POWER

09.757147211.13956311.56951411.61638111.39688

10.93032410.2534357,23890310.0245396

512-98'

24

1

24,312 cm^270 °C

-0,24 %VOC / °C17.1 uA/cm^2/°C

0.3

0.20,15ill

0.1

0 0,05

0

20 40

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Elf:

53.3230 V0.2748 A

11.6164 W44.7990 V0.2593 A

79.2756 %14.7144 %

6O

i

m

Test date: 05/01/2000

ESCA

HOT-FLASH TEST

QUAL COUPON

CKT:D


m

PARAMETERSCallbrati0n Standard:





VOLTS AMP$ IPOWER53.123049.423047.814046.204044.636043.033040.918038.233026.5650

0.0847

0.00000.19570,22950.24680.25830.26400.26600.26710.27060.2749

0.00009.6721

10.973311.403111.529511.3607'10.884210.21207.18850.0233!


VOLTS AMPS P()WER

53.123i49.42347.81446.20444.63643.03340.91838.23326.5650.0847

00.19570.22950.24680.25830.2640.266

0.26710.27060.2749

09.872O81110.97331311.40314711.52947911.36071210.88418810.2120347.1884890.023284

b12-9_

24

1

24.312cm^270 °C

-0.24 %VOC / °C17.1 uNcm^2/°C

0.3

,_ 0.2

0.15UJ

0.1

_J 0.05

l ]

0 20 40

VOLTAGE (VOLTS}

RESULTS

VOC:ISC :PMAX :VMAX :IMAX :FF :Elf :

53.1230 V0.2749 A

11.5295 W44.6360 V0.2583 • A

78.9500 %14.6043 %

Testdate:

ESCA

HOT-FLASH TEST

CKT:A @ 70°C


Voltage Ratio: 1.007 Current RaUo:l.3005/01/2000

PARAMETERScalmrauon stan¢laro:



Area per Cell :Target Temperature:Voltage Temp Coef,:Current Temp Coef:

b12-98

24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uA/cm*2/°C

w


VOLTS AMPS54.4183 0.0000

50.6148 0.259148.9865 0.305047.3632 0.325945.7047 0.333844.0865 0.337441.9164 0.339439.1673 0.340627.1799 0.3437

0.0788 0.3546

POWER0.0000

13.113814.939915.436215.258114.872614.227713.3404

9.3423

0.0280


0.4

0.35

0.05

VOLTS54.41828

50.61484

48.9865247.3632445.7047144.0864641.9163839.1672727.179940.078848

AMPS0

0.25909

0.304980.325910.333640.337350.33943

0.34060.34372

0.35464

_OWER0

13.11379915

14.9399094815.4361529

15.2580600514.8725672814.2276751713.340370469.342287946

0.02796269

AA A

I I

0 20 40

VOLTAGE (VOLTS)

RESULTS


60

w

w

Test date:

ESCA

HOT-FLASH TEST

CKT:B @ 70°C



PARAMETERScaliDratJon :Standard:



Area per Cell :Target Temperature:Voltage Temp Coef.:Current Tem_p Coef:.

512-9U

24

1

24.312 cm^270 °C

-0.24 %VOC / °C•17.1 u/Vcrn^2/°C

i i ii ml

w

w


VOLTS AMPS53.7565 0.0000

50.0000 0.265348.4007 0.314046.7752 0.339645.1578 0.348643.5394 0.350941.4043 0.352438,7022 0,353626.8757 0.3580

0.0783 0.3617

POWER0.0000

13.263715.196215.882615.741615.280114.590513.68399.62210.0283


VOLTS AMPS POWER53,75851

49.99999

48.4007246.77522

45.157843.5393641.4043238.7022126.875720.078298

O

0.265275]

0.31400710.3395520.3485910.3509490.35239

0.3535690.3580230.361691

0

13.26374629

15.198185215.8826201815.7416009215.2800945

14.5904665613.683902759.6221273340.028319827

0,4

0.35

0.30.25

0.2

0.15

0.05

0 1 i

0 20 40

VOLTAGE (VOLTS)

RESULTSVOC:ISC :PMAX :VMAX :IMAX :FF :Eft:

53.759 V0.362 A

15.883 W46.775 V0.340 A

81.684 %20.118 %

-4

60

Testdate:

ESCA

HOT-FLASH TEST

CKT:C @ 70°C


Voltage Ratio: 1.009 Current Ratio:l,3005/01/2000

PARAMETERSCalibration 5tanOaro:




512-9;5

24

1

24.312 cm^270 °C

-0.24 %VOC / "C17.1 uA/cm^2/°C

r

m


VOLTS AMPS53.8029 0.0000

50.0252 0.255848.40581 0.301946.8257, 0.324145.2022! 0.3371

43.5585 0.343241.4457 0.345938.7335 0.347226.8828 0.3532

0.0901 0.3572!

POWER0.0000

12.798414.611815.175715.237214.949314.337313.449419.49530.0322!


VOLTS AMPS POWER53,80291 0

50.02521 0.25584

48.40577 0.3018646.82567 0.3240945,20219 0.3370943.55853 0.343241.44568 0.3459338.73349 0.3472326.88279 0.353210.090104 0.35724

0

12.79844998

14.6117645215.1757320415.23720656

14.949287514.3373054713.449430439.495269196

0.032188646

0.4

0.35

0.3

0.25

0.2

0.15

0,1(.I

0.05

0

0

I t--

2O 4O

VOLTAGE (VOLTS)

RESULTS

VOC:ISC :PMAX :VMAX : -

Eft :

53.803 V0.357 A

15.237 W45.202 V0.337 A

79.276 %19.301 %

6O

Testdate:

ESCA

HOT-FLASH TEST

CKT:D @ 70°C



PARAMETERS_;almrat_on 8tanclarcl:




,512-9U

.24

1

24.312 cm^270 °C

-0.24 %VOC / °C17.1 uA/cm^2/°C

m

53.601149.867848.244346.619845.037743.4203


'VOLTS AMPS POWER

0.00000.25830.30290.32580.34100.3485

41.2863 0.351138.5771 0.352626.8041 0.3572

0.0855 0.3629DATA CORRECTED TO

0.000C12.882114.615115.187(15.355915.131114.496413.60129.57420.0310

TARGET TEMPERATURE

VOLTS AMPS POWER53.60111

49.86781

48.2443346.8198445.03772

43.420341.28626

38.577126.804O90.085462

o_0.258324!

0.302940.3257760.3409560.348480.35112

0.3525720.3571920.362868

0

12.88205138

14.8151361215.1876236915.3558822215.1311051

14.4964323113.601204249.5742047290.031011534

0.4

0.35

0.30.25

0.2m 0.15

0.05

0

¢

t

20 40 60

VOLTAGE (VOLTS)

RESULTS


53.601 V0.363 A

15.356 W45.038 V

0.341 A78.950 %19.451 %

m

Appendix 4 - Acoustic Environment Test Report

w

w

w

COMPOSITE OPTICS INCORPORATED

9617 Distribution Avenue

San Diego, CA 92121

REPORT NO.: 43899

OUR JOB NO.: 43899

CONTRACT: N.A.

YOUR P.O. NO.: 55246

15 PAGE REPORT

04 February 2000

REPORT

ON

ACOUSTICNOISETESTSOF ONE

TESTPANELFOR

,liB'

COMPOSrrE OPTICS, INC.

m

STATE OF CALIFORNIA I

COUNTY OF LOS ANGELES I S.S.

C. GLARETAS, MNGR EL SEGUNDO ACOUSTICS, b.,. oduly sworn, degosN and .yl: That the information ¢ont&tned In thkl repo=l kl the ruu# of

¢ompkNe and camluly conduc_ecl te_l and is to Ihe best of his knowle¢_ true IM1d _ in d

res_x:_.

8 ,,o00

DEPARTMENT

TEST ENGINEER

TESTWlTNESS

Acoustics

F. E. Hermoso

(Not Applicable)

DCAS-QAR VERIFICATION

QUALITY ASSURANCE . / G. Mont?_ery,.-._

W-781

REPORT NO.

PAGE NO.

43899

2

TABLE OF CONTENTS

1.0 PURPOSE

2.0 REFERENCES

3.0 TEST CONDITIONS AND EQUIPMENT

3.1 Ambient Conditions

3.2 Instrumentation and Equipment

4.0 SUMMARY

LIST OF ATTACHMENTS

(Note: each Attachment can contain Data Sheets, data plots, Notices of Deviation,

Equipment Lists, and other explanatory documentation)

ATTACHMENT "ACO--A" ACOUSTIC NOISE TEST

LIST OF PHOTOGRAPHS

PHOTOGRAPH 1 ACOUSTIC NOISE TEST SETUP

w

m

w

i

wyle _ REPORTNO,

PAGENO.

43899

3

li[olll |11,11I:li_ll I [41,11_lllol:llloltl._lI 1,

1.0

2.0

2.1

2.2

2.3

2.4

3.2.2

3.2.3

PURPOSE

The purpose of this report is to present the procedures employed and the results

obtained during Acoustic Noise Tests on one Test Panel.

REFERENCES

Composite Optics, Incorporated Purchase Order No. 55246.

Composite Optics, Incorporated, FAX, dated 28 May 1999.

ANSI/NCSL Z540-1-1994, Calibration--Calibration Laboratories and

Measurement and Test Equipment--General Requirements which supersedes

MIL-STD--45662A, Calibration Systems Requirements, 10 June 1980.

Wyle Laboratories Western Test and Engineering Operation E1 Segundo Facility

Quality Assurance Program Manual for ISO 9001 Compliance, Rev. 04, dated 20

January 2000.

TEST CONDITIONS AND EOUIPMENT

Ambient Conditions

Unless otherwise specified all tests were performed at a barometric pressure of

between 710 and 815 mm of mercury absolute, a temperature of +75__.10 OF and a

relative humidity between 30 and 70%.

Instrumentation and Equipment

Measuring and test equipment, utilized in the performance of this contract, were

calibrated in accordance with ANSI/NCSL Z540-1-1994 (supersedes

MIL--STD--45662) by the Wyle Laboratories Standards Laboratory, or a commercial

facility, utilizing reference standards (or interim standards) whose calibrations have

been certified as being traceable to the National Institute of Standards and

Technology. All reference standards, utilized in the above calibration system, are

supported by certificates, reports or data sheets attesting to the date, accuracy andconditions under which the results furni'shed were obtained. All subordinate

standards, and measuring and test equipment, are supported by like data when such

information is essential to achieve the accuracy control required by the subject

contract.

Wyle Laboratories attests that the commercial sources providing calibration services

on the above referenced equipment, other than the National Institute of Standards

and Technology, are in fact capable of performing the required services to the

satisfaction of the Wyle Laboratories Quality Control Department. Certificates and

reports of all calibrations performed are retained in the Wyle Laboratories Quality

Control files and are available for inspection, upon request, by customer

representatives.

The test equipment utilized during this program is listed in Attachment "ACO-A."

w

_oREPORT NO.

PAGENO.

43899

4

;Or,IPOSITE PTICSINCORPORATED P,O, NO, 55246

4.0

The Test Panel was subjected to an Acoustic Noise Test according to Reference 2.1

and Reference 2.2, Table 1. Equalization tests were performed on the empty test

chamber using four control microphones. The test setup is shown in Photograph 1.

The specimen was subjected to the required acoustic spectrum at 142.5 dB for 60

seconds. The Test Panel completed the Acoustic Noise Test without apparent

damage. Refer to Attachment "ACO-A" for specific details of the test setup,

conditions during the test, and test results.

w

!

ACOUSTICTESTLEVELSANDRESULTS

REPORT NO.

PAGE NO.

1/3 OCTAVEBANDCENTERFREQUENCY

(Nz)31.5

40

50

63

80

100

125

160

200

250

315

400

500

630

800

1000

1250

1600

2000

2500

3150

4000

5000

6300

8000

10000

Allowable Overall SPL

MEASURED1/3 OCTAVE BAND

SOUNDPRESSURELEVELS

(dB*)122.5

124.7

129.0

130.1

129.9

131.1

131.8

131.0

132.7

133.4

134.2

133.5

131.2

128.0

125.2

123.1

120.8

119.9

119.4

117.2

113.9

113.5

112.8

112.1

112.3

112.6

142.8

*dB-Ref.: 2.0 x 10 -5 Pa

43899

6

m

i

JOB NO.

PAGE NO.

43899

ACO.A. 1

ATTACHMENT "ACO-A"

ACOUSTIC NOISE TEST

E =

RECEIVING INSPECTION DATA SHEET

JoB NO. 43 899

PAGE NO. ACO.A.2

Customer COMPOSITE OPTICS, INC. Iob No. 43899

Specimen PANEL Date 1-28-2000

i

i

m

No. of Specimens Received: 1

Record identification information exactly as it appears on the tag or specimen:

Manufacturer Comoosite Optics.Inc.

P/N's NA S/N's NA

How Does identification information appear: (e.g. name plate, tag, painted, imprinted, etc)

Per Customer Direction

Examination: Visual, for evidence of damage, poor workmanship, or other defects, and completeness of identification

Inspection Results: There was not visible evidence of damage to the specimen(s) unless otherwise noted below.

Inspected By F.E. Hermoso

Sheet Number 1 of 1

Approved Costa Glaretas Date January 28, 2000

W614 QA Form Approval

wle_e F

;

L _

JOB NO.

PAGE NO.

43899

ACO.A.3

O

O'r..)

TEST RECORD DATA SHEET

JOS NO. 43899

PAGENO. ACO.A.4

TEST TITLE ACOUSTIC NOISE

Customer COMPOSITE OPTICS, INC. Job No. 43899

Specimen PANEL Date Started 1-28-2000

Part No. NA Serial No. NA Date Comp 1-28-2000

Spec. Facsimile Dated 5-28-99 Par. Table 1 Photo Yes Amb. Temp. 75 + 10 deg. F

. I

n

PROCEDURE:

The Specimen was subjected to Acoustic Random Noise Testing in accordance with the above referenced

specifications. Adjustment of sound pressure levels and spectrum shapes were accomplished prior to

installing the Specimen in the High Intensity Reverberation Room. The specimen was suspended in the

Reverberation Room by nylon net

High intensity noise was then introduced into the chamber with an overall Sound Pressure Level (SPL) of142.5dB. This condition was maintained for 60 Seconds.

RESULTS:

Qualification Test was completed with no apparent damage to the specimen.

Measured acoustic noise data are shown on 1/n octave plots.

Tested By

W614A-82 QA FormApproval Engineer

F.E. HERMOSO

F.E. HERMOSO

rimO

JOB NO,

PAGE NO.

43899

ACO.A.5

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5

',OF,1POSITEOPTICSItlCORPORATED P,O,NO.55246

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PHOTOGRAPH 1

ACOUSTIC NOISE TEST SETUP

Ivi

REPORT NO.

PAGE NO.

43899

5

30P,IPOSITEOPTiC_IltCORPORATEO P.O, 1]O. 5246

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PHOTOGRAPH 1

ACOUSTIC NOISE TEST SETUP

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REPORT DOCUMENTATION PAGE FormAp o OMB No. 0704-0188

I I Ill] ]llr F

Public reporting burden for this collection of information is estimated to average 1 hour per response, Irck_ing the time for re_c_ng instructions, searching e0_ting data sources,gathering and maintaining the data needed, and completing and _ng the collection of infocmation. Send onmmen_ regarding this burden estim_e or any other aspect of thisoollectionof information, includingsuggestings for reducing this b_rden, to Washington Headquarters Sewices, Directorate for Information Operations and Repods, 1215 Jefferson

Da_s Highway,, Suite 1204r Adin_on, VA 22202-43021 and to the ofrce of Management and Bud_..t, Paperwork Reduction Pm_.ct 10704-01881r Washington r DC 20503

t. AGENCY USE ONLY (Leave blank) 2. REPORT DATE 3. REPORT TYPE AND DATES COVERED

16 May 2000 Final Report, 30 July 1999 - t6 May 20004. TITLE AND SUBTITLE 5 _'• FUNDING NUMBERS

Development of Electrostatically Clean Solar Array Panels NAS5-99236

(L AUTHOR(S)

Theodore G. Stem

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESSES

Composite Optics, Inc.9617 Distribution Avenue

San Diego, CA 92121-2307

9. SPONSORINGI MONITORINGAGENCYNAME(S)ANDADDRESS(ES)

NASA I Goddard Space Flight CenterGreenbelt Road

Greenbelt, MD 20771

8. PERF'C)I_I_ING ORGANIZATION

REPORT NUMBER

COI-TR-1413-002

10. SPONSORING I MONITORING

AGENCY REPORT NUMBER

11. SUPPLEMENTARY NOTES

12a. DISTRIBUTION I AVAILABILITY STATEMENT 12b• DISTRIBUTION CODE

13. ABSTRACT (Maximum 200 words)

CertainmissionsrequireElcctrostaticallyCleanSolarArray(ECSA) panelstoestablisha favorableenvironmentforthc

operationofsensitivescientificinstruments.The objectiveofthisprogramwas todemonstratethefeasibilityofanECSA panel

thatminimizcspanelsurfacepotentialbelow100mV inLEO and GEO chargedparticlecnvironmcnts,prcvcntsexposureof

solarcellvoltageand panelinsulatingsurfacestotheambientenvironment,and providcsan cquipotcntial,groundedstructure

surroundingtheentirepanel.An ECSA paneldesignw_ developedthatusesaFrontSideAperture-Shield(FSA)thatcoversall

inter-cellareaswitha singlegraphitecompositelaminate,compositecdgcclipsforconnectingtheFSA tothepanelsubstratc,

andbuilt-intabsthatinterconnecttheFSA toconductivecoatedcoverglasscsusingaconductiveadhesive.Analysisindicated

theabilityofthedcsigntomeattheECS/_ requirements.Qualificationcouponsand a0.SmX 0.Sinprototypepanelwcrcfabricatedand testedforphotovoltalcpcrlbrmanceandelectricalgroundingbeforeandafterexposuretoacousticand thermal

cyclingenvironments.The resultsshowthefeasibilityofachievingelectrostaticcleanlinesswitha smallpenaltyinmass,

photovoltaicperformanceandcost,witha designisstructurallyrobustandcompatiblewithawiderangeofcurrentsolarpaneltechnologies.

14. SUBJECT TERMS

Electrostatic, Solar Panels, Photovoltaics, Environmental Interactions,Graphite Fiber Reinforced Composites

17. SECURITY CLASSIFICATION

OF REPORT

Unclassified

NSN 7540-O1-280-5500

18, SECURITY CLASSIFICATION

OF THIS PAGE

Unclassified

15. NUMBER OF PAGES

139

16. PRICE CODE

11). SECURITY CLASSIFICATION 20. LIMITATION OF ABSTRACTOF ABSTRACT

Unclassified SAR

Standard Form 298 (Rev, 2-89)

cor ad nasa99236 development of electrost cally clean ... · development of electrost_cally clean...

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