Abstract

Abstract As part of a controlled, step-wise development program, silicon cells from an early production run were assembled into packages and installed in a prototype electrical module. After three years field service, the module was disassembled and the cell packages were examined in detail. Although all 48 cell packages were still functional, significant cracking was discovered in the solder layers between ceramic stand-offs and copper heat-spreaders. A simplified analysis of thermal fatigue as a cyclic creep process predicts useful lives of about twelve years for cell packages of this configuration and solder joint thickness.

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