We present a holistic approach for the photovoltaic (PV) module frame improvement that considers mechanical, electrical, economic, and ecological aspects for different frame designs. In a comprehensive study, the approach is applied to exemplary PV module frame designs. The analyses performed in this study show a potential improvement path of the module frame design. This leads to an overall better module performance and helps finding the balance point between technical performance, cost, and environmental impact. Based on the results, the PV module frame design affects the aspects analyzed in this work differently. For the comparison, we defined reference frame design with 16 and 20 mm front and rear frame widths. The improvement is reached by unitizing the frame width for both sides to 18 mm and increasing its cavity width to 12 mm instead of 8.5 mm. Tuning the frame parameters in this way leads to the best balance point for frame designs in this study regarding all aspects. The mechanical finite element method (FEM) simulation results show that
We present an evaluation of the silicon solar cell as well as the photovoltaic (PV) module size and its effect on thermomechanical stress. The evaluation is based on finite-element method (FEM) simulations. Within these simulations, we perform parameter variations of the number of solar cells within a PV module from 60-140 cells, of the cell size from 156.0-161.75 mm, and the cell format from full cells down to quarter cells. The FEM simulations cover the lamination process, mechanical load, and thermal cycling for glass-foil as well as glass-glass modules. The presented results reveal correlations between the solar cell and module size with the stress in the solar cells. We also find that the interaction of the laminate with the module frame plays a significant role in thermal cycling. Of the varitations under investigation, the increase in cell size has the largest effect on the stress. However, at a mechanical load of 2400 Pa, glass-foil modules with less than 96 solar cells have a negligible failure probability. The advantage of placing the solar cells in the neutral axis of the laminate is proven by the negligible tensile stress values for all variations of the glass-glass modules.
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