Holistic Design Optimization of the PV Module Frame: CTM, FEM, COO and LCA Analysis

We present a holistic approach for the photovoltaic (PV) module frame optimization that considers technical as well as economic and ecological aspects for different frame designs. This provides insights into a method to reduce frame costs and carbon footprint without compromising mechanical stability as well as module power. Finite element method (FEM) simulations of module and frame are used to assess mechanical stability, cell-to-module (CTM) analysis is used to evaluate power losses affected by frame overlap, a bottom-up cost model is applied for the economic assessment of material and process cost shares of frame manufacturing, and a life cycle assessment (LCA) analysis is applied to evaluate the ecological footprint (CO2-eq/kWP). Compared to a reference frame, the exemplary optimized frame design shows 2.6% less deflection, which corresponds to around 0.7 mm. Cell to module (CTM) analysis shows that a bigger frame width lightly decreases the cover coupling power gain. Results show that increasing the front frame width from 16 mm to 20 mm reduces the module power by about 0.12 WP. Cost analysis findings suggest that the optimized frame can save around 30 g aluminum which reduces the total module cost by 0.1%. Life cycle assessment results are directly correlated to the material mass of the corresponding design. Results show that using the optimized frame can save 0.8 kg CO2-eq/kWP due to the saving in aluminum compared to the reference frame.