Coupled Electro-Thermal Modeling of Cell-to-Module Power Loss Mechanisms in Modern High-Density Photovoltaic Modules

Abstract

Cell-to-module (CTM) power loss represents the integrated effect of optical, electrical, and thermal loss mechanisms occurring during cell integration into the finished module. As cell efficiencies have advanced into the 24-percent range and module designs have grown denser, the relative contribution of each CTM loss mechanism has shifted, complicating the use of legacy decomposition frameworks. This work presents a coupled electro-thermal modeling framework that resolves CTM loss into eleven distinct contributors and validates the decomposition against indoor-laboratory and outdoor-monitoring measurements for representative module architectures. The framework supports module-design optimization by enabling the comparative ranking of design changes (cell-spacing reduction, anti-reflection coating addition, busbar geometry alteration) before fabrication of full prototypes.