Steady-state and residual FEA thermal stress analysis of a Concentrating Photovoltaic (CPV) cell module is performed in this study. This investigation covers the nominal and extreme operating conditions, including system startup and shutdown. The physical properties of different epoxies were substituted into the model and the model results were used to identify the optimal bonding materials. Different thermal boundary conditions were evaluated for optimal performance. As the first step of module life prediction, residual stresses corresponding to different temperatures were calculated. The analysis revealed that the thermal expansion mismatch between the bonded materials is a major design concern, since it can cause structural failure at critical interface locations.

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