Insights into effect of thermal distribution on overall efficiency and effective life span of solar photovoltaic (PV) modules

• Effect of thermal distribution on overall efficiency and effective life of PV panels is reviewed. • Thermal non-uniformity reduces PV efficiency and accelerates degradation via hotspots and material stress. • Temperature homogeneity boosts efficiency and prevents hotspots. • ML algorithms detect PV hotspots with >99% accuracy using drone imagery. • Integrated thermal management is key for long-term PV performance and reliability. Solar photovoltaic (PV) systems are a major source of sustainable energy, but despite advances in cell materials, efficiency, and design, significant challenges remain most notably thermal distribution, which strongly affects both performance and lifespan. The uneven temperature distribution, known as nonuniformity, adversely affects PV system performance by causing hotspots, material fatigue, and encapsulant aging. This review assesses the effects of thermal distribution on solar PV modules, emphasizing their energy conversion efficiency, reliability, and durability. Hotspots and thermal stress have profound effects on the module performance and effective life, highlighting the importance of efficient thermal management strategies. The review also explores various thermal management approaches, including cooling systems, phase change materials (PCM), and heat sinks. Additionally, this paper evaluates computational methods like computational fluid dynamics (CFD) and the finite element method (FEM) for analyzing thermal distribution in PV systems. It also examines the application of machine learning techniques for predictive modeling and experimental investigations aimed at mitigating thermal effects on PV modules. Future research should focus on the role of thermal management in optimizing PV system performance and extending system lifespan. This paper also highlights the need for further research into developing cost-effective and sustainable thermal management solutions for PV systems. Graphical Abstract.