The bottleneck of traditional materials is becoming more and more prominent. How can composite materials solve the upgrading problems of the photovoltaic industry?
The photovoltaic industry is accelerating its evolution towards high efficiency, lightweight, long lifespan and low carbon. The performance upgrade of core component materials has become a key driver for the green transformation of the entire industrial chain. Traditional photovoltaic components generally use materials such as aluminum alloy, steel and glass, which have problems such as heavy weight, high production energy consumption, insufficient weather resistance and difficulty in recycling, making it difficult to adapt to complex application scenarios such as deserts, coasts and high altitudes. 
Composite materials, with their integrated advantages of lightweight, corrosion resistance, fatigue resistance, recyclability, and low carbon and environmental friendliness, have achieved large-scale application in core components such as photovoltaic frames, brackets, front plates, and back plates through formula optimization and innovative molding processes. They have systematically broken through the technical bottlenecks of traditional technologies at the material level, providing key support for improving the power generation efficiency of photovoltaic power stations and reducing their life-cycle costs. 
?? Core Characteristics of Composite Materials: Precisely Meeting the Demands of Green Transformation
The performance advantages of composite materials precisely meet the strict requirements of photovoltaic components in various application scenarios, laying a solid foundation for the green transformation of the industry. 
Characteristic Indicators
Performance of Composite Materials
Comparison with Traditional Materials
Density
Only 2/3 that of aluminum alloy and 1/4 to 1/3 that of steel
Weight reduction of 30% to 60%
Weather Resistance
Stable service in a wide temperature range from -40°C to +85°C
Life extension of 30% to 50%
Production Efficiency
Energy consumption reduced by 40% to 60% compared to aluminum alloy
Carbon emissions reduced by 35% to 50%
Recycling Rate
Can reach over 80%
Solves the recycling problem of traditional materials
Significant lightweight advantage
The density of composite materials is typically only 2/3 that of aluminum alloy and 1/4 to 1/3 that of steel. Using composite materials to manufacture photovoltaic components can achieve significant weight reduction. This not only significantly reduces transportation and installation costs but also reduces the load on the foundation structure of photovoltaic power stations, making it particularly suitable for scenarios with limited load-bearing capacity such as rooftops and weak foundations. 
Outstanding weather resistance
The composite material has excellent resistance to ultraviolet aging, salt spray corrosion, and extreme temperatures. In a wide temperature range from -40℃ to +85℃, as well as in harsh environments with high humidity, high salt content, and strong radiation, its service life can reach over 25 years, with key mechanical properties remaining above 85%. Compared to traditional materials, its lifespan is increased by 30% to 50%, significantly reducing maintenance frequency and costs. 
The entire life cycle is environmentally friendly and green.
The energy consumption of the composite material production process can be reduced by 40% to 60% compared to aluminum alloy. Some bio-based composite materials also have the potential for natural degradation. Waste parts can be recycled through processes such as crushing and remolding, with a recycling rate of over 80%. The carbon footprint throughout the entire life cycle is expected to be reduced by 35% to 50% compared to traditional materials, which is highly consistent with the green development concept of the photovoltaic industry. 
A Deep Analysis of the Application of Composite Materials in Photovoltaic Components
1. Photovoltaic Frame: Solving Pain Points with Strong Corrosion Resistance and Lightweight Properties
Traditional aluminum alloy frames are prone to pitting corrosion and oxidation in corrosive environments such as coastal areas and saline-alkali lands, affecting the sealing and lifespan of the modules. Steel frames, on the other hand, are heavy and have high anti-corrosion costs. 
Composite material solutions: 
Glass fiber reinforced epoxy resin and basalt fiber reinforced composite material frames
The weight is reduced by 20% - 30% compared to aluminum alloy frames, and the transportation and installation efficiency is increased by more than 40%.
Excellent salt spray corrosion resistance, no obvious corrosion after 10,000 hours of salt spray test.
The service life is extended to 25 - 30 years, and the operation and maintenance cost is reduced by more than 60% compared to aluminum alloy frames.
Actual application case: After a coastal photovoltaic power station adopted composite material frames, the component failure rate dropped from 8% to 2%, and the life cycle cost was reduced by about 15%. 
2. Photovoltaic Racking Systems: Empowering Complex Scenarios, Enhancing Structural Stability and Land Utilization Efficiency
Photovoltaic racking systems must endure wind loads, snow loads, and other forces for a long time. Traditional steel racking systems are prone to rust and are heavy, while aluminum alloy racking systems may have insufficient rigidity or be relatively expensive. 
The core advantages of composite material scaffolds: 
The specific strength is 5 to 6 times that of steel, and the weight is reduced by 50% to 60% compared to steel supports.
It has excellent fatigue resistance, with a strength retention rate of over 90% after 10⁷ cycles of alternating loads.
It has strong weather resistance and can serve for more than 20 years without deformation in complex environments such as deserts, coastal areas, and extremely cold regions.
The maintenance cycle is extended to 5 to 8 years, significantly reducing operation and maintenance costs.
3. Front and back panels of photovoltaic modules: Lightweight and high strength, ensuring core performance
Innovations in front panel application
Traditional glass front panels are heavy and have insufficient impact resistance. Front panels made of composite materials such as transparent carbon fiber reinforced polycarbonate (PC) and glass fiber reinforced transparent resin have the following advantages: 
The weight is reduced by 40% to 50% compared to traditional glass front plates.
The impact resistance is increased by 3 to 5 times, effectively reducing the component breakage rate.
The light transmittance is over 90%, without affecting the power generation efficiency.
It is suitable for new products such as flexible photovoltaics and portable photovoltaics.
Backsheet technology upgrade
Traditional fluorine film backsheet is prone to aging and has insufficient weather resistance, while metal backsheet is heavy and has the risk of electrical conduction. Composite material backsheet provides a comprehensive solution: 
Material composition: Glass fiber reinforced epoxy resin, polyimide-based composite material
Core functions: Excellent insulation, weather resistance and barrier properties
Performance indicators: Weight reduction of over 30%, service life matching the components for up to 25 years
Technological innovation and future outlook
Technological innovation continues to expand the application boundaries of composite materials in the photovoltaic field. 
Material-level breakthroughs
Nanomodification technology: Carbon nanotube-modified composite materials increase the front panel's light transmittance to over 92%.
Fiber hybridization technology: Further enhance mechanical properties and weather resistance.
Bio-based resins: Develop degradable composites to promote the "zero-carbon" upgrade of components.
Process innovation progress
High-pressure resin transfer molding (HP-RTM): Improve component molding efficiency and precision.
Automated pultrusion process: Achieve large-scale production and reduce production costs.
3D printing technology: Meet the manufacturing demands of complex-structured components.
Recycling system improvement
Establish a mechanical crushing and chemical depolymerization recycling system for composite photovoltaic components, enhance the performance stability of recycled materials, and build a closed-loop cycle of "raw materials - manufacturing - use - recycling" to further reduce the industry's carbon footprint. 
Future Development Trends
As the cost of composite materials gradually decreases and their performance continues to improve, they will play a more central role in the lightweight, high-efficiency, and long-life development of photovoltaic modules, especially in the following high-end scenarios: 
Floating offshore photovoltaic
Flexible building-integrated photovoltaic (BIPV)
Polar photovoltaic
High-altitude photovoltaic applications
The integration of composite materials and intelligent sensing technology enables full life-cycle health monitoring of photovoltaic components, providing early warnings of aging and damage risks and enhancing the intelligent operation and maintenance level of power stations. The all-round empowerment of photovoltaic multi-components by composite materials will continue to drive cost reduction and efficiency improvement in the photovoltaic industry, as well as green upgrades, and contribute to the realization of global energy transition goals.