Covestro claims 3 GW of PV module shipments with PU composite frames

German materials firm Covestro says that its shipment of photovoltaic (PV) modules using frames made with its polyurethane (PU) composites technology have surpassed 3 gigawatts, which it says is a major milestone for this cost-effective, low-carbon alternative to aluminium and is pioneered in China. This volume is equivalent to about 5 million standard solar panels, covering more than 1,100 soccer fields, it adds.

Made with Covestro’s Baydur PU composites, the frames are said to offer high strength, corrosion resistance, and insulation properties, enhancing solar module performance and longevity.

As the second-most costly PV module component after the solar cells themselves, aluminium frames typically account for 10-15% of total module costs. PU composites provide a stable, cost-effective alternative amid aluminium price volatility, it adds.

The PU composite also enables up to 85% lower cradle-to-gate carbon emissions compared to aluminium in frames, due to its less energy-intensive production process.

As the world’s largest producer of PV modules, China has been at the forefront of adopting composite frames. In 2023, when the PV industry faced mounting cost pressure, manufacturers seeking cost-effective components began adopting composite frames, leading to a breakthrough in their application. With certifications from both TÜV Rheinland and TÜV SÜD, Baydur is said to have rapidly gained industry-wide recognition.

The Baydur composite technology reached a pivotal milestone in 2024 as major Chinese solar manufacturers integrated this technology into their mass production lines. This advancement comes at a crucial time in the renewable energy landscape.

According to the International Energy Agency’s Renewables 2024 report, the global renewables capacity is set to expand by 5,520 GW by 2030, with solar PV installations accounting for 80% of the growth.