Composite PV Module Frames: What Pultrusion Technology Changes

Demand in the photovoltaic industry for frames that are lightweight, corrosion-resistant and electrically insulating has grown steadily in recent years. Composite frames based on glass-fibre reinforced polyurethane (GF-PU) are becoming an important technical option alongside traditional aluminium profiles, thanks to their material properties and the pultrusion process used to make them.

Material and process characteristics

The frame uses glass fibre as reinforcement and polyurethane resin as matrix, produced continuously by pultrusion: the fibre rovings are impregnated with resin and cured inside a heated die to form a profile with a defined cross-section. This route delivers high efficiency and high dimensional accuracy in volume production, which matches the manufacturing scale of PV module frames.

Six core advantages

• Lightweight: composite density is lower than aluminium alloy, so the finished frame weighs noticeably less, reducing transport cost and installation effort.
• Excellent corrosion resistance: the material withstands salt spray, ammonia, acid and alkali media and hot-humid environments, making it suitable for coastal, agricultural, industrial and desert installations.
• Electrical insulation, no grounding: as a non-metallic material the frame has high resistivity, which removes grounding hardware and helps mitigate potential-induced degradation (PID), improving long-term system reliability.
• Matched thermal expansion: its coefficient of thermal expansion is close to that of glass, reducing thermomechanical stress inside the laminate as temperature changes and extending module life.
• Flame retardance and weather resistance: good flame-retardant rating and stable mechanical properties after UV and damp-heat ageing tests, for safe long-term outdoor service.
• Recyclable: the non-metallic nature allows classification as a recyclable material, processable through existing mechanical or chemical recycling routes, which helps reduce carbon footprint.

Application scenarios

The frame is available in multiple configurations — glass-glass, glass-backsheet and lightweight modules — so it adapts flexibly to different module designs. Its corrosion resistance and low weight make it particularly suitable for coastal areas with severe salt spray, humid and rainy regions, and desert zones with wide temperature swings.

What volume production requires

For series production of composite frames, GOOGIO supplies three elements:

• Complete pultrusion line: creel, resin impregnation system, heated die, pulling unit and automatic cutting as core modules.
• Customised process support: pultrusion speed and temperature profile optimised for the customer's resin system (polyurethane, epoxy and others) and profile cross-section, to keep product quality stable.
• Automation package: optional in-line inspection and control systems that raise yield and productivity.

Manufacturers with composite frame production requirements can review equipment and technical options on the composite industry equipment page, or contact us directly for advice specific to their project.