We select the most suitable materials according to different application scenarios and customer needs to ensure the long-term stable operation of our products in various environments.
Focus on meeting international standards.
Meet the needs of different application scenarios.
Weather resistance, corrosion resistance, impact resistance, insulation.
Extend product life.
The following is an analysis of the advantages and disadvantages of commonly used materials for PV combiner boxes and their applicable scenarios (based on industry practices and manufacturer data):
– Advantages:
– Lowest cost, suitable for projects with limited budgets
– Medium mechanical strength, can meet basic protection needs
– Mature production process, short supply cycle
– Applicable scenarios:
– Temporary PV projects for short-term use
– Inland industrial and commercial roofs with drought and little rain (regular maintenance required)
– Advantages:
– Optimal corrosion resistance (salt spray/chemical environment)
– Maintenance-free throughout the life cycle, service life of 20 years+
– Highest fire protection level (can be used directly as a grounding body)
– Applicable scenarios:
– Power stations in coastal/highly corrosive industrial areas
– Large ground-based power stations with extremely high safety requirements
– BIPV projects that need to have the same lifespan as the building
– Advantages:
– Lightest weight (reducing roof load by 30%)
– Natural rust prevention (self-protection of oxide layer)
– Best heat dissipation performance (reducing the risk of temperature rise)
– Applicable scenarios:
– Distributed rooftop photovoltaics (especially projects that require weight reduction in actual measurements)
– Bifacial module systems with high heat dissipation requirements
– Mobile/portable photovoltaic devices
– Advantages:
– Best insulation performance (CTI ≥ 600V)
– Outstanding anti-UV aging ability (10-year outdoor warranty)
– Transparent version can realize working status visualization
– Applicable scenarios:
– High UV areas (plateau/desert power stations)
– School/hospital projects that require protection against electric shock
– Combiner box with intelligent monitoring function
– Advantages:
– Injection molding is suitable for complex structural design
– Optimal short-term cost-effectiveness ratio (3-5 years cycle)
– Lightweight and easy to install
– Applicable scenarios:
– Household small-power distributed systems
– Short-term replaceable poverty alleviation photovoltaic projects
– Areas without mandatory fire protection requirements
– Power station life cycle cost: stainless steel > PC > aluminum alloy > ABS > painted steel
– Failure rate comparison: painted steel (12%) > ABS (8%) > Aluminum alloy (5%) > PC (3%) > Stainless steel (1%)
– Operation and maintenance complexity: Painted steel (annual maintenance required) > ABS (replaced every 5 years) > Others (maintenance-free)
Here is the performance rating table of common materials for PV combiner boxes (painted steel, stainless steel, aluminum, PC, ABS) under typical installation conditions (★=Not suitable, ☆=half-star; ★★★★★=Best):
| Evaluation Condition | Painted Steel | Stainless Steel | Aluminum | PC (Polycarbonate) | ABS(Engineering plastic) |
| High Temp (70°C+) | ★★★ (Paint degrades) | ★★★★★ | ★★★☆ (Good heat dissipation) | ★★★★ | ★★ (Softens) |
| High Humidity | ★★ (Rust risk) | ★★★★★ | ★★★ (Oxidation risk) | ★★★★ | ★★★ (High water absorption) |
| UV Exposure | ★★ (Fading/peeling) | ★★★★★ | ★★★ (Requires treatment) | ★★★ | ★★ (Requires additives) |
| Corrosive Gases | ★★ | ★★★★ | ★★★ | ★★★★★ (Acid/alkali resistant) | ★★★☆ |
| Wind/Sand/Dust | ★★★ (Paint abrasion) | ★★★★ (Self-cleaning) | ★★★ | ★★★★★ (IP66 sealed) | ★★★★ (IP65) |
| Saltwater Environment | ★ (Rusts in 6 months) | ★★★★★ (316L best) | ★★ (Electrochemical corrosion) | ★★★★ (PC+ABS blend) | ★★ |
| Extreme Cold (-30°C) | ★★ (Brittle) | ★★★★ | ★★★☆ | ★★★★ | ★ (Cracks) |
| Mechanical Strength | ★★★☆ | ★★★★★ | ★★★ | ★★★★ (Impact resistant) | ★★★ (Requires reinforcement) |
| Flame Rating | ★★★ (Steel base) | ★★★★★ | ★★ (Fast heat conduction) | ★★★★ (UL94 V0) | ★★★ (HB grade) |
| Cost Efficiency | ★★★★ | ★★ | ★★★ | ★★★ | ★★★★ |
1. PC/ABS hybrid material:
It has both the weather resistance of PC and the toughness of ABS, suitable for projects with strong UV rays but limited budget.
2. Advantages of engineering plastics:
– Modified PPE resin provides the best resistance to moisture and heat
– Mechanical properties are maintained for 4000 hours under 85°C/85%RH
3. Notes on metal materials:
– Stainless steel should be selected as 316L grade to resist salt spray
– Aluminum should be anodized to improve weather resistance
Recommended Applications by Location:
Desert Plants: PC + stainless steel combo (UV + sand resistance).
Coastal Plants: 316L stainless steel or PC/ABS blends (salt spray resistance).
Polar/Cold Regions: PC (withstands -60°C) or stainless steel.
Chemical Plant Vicinity: PPE resin (acid/alkali resistance).
(Note: ratings based on actual.PV combiner box operational data.
When selecting photovoltaic combiner boxes, IP (Ingress Protection) and IK (Impact Protection) ratings are critical for ensuring long-term reliability in harsh environments. At LETOP, we engineer our combiner boxes with industry-leading protection to match your installation challenges:
UV exposure levels → Recommend UV-stabilized PC or powder-coated steel
Annual rainfall data → Specify
IP65/IP66 gasket designs
Seismic/wind zone → Customize IK08-IK10 mounting brackets
• Fish Farms: IP68 + IK08 submerged models with anti-biofouling coating
• Oil Refineries: IP66 + IK09 explosion-proof stainless steel units
• Alpine Plants: IP66 + IK10 heated enclosures (-40°C rated)
The International Electrotechnical Commission’s IP and IK protection standards for electrical box products are as follows:
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