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Case study

Reliable, lightweight outdoor polycarbonate with effective EMI shielding

The residential solar-plus-storage market is growing rapidly as more households embrace photovoltaic systems and energy storage devices. Our innovative polycarbonate solution with EMI shielding offers a lightweight, cost-effective, and sustainable alternative to metal for PV and ESS inverters, boosting efficiency.
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Task

Safeguarding inverters: The key to reliable solar energy systems

As the central component of a residential solar storage system, the inverter plays a crucial role in managing the conversion and flow of electricity, directly influencing system efficiency and stability. 

To ensure reliable performance in outdoor environments, the inverter requires a robust, durable enclosure. Designed to withstand extreme weather and impacts, the enclosure safeguards internal components, reducing maintenance costs and enhancing long-term reliability. Additionally, with rising residential storage voltages, it must ensure electrical safety to minimize the risk of accidents.

Challenge

Achieving excellent EMI shielding and durability with outdoor polycarbonate

Metal has long been used in outdoor new energy applications, but it presents several challenges: complex structures, high processing costs, excessive weight, limited design flexibility, and susceptibility to corrosion. 

Our high-performance outdoor polycarbonate solution is an excellent alternative due to its significantly lighter weight, superior quality and performance, total cost-effectiveness and enhanced design flexibility.

The key challenge in transitioning from metal to plastic lies in maintaining effective EMI (Electromagnetic Interference) shielding while ensuring long-term reliability. This requires, first and foremost, strong adhesion between metal coatings and plastic substrates to withstand daily harsh outdoor conditions, including extreme temperature fluctuations, intense UV exposure, and high-impact scenarios. Additionally, the plastic must provide effective protection against interference from high-frequency circuits.

As the global energy transition accelerates and household energy storage solutions gain widespread adoption, we are proud to introduce our innovative metal replacement technology. This cutting-edge solution offers exceptional reliability, lightweight benefits, and significant cost-efficiency, setting a new benchmark for performance and value in the industry.

Nan Hu

Global Head of Industrial Marketing, Electronics & Electrical Engineering Plastics, Covestro

Solution

Ensuring outdoor reliability with high-performance Makrolon® 

Our high-performance outdoor polycarbonate, Makrolon®, is an exceptional alternative to metal for outdoor applications, offering outstanding performance and reliability. Our advanced technology combines Makrolon® with a tailor-made conductive coating, delivering effective EMI shielding while maintaining exceptional reliability in harsh environments. This innovative solution not only reduces total costs but also increases design freedom and enhances production efficiency. Optimized engineering further contributes to significant weight reduction, making it a superior choice for modern outdoor applications. 

The material is rigorously tested, withstanding thousands of hours of UV, aging and other tests. It demonstrates excellent weatherability, low-temperature impact resistance, hydrolysis resistance, and 5VA and V0 flame retardancy. Additionally, it supports appliance-style designs for home installations and offers a more sustainable alternative to aluminum die-casting, helping to lower CO2 emissions. We also offer low-carbon materials to further contribute to a sustainable future while maintaining mechanical performance and electrical safety.

Key benefits

  • Efficiency-improving Enhanced system heat dissipation helps extend equipment lifespan.
  • Long-term reliable  Boosts excellent durability and stability, ensuring long-term system reliability.
  • Cost-effective Help lower overall system costs through optimized design and material selection.
  • Lightweight design Significantly reduces equipment weight, facilitating easier installation and maintenance.
  • Low-carbon Utilizes recyclable materials and reduces carbon emissions during production

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Request a quote

Hello! Thanks for reaching out to us.
We have received your request and one of our experts will be in touch with you as soon as possible.
In the meantime, feel free to discover our innovative material solutions!

Speak to you soon,
Your Covestro Team

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