2 Qsolar now offers a revolutionary PV panel manufacturing process without the use of laminators, glass, EVA or TPT!!!
3 As we believe that nothing is carved in stone, we have changed the entire solar panel manufacturing process, using our proprietary patent pending Spraytek99® and ESS® technology.What is the main problem in conventional solar panel manufacturing?The major bottleneck in any automatic PV manufacturing line is the lamination process; this is why production lines use multiple laminators to achieve the required throughput. The reason is the time it takes to cut and position the EVA sheets for encapsulation of the solar cells as well as the actual lamination process. This leads to significant increase of the total investment and operational cost.Why is Qsolar’s SPRAYTEK99 ® manufacturing process better?At QSOLAR we took a different approach in improving an already established technology using the crystalline silicon cells; but instead of using an expensive laminator to seal the cells, we have adopted a spraying technique we call SPRAYTEK99 ® using a highly protective insulator plastic compound which forms an impenetrable film around the cell protecting it from the weather under any conditions.
4 Design of a conventional glass solar panel Disadvantages:Requires an expensive flat bed laminator, production expansion is therefore costly.Lamination requires a significant amount of electricity.Solar panel sizes are restricted to the size of the laminatorRestricted to conventional materials such as solar glass, which is heavy and breakable.
5 Design of QSOLAR module Advantages:Manufacturing process is 35% fasterManufacturing does not need a laminator machine, reducing capital expenditure significantly.Major reduction in the use of power during manufacturingNot using Solar Glass, TPT or EVAQsolar can vary the backsheet! Instead of glass we use an ultra light composites which are 50% lighter in weight and stronger than glass.
6 QSOLAR has developed a new solar wafer manufacturing process " The Crucible Cell " pushing the boundaries of cost effective solar manufacturing to new levels. With the adoption of this advanced patented technology (KRUCIWATT®) enables the company to cut down significantly on polysilicon consumptionConventional wafer manufacturing processes consist of growing large ingots of silicon in furnaces and then cutting them with wire saws into thin wafers. This process results in material losses of up to 50% from the silicon dust produced during cutting. The silicon dust can not be reused as it is no longer pure to the level required for solar wafer manufacturing.KRUCIWATT®, Qsolar’s new Crucible Cell process, eliminates this waste and leads to up to 50% saving in silicon material which in turn results to up to 20% saving on the cost of the finished solar module
7 The new ICYCELLS® design from QSOLAR consists of 3 different cooling systems: A new UV reflector coating on top of the module that will reflect 99% of the UV so the panel remains cool.A 10mm hollow polymer backsheet with air cooling ducts where air can circulate underneath the cellHigh quality silver tab ribbons elementsSolar panels with the ICYCELLS® design allow air to flow through them. Increased ventilation helps cool down the solar panel and will guarantee peak performance every time
8 ESS – Embedded Solar Solutions SPRAYTEK 99® solar manufacturing process opens a wide range of new applications in the solar market. With the ESS ®SPRAYTEK process, solar cells can beThis technology allows true integration of solar electricity generation as the solar cells can be encapsulated on materials such as concrete, wood, bricks, tiles and more.ESS – Embedded Solar Solutions
9 The Qsolar Patented Spraytek99 manufacturing process Substrate Preparation1st Spraytek LayerString Layup Connection2nd Spraytek LayerVacuum ChamberCuring Room3rd Spraytek LayerJunction BoxTesting
18 Spraytek99 manufacturing advantages Higher throughput and light transmissivityCan be manufactured on virtually any substrateAvailability of custom colours and flexible panelsCan manufacture to virtually any size10 times the impact strength of tempered glassFramed or Frameless designUp to 70% lighter than conventional glass panelsLow carbon footprintLower costs
20 QliteX The lightest silicon-cell panel ever Cooling ducts for superior performanceUV reflective layerNo exposed metal partsPID-freeNo EVA, no TPT and no glass10x the impact strength of glassAvailable in any colour
21 QSS The world's thinnest framed panel No exposed metal parts PID-free No EVA, no TPT and no glass10x the impact strength of glassAvailable in any colourLightly flexible, allowing to freely expand and contract extending the module's lifetime up to and even over 25 years.capable of operating in temperatures anywhere between -40°C and 90°CDesigned for utility scale
22 QSF QST The most flexible silicon panel ever Bends up to 30° No EVA, no TPT and no glassPID-freeLess than 5mm thickNo exposed metal partsQSTSemi TransparentAllows light to pass throughNo EVA, no TPT and no glassPID-freeNo exposed metal parts
23 Current Applications Roof installations Ground installations Solar Tiles / PavementSpecialty VehiclesOff Grid Mobile Power SolutionsHigh Heat Desert Ready Applications
24 Rooftop Installation Poland QliteX PanelsCustom 40kw roof installationColour matched panels for a more aesthetically pleasing appearance.Significant weight reduction to traditional Glass Panels
25 Rooftop Installation Italy QliteX Panels400KW roof installation14.4 tons lighter than traditional glass panels.
32 The Solar Box Low cost solar power for basic needs Utilized as charging station for smaller electronic devices in remote locationsIncorporated USB device terminalCan provide lighting in remote locations10 – 40 watt applications available
33 Portable solar power pack AC power on the go!Various sizes availablePP20-5005 LED lamps for 4 hoursSmall TV for 4 hoursFan for 5 hoursSmall fridge for 3 hoursAny appliance up to 400WPP5 LED lamps for 15 hoursLarge TV for 5 hoursNormal fridge for 3 hoursSmall A/C for 1 hourAny appliance up to 900W
34 Heli Portable Solar system Diesel generator replacement4KW output AC power6 KWh of storage capacityIdeal for larger scale needs in remote locationsEliminate lengthy wait times and or costly delivery of fossil fuels in hard to access off grid locationsNo noise or harmful exhausts associated with traditional gas/diesel generatorsCan be deployed in MinutesModule can be Charged from its solar panels ,mains power, generator, or wind generator.Rugged construction ideal for field operation.Operating range from -40°C to 90 deg. C
35 Solar powered golf cart 160w ultra light flexible panelExtended drive times up to 14 milesEasy installationCompatible with all 48v cartsEliminate over 1000 lbs of C02 per yearSignificantly extend the battery lifetime to eliminate costly replacementsIn typical use, a golf cart battery is discharged to twenty percentage of capacity (80% discharge). In this usage, batteries willneed replacement after 520 charge cycles or 1 3/8 years.Use of a Qsolar solar panel reduces depth of discharge to no lower than 30%. In most cases through typical cart use the batterydischarge will be in the 30%-50%, equaling a gain of more than double in battery life.In one test case, battery discharge depth was limited to 10% of the battery capacity. Battery lifetime for this battery could beextended to 5000 charge cycles
36 Autonomous Solar Powered Scooter Powered by a 120W QSF ultra light Panel2Kg weightSignificantly extend the battery lifetime to eliminate costly replacementsOperate a daily driver without ever having to gas up or plug in!
37 Specialized Products Solar Pavement / Tiles 40kw 200 meter walking pathUsed as walkwaysCan be installed on buildingsCustom colours available
38 Specialized projects – Solar Tiles Solar tiles integrated in building design
39 Specialized Products – QST Letters or images can be directly inlayed into the panel.
41 SummaryA new revolutionary Solar panel manufacturing processSignificant cost advantageHigher production throughputNo size limitationsWeight advantageCustom colours availableMuch higher impact strength than traditional Glass ModulesLower power consumption during production, therefore much greener processUV reflector layerOpening an unlimited number of applications in the solar field
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