QSOLAR NOW OFFERS A REVOLUTIONARY PV PANEL
MANUFACTURING PROCESS WITHOUT THE USE OF
LAMINATORS, GLASS, EVA OR TPT!!!
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.
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 laminator
•Restricted to conventional materials such as solar glass, which is heavy and breakable.
Design of QSOLAR module
Advantages:
•Manufacturing process is 35% faster
•Manufacturing does not need a laminator machine, reducing capital expenditure significantly.
•Major reduction in the use of power during manufacturing
•Not using Solar Glass, TPT or EVA
•Qsolar can vary the backsheet! Instead of glass we use an ultra light composites which are 50% lighter in
weight and stronger than glass.
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 consumption
Conventional 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
The new ICYCELLS® design from QSOLAR consists of 3
different cooling systems:
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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 cell
High quality silver tab ribbons elements
Solar 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
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 be
This 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.
The Qsolar Patented Spraytek99
manufacturing process
Substrate
Preparation
Curing Room
1st Spraytek
Layer
String Layup
Connection
3rd Spraytek
Layer
2nd Spraytek
Layer
Curing Room
Vacuum
Chamber
Junction Box
Testing
First Spraytek layer
Layup
String Connection
Second Spraytek Layer
Vacuum chamber / Curing room
Inside the Curing Room
Inside the Curing room
Colour Panels
Before Curing
Finished Product
QliteX – Composite Substrate
Spraytek99 manufacturing advantages
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Higher throughput and light transmissivity
Can be manufactured on virtually any substrate
Availability of custom colours and flexible panels
Can manufacture to virtually any size
10 times the impact strength of tempered glass
Framed or Frameless design
Up to 70% lighter than conventional glass panels
Low carbon footprint
Lower costs
PRODUCT LINES
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QLX
QSS
QST
QSF
QliteX
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The lightest silicon-cell panel ever
Cooling ducts for superior performance
UV reflective layer
No exposed metal parts
PID-free
No EVA, no TPT and no glass
10x the impact strength of glass
Available in any colour
QSS
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The world's thinnest framed panel
No exposed metal parts
PID-free
No EVA, no TPT and no glass
10x the impact strength of glass
Available in any colour
Lightly 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°C
Designed for utility scale
QSF
• The most flexible silicon
panel ever
• Bends up to 30°
• No EVA, no TPT and no glass
• PID-free
• Less than 5mm thick
• No exposed metal parts
QST
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Semi Transparent
Allows light to pass through
No EVA, no TPT and no glass
PID-free
No exposed metal parts
CURRENT APPLICATIONS
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Roof installations
Ground installations
Solar Tiles / Pavement
Specialty Vehicles
Off Grid Mobile Power Solutions
High Heat Desert Ready Applications
Rooftop Installation
Poland
• QliteX Panels
• Custom 40kw roof
installation
• Colour matched panels for
a more aesthetically
pleasing appearance.
• Significant weight
reduction to traditional
Glass Panels
Rooftop Installation
Italy
• QliteX Panels
• 400KW roof installation
• 14.4 tons lighter than
traditional glass panels.
Ground Installations
Spain
• QSS Panels
• Cost effective solution
• Lower installation costs
Rooftop Installations
Spain
Rooftop Installations
China
80KW & 50KW
Ground Installation
China
30KW
Rooftop Installation
100KW
Germany
Rooftop Installation
6KW
Denmark
The Solar Box
•Low cost solar power for basic needs
•Utilized as charging station for smaller electronic devices in remote locations
•Incorporated USB device terminal
•Can provide lighting in remote locations
•10 – 40 watt applications available
Portable solar power pack
AC power on the go!
Various sizes available
PP20-500
• 5 LED lamps for 4 hours
• Small TV for 4 hours
• Fan for 5 hours
• Small fridge for 3 hours
• Any appliance up to 400W
PP30-1000
• 5 LED lamps for 15 hours
• Large TV for 5 hours
• Normal fridge for 3 hours
• Small A/C for 1 hour
• Any appliance up to 900W
Heli Portable Solar system
•Diesel generator replacement
•4KW output AC power
•6 KWh of storage capacity
•Ideal for larger scale needs in remote
locations
• Eliminate lengthy wait times and or
costly delivery of fossil fuels in hard to
access off grid locations
• No noise or harmful exhausts
associated with traditional gas/diesel
generators
•Can be deployed in Minutes
•Module 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
Solar powered golf cart
•160w ultra light flexible panel
•Extended drive times up to 14
miles
•Easy installation
•Compatible with all 48v carts
•Eliminate over 1000 lbs of C02
per year
•Significantly extend the battery
lifetime to eliminate costly
replacements
In typical use, a golf cart battery is discharged to twenty percentage of capacity (80% discharge). In this usage, batteries will
need 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 battery
discharge 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 be
extended to 5000 charge cycles
Autonomous Solar Powered Scooter
•Powered by a 120W QSF ultra
light Panel
•2Kg weight
•Significantly extend the battery
lifetime to eliminate costly
replacements
•Operate a daily driver without
ever having to gas up or plug in!
Specialized Products
Solar Pavement / Tiles
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40kw 200 meter walking path
Used as walkways
Can be installed on buildings
Custom colours available
Specialized projects – Solar Tiles
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Solar tiles integrated in building design
Specialized Products – QST
• Letters or images
can be directly
inlayed into the
panel.
Qsolar in the news
Summary
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A new revolutionary Solar panel manufacturing process
Significant cost advantage
Higher production throughput
No size limitations
Weight advantage
Custom colours available
Much higher impact strength than traditional Glass Modules
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Lower power consumption during production, therefore much greener
process
UV reflector layer
Opening an unlimited number of applications in the solar field
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