Extending EV Range With Solar Roof Rack

DartSolar LLC has launched a 1,000 W solar roof rack for electric vehicles (EVs) in 2024. Developed in-house, this expandable roof rack system is capable of producing about 5 kWh of electricity per day, enough to extend the EV’s range by 5 to 10 miles or power 120 V electric tool for hours.

The company is now set to do one better by developing a 2,000-watt expanding solar roof rack system that can generate up to 10 kWh per day, extending an EV’s range by about 20 to 40 miles or powering a small home. 

The system is designed with custom 1/8-inch thick solar panels, 3D-printed components, and aluminum telescopic tubes. When the vehicle is parked, the rack expands to provide 2,000 W and contracts while in motion to provide 360 W. This configuration allows EVs to generate solar power both when stationary and on the move. 

The company has structured the system for component replacement and future upgrades. The design includes replaceable solar panels and 3D-printable parts, with digital blueprints available for maintenance. By 2027, the company plans to expand the roof rack’s capacity further to 3,000 W, enabled by tandem perovskite solar cells. Perovskite solar cells can deliver over 30% conversion efficiency, compared to the 20% efficiency of current solar cells. 

While the roof rack is compatible with EVs, hybrids, vans, trucks, and RVs, Tesla vehicles can accommodate the system without requiring an additional roof rack, says DartSolar. The system is designed for easy integration with 3^rd party power units and solar chargers, allowing flexibility in energy storage and use.