My Blog

What Are Solar Panels?

The sun is the primary source of energy on Earth and sunlight can be converted directly into electricity using solar panels. Electricity has become indispensable in life. It powers the machines that most us use daily.

For more information visit here: Solar Panel Manufacturers and Solar Business Opportunity

 

 

THE COMPONENTS

A solar panel is usually manufactured from six (6) components namely the PV (photovoltaic) cell or solar cell which generates the electricity, the glass which covers and protects the solar cells, the frame which provides rigidity, the backsheet where the solar cells are laid, the junction box where the wirings are connected and enclosed, and the encapsulant which serves as adhesives.

Since most people does not have access to equipment in manufacturing solar panels, it is important to note and understand those six components in order for anyone to be able to plan the materials needed to create a do-it-yourself or home-made solar panel.

The materials needed on how to make a solar panel must be available for purchase locally or online and should not exceed the expense of a brand new solar panel or does not take a long time to build.

1.) PV Cell

The first thing to consider when building your own solar panel is the solar cell.

Photovoltaic (PV) cell or solar cell converts visible lighting into electricity. One (1) solar cell however is not enough to produce an usable quantity of electricity much like the microbot in Baymax (Hero 6) which only becomes useful when combined as a group. This basic unit generates a DC (direct current) voltage of 0.5 to 1 volt and although this is reasonable, the voltage continues to be too small for most applications. To produce an useful DC voltage, the solar cells are connected in series and encapsulated in modules making the solar panel then. If one cell generates 0.5 volt and is connected to another cell in series, those two cells need to then be able to generate 1 volt and they can then be called a module. A typical module usually consists of 28 to 36 tissue in series. A 28-cell module should be able to generate roughly 14 volts (28 x 0.5 = 14VDC) which is enough to charge a 12V battery or power 12V gadgets.

Connecting two or more solar cells require which you have a simple understanding of series and parallel connection which is similar to connecting batteries to make up a battery storage system.

There are two most common solar cells that can be bought in the market; a monocrystalline cell and a polycrystalline cell. These two can have the same size, 156mm x 156mm, but the main difference would be efficiency. It is important to purchase additional tissue to serve as backup in case you fail on some of the cells i.e. bad solder, broken cell, scratched, etc.

Monocrystalline solar cells are black and octagonal in shape usually. This type of solar cell is constructed of the best and purest quality silicon which makes them expensive. But they are the most efficient of all types of solar cells and are almost always the choice of solar contractors when area is an important factor to consider in achieving the power they want to attain based on their solar system design.

Polycrystalline PV Cells are characterized by their bluish color and rectangular shape. These cells are manufactured in a much simpler process which lowers the purity of the silicon content and also lowers the performance of the end product.

Generally, monocrystalline cells are more efficient than polycrystalline cells but this does not mean that monocrystalline cells perform and outputs more power than polycrystalline cells. Solar cell performance has something to do with the size of the tissue and every solar panel or tissue have an efficiency rating based on standard tests when they were manufactured. This rating is usually in percent and the common values range from 15% to 20%.

2.) Glass

The glass protects the PV tissue while allowing optimal sunlight to pass through. These are usually made of anti-reflective materials. Tempered glass is the choice of material nowadays also for unknown and brand-new manufacturers although there are still those who utilize flat plate glass on their solar panels. Tempered glass are created by chemical or thermal means and is many times stronger than plate glass making it more expensive to produce but the price of manufacturing them today is sensible and cost-effective. Flat plate glass creates sharpened and long shards when broken as opposed to tempered glass which shatters properly in small parts upon impact, that is why they call it safety glass also. It should be noted here that most amorphous solar panels uses toned plate glass because of the way the panel is constructed.

Tempered glass is definitely what manufacturers use in mass producing their solar panels. In our DIY project, we suggest to use Plexiglas also called acrylic glass which is safer than the regular normal glass from your local hardware store. It is a bit expensive than regular glass but is weather resistant and does not break easily. The Plexiglas can be screwed or glued easily to the frame also.

3.) Frame

A frame is usually made of anodized aluminum which provides rigidity and construction to the solar module. These aluminum frames are also designed to be compatible with most solar mounting systems and grounding products for easy and safe installation on a roof or on the ground.

The frame in a factory-built solar power is usually the aluminum part where all four sides of the solar panel sheet are inserted. Think of it as a skeletal rectangular body. The solar panel sheet by the way is composed of the other 4 components and are layered and laminated in the following order from top to bottom; the tempered glass, top encapsulant, the solar cells, bottom encapsulant, then the backsheet. In our DIY solar panel, we will be using a wooden body and the end-result would be something analogous to a picture frame where the picture is the solar cells glued to a non-conductive board, the glass for the Plexiglas top cover, and the wooden part as the frame and backsheet.

4.) Backsheet

The backsheet is the level of plastic film on the relative back surface of the module. This is the only level protecting the module from unsafe DC voltage. The main function of the backsheet is to insulate and guard the handler from shock and provide the safest, efficient, and dependable electrical conductivity possible.

The backsheet will be a wooden plywood where the frame shall be screwed on top and on the sides. It should be noted here that a perforated hardboard (Pegboard) will be used to place and align the PV Tissue and this Pegboard will sit on top of the wooden backsheet and fitted inside the wooden frame.

5.) Junction Box

The junction box is where the terminal bypass and wires diodes are located and concealed. The terminal wires are basically the positive and negative wires based on the series connections of the PV Tissue and will be connected to another solar panel, a charge controller, a battery system, or to an inverter, according to the operational system design. The bypass diode is a protective mechanism that prevent strength from getting back to the solar panel when it is not producing energy as in the case when it is night time.

There are junction boxes designed for factory-built solar panels that are now available to purchase online especially from China. If you are not pressed for time, you can order online and wait for the delivery otherwise you can just purchase a regular electrical junction container from your local hardware store. The purpose of the junction container is to guard the terminals (positive and negative terminals) from water, dust, and other elements. This is also where the two wires (reddish colored for positive and black for negative) will be coming from. The other end of these two wires can also be protected by using a PV accessory called MC4 which can also be purchased on-line together with the PV junction box.

6.) Encapsulant

Encapsulant sheets prevent water and grime from infiltrating the solar modules and assist as shock-absorbers that protect the PV tissue. They have this adhesive bonding capability to the glass, the PV tissue, and the backsheet similar to a glue but stronger. Encapsulants are usually made of Ethylene-Vinyl Acetate or EVA and are applied using lamination processes and machines. Solar panel manufacturers use a vacuum and a large oven to properly seal and treatment the EVA sheet onto the solar panels. Most of us do not have the capability to do this but many still have tried and failed while others had varying levels of success.

Encapsulants are thin plastic sheets that are usually laminated on the top and base parts of the solar cell sheet. The bottom encapsulant is the layer on top of the backsheet where the solar cells are actually placed and supported. In our project, we will use a latex acrylic paint instead. This paint will not be applied to the pv cells because when attempted, will not result in an equal distribution or program of the liquid to the surface of the cells which can degrade performance. The paint will be applied to the wooden frame, wooden backsheet, and to the Pegboard. This Latex Acrylic paint should be able to guard the wooden parts from UV rays and will better resist blistering and cracking overtime. This paint, although water-soluble, can dry and becomes water-resistant quickly.

Go Back

Comment