How to Build Photovoltaic Solar Panels

Photovoltaic solar panels are quite costly when purchased from a manufacturer, but in actuality the devices are relatively simple and can built at home for a fraction of the cost. A typical solar panel consists of an array of 36 mono-crystalline cells housed in a frame covered in Plexiglas. With minimal knowledge of carpentry and electrical wiring, you can build these devices yourself.

Things You'll Need

• 36 mono-crystalline Solar cells
• 45 3/4-inch by 22 1/4-inch piece of Plywood
• 45 3/4-inch by 22 1/4-inch piece of Plexiglas
• 3/4- by 3/4-inch wood molding, 135 inches in length
• Masonite pegboard
• Blocking diode
• Electrical jack
• Solder
• Copper wire
• Heat-resistant adhesive
• Silicone caulk

Instructions

Solar Cell Array

1. Lay the solar cells face down in rows of six on the plywood so that you can easily solder them together.

2. Using separate copper wire for the positive and negative currents, solder each cell together in an array from the top left cell to the bottom left cell. Be sure to touch on each soldering point. If you miss one, the array will not work. Leave approximately three feet of extra wire at the end for connecting the blocking diode.

3. Place a small amount of heat resistant adhesive in the middle of each cell, and then carefully place the masonite pegboard over the backs of the cell so that it covers all of them. Turn the entire configuration over so that the cells are resting on the pegboard, and the plywood can be removed.

Panel Assembly

1. Using the 3/4-inch by 3/4-inch wood molding, create a frame around the perimeter of the, and secure it into place with nails or wood screws.

2. Carefully place the pegboard with the cells now stuck to it inside the frame. It should fit snugly in the frame but, if not, shave down the edges until it does. Secure the pegboard to the frame with wood screws and be sure not to damage any wires.

3. Cut a notch in the bottom of the frame to run the excess wire through.

4. Connect the excess wire to a blocking diode, being sure to connect the positive and negative leads to the proper connections on the diode. Using some more copper wire, run another connection from the diode to the electrical jack to complete the circuit.

5. Cover the entire panel with a sheet of Plexiglas and secure it to the frame with screws.

Tips & Warnings

• When working with the cells, be careful not to press too hard on them, because they will crack or chip easily.

• It is a good idea to test the panel before everything is secured to ensure the array is functioning properly so that you don't have to dismantle the panel if there is a problem.

• You can acquire solar cells at a fraction of their usual cost by purchasing lots of slightly damaged cells. Although these cells will produce slightly less electricity, once the entire array is complete, it will only make a small difference in the panel's overall functionality.

References

• Mike's World: How I Built an Electricity-Producing Solar Panel
• Home Solar and Wind: DIY Solar Panel
• Olino Renewable Energy: Building my own Solar Panel

Resources

• Solar Panels DIY