How to Make Solar Voltaic Panels

Solar panels that produce electricity work by the photovoltaic process, through which energy is produce by the interactions between electrons contained in the solar cells and photons from the sun's radiation. Solar panels can be constructed fairly easily with basic knowledge of carpentry and electrical wiring and materials available at your local hardware store. A solar panel consists of two basic components: a solar cell array and a frame structure that protects the array.

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
• 135 inches of 3/4-inch-by-3/4-inch wood molding
• 18-inch by 36-inch piece of Masonite pegboard
• Blocking diode
• Electrical jack
• Solder
• Copper wire
• Silicone caulk

Instructions

Building the Array

1. Place the 36 mono-crystalline solar cells face down on the plywood in six rows of six so that the leads on the backs of the cells are exposed.

2. Solder all of the connections on the solar cells together in an array using copper wire. Be sure to touch on all soldering points or the array will not function, and be sure to use separate wires for the positive and negative connections. Leave about a foot of extra wire at the end of the array for connecting the blocking diode.

3. Place a small amount of silicone caulk on the back of each solar cell and then cover the cells with the Masonite pegboard. The dimensions of the pegboard should just cover all of the cells. Let the caulk dry and then flip the entire configuration over so that the cells are resting on the pegboard and the plywood is free to work with.

4. Test the solar array with a voltmeter before proceeding.

Building the Panel

1. Build a frame around the entire perimeter of the plywood with the 3/4-inch-by-3/4-inch wood molding. Secure the molding to the plywood with wood screws.

2. Position the Masonite pegboard holding the solar array in the center of the frame and screw it down. Be very careful not to damage any of the solar cells or the wires when securing the pegboard.

3. Connect the blocking diode at the end of the array using the excess wire. Be sure to connect the positive and negative leads to the right soldering points on the diode.

4. Cover the panel with Plexiglas and secure the Plexiglas to the frame.

Tips & Warnings

• Mono-crystalline solar cells are very expensive, but you can obtain them for a fraction of the price by purchasing lightly damaged cells from manufacturers or online auctions. Slightly damaged cells will produce fewer watts than pristine cells, but once they are connected in the array the decreased amount of wattage will not make a huge difference.

• Solar cells are very delicate. Be extremely careful when handling them.

References

• Olino Renewable Energy: Building my own Solar Panel
• Home Solar and Wind: DIY Solar Panel

Resources

• Read this Article in Spanish
• Solar Panels DIY
• Mike's World: How I Built an Electricity-Producing Solar Panel