Make Solar Panels
In order to make solar panels you’ll need three things:
- The raw materials and tools
- Some spare time
- The proper knowledge
Deciding to make solar panels is a big step, but with these three things in mind, and a constant focus on safety, literally anyone can do it. Obviously the first step is to make the solar panels, so here’s a couple of things you’ll definitely need: Solar cells, backing (plywood, melamine, or aluminum), plexiglass, 2-pin “Jones” plugs, wires, screws, and a diode. You can also get a battery for night-time electricity use.
Always remember that electricity runs in a circuit, so keep your polarity (aka positive and negative) running in the correct direction. Each solar cell is individually powered and wired, and there will be several on each panel. Solar cells are extremely fragile, so when buying online, try to get a delivery guarantee. Another thing you can do is buy them used, and get extras. This way you’ll save a lot of money and if you break a couple, its ok. I do not recommend attempting to make your own solar cells, this is highly inefficient and silicon is best handled professionally.
Next you have to think about what to base the panel on. Although some say to use plywood because of its relatively low price, I recommend aluminum. Aluminum won’t rust, crack, rot, or soak up rain. For a truly durable panel, use a melamine backing with an aluminum frame. This is actually the exact way a lot of store-bought solar panels are made, and melamine isn’t expensive.
The most important parts of the panel are the solar cells. So you have to make sure they are protected! Glass and plexiglass are your best options. Since you’re making your own solar panels, plexiglass is usually the way to go. You can cut it and drills holes and it won’t shatter. Also plexiglass is pretty strong, and sometimes you can get really great deals on small amounts of used plexiglass pieces.
Not the most labor-intense area, but still pretty tricky, wiring your solar panels is not as hard as you might think. There are very detailed Solar Wiring Guides available. You’ll need plenty of wire (color coded is easiest), a soldering iron, and a roll of solder. Make sure you aren’t running the iron too hot or too long in one spot, because this could be counter-productive. The gauge (thickness) of the wire depends on what type of cells, voltage, and amps you are working with. Just make sure you have the right wire for the job, this is very important! The wrong wire could cause catastrophic failure throughout the entire system, electric shock, and fires. If you are unsure, it doesn’t hurt to get a second opinion from an electrician or similar professional.
Finally, if you want (or need) to have a completely off-the-grid solar system, you’re going need a battery (or several). Batteries are pretty easy to work with, but two things need to be certain. One, you’ll need a diode to control the direction of charge. This means the electricity can only flow from the panels to the battery; the diode ensures this. Two, you need to have some sort of charge controller. This will protect the life of the battery by preventing over-charging. As soon as the battery is full, the charge controller will no longer allow energy to pass into the battery. Batteries come in all shapes and sizes, so plan before you buy. Do you need to power the whole house, or just a few select appliances? Remember to do your research! Read ratings and reviews about the battery before deciding which brand to use.
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