Are you wondering how to build solar panels to satisfy your curiosity or do you want to build something for practical off grid living? Either way, the basic principles are the same. A solar panel is simply a number of solar cells connected together and housed in a rigid weatherproof structure.
The first step in planning your solar panel project is to determine the desired output in terms of voltage and current. A basic understanding of the principles of electricity are required for this. Each individual solar cell will produce around 0.5 volts. If you wanted to use your panel for something as basic as charging a 12 volt battery, you would need a panel that puts out 18 volts in full sunlight. That means your panel should contain 36 photovoltaic cells connected in series.
A typical arrangement would be 4 cells wide by 9 cells long. The standard practice is to connect PV cells in series within a panel and to create parallel connections of several panels to increase the wattage of the system.
A very important tip that I have only seen from a few sources is to attach the cells to the back of your panel using only a spot of silicon adhesive on the middle of the cell. The materials of your panel will expand and contract slightly as temperatures fluctuate. If you fasten the cells incorrectly they might break.
Another important tip is to test each panel and each connection as you progress with the project. It would be very frustrating to completely assemble a solar panel only to find that it doesn’t work and that you have no way of telling which of the dozens of cells and dozens of connections is at fault. This brings up another important point. Buy more solar cells than you think you need for your first project. Solar cells are delicate and you will probably break a few.
You can use a variety of building materials for the structural parts of the solar panel. Be sure to check out your local used building material outlets before you shell out for new materials. If you opt for lumber and plywood, be sure to seal all sides of every piece to make your panel as weatherproof as possible. The solar cells should last for decades, but a poorly constructed wooden frame will not. Metal materials are more durable, but you may find yourself buying specialized tools and hardware that will add to the cost.
Deciding between glass and plexi-glass is complicated. The plastic material is not as prone to accidental breakage but it may cloud slightly over time reducing your panel’s efficiency. If you are confident that your panels are not at risk from tree branches, hail, or baseballs, you might want to go with glass.
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