Introduction: How to Make a Small Solar Panel

I want to make a panel of 10W18V.

Of course, first step is cutting cell

Step 1: Cut Cells to Pieces and Solder Copper Strips on Chips

Picture of Cut Cells to Pieces and Solder Copper Strips on Chips

Ahead of cutting cell, you should calculate how many pieces and what the size you should cut.
The voltage of a common polycrystalline silicon cell is 0.5V, whatever the size it is. So I need 18/0.5=36 pieces of chip. And 36 chips compose a 10W panel, so the power of each chip =10/36, the answer is 0.28W approximately. What is the power of a cell? I choose polycrystalline cell, 156*156mm, efficiency is 17%. This cell is around 4.1W. Now we can get the number is 4.1/0.28=14(it is must be integer). How to cut to 14 pieces? 1*14 or 2*7? I choose the cell with 2 main grid lines, and array 2*7. Now I get 78(156/2)*22.2(156/7)mm.

Length of copper strip is near twice of width of chip(width of chip is 22.2mm here). I can't solder the strips across the chip, for avoiding short circuit.

P.S. Blue face is negative.

Step 2: Connect the Chips in Series

Picture of Connect the Chips in Series

Before this step, you could make a module, it looks like a matrix. However, it is not necessary to you, but I want it good look.

Follow the picture, put positive side upwards, and remember the principle: negative connect to positive. Connect them all in series and place in 4 lines, 9 in a line. But I want to hide tips ;)

Step 3: Place Materials

Picture of Place Materials

Make the steps simple:

1. Place insulative PET plate in the middle of string.

2. Place EVA film.

3. Place PET backplate, and pull out two output strips through PET backplate.

4. Tape the edge and output strips.

The front plate glass what I choose is tempered glass.

Step 4: Last Step , Uh...

Picture of Last Step , Uh...

Look, this machine, I don't know the name of it. Laminator? Sort of.

It's not household machine, perhaps iron would be qualified. :)

Step 5: "Encore" Omit This Step....

Picture of "Encore" Omit This Step....

Because you need a set of ABS frame and a cable....

Comments

techie66 (author)2015-12-19

I wonder if step for could be done with a paint-stripper if you manage top keep the cells straight under a piece of glass or something, have you tried that, or do you own the machine ?

Lucio Liang (author)techie662015-12-19

If you make 1-2 panels, design and print a pattern with 1:1, then you would know how to do. If you want to make more, you should make a specific module which made of paper, glass, transparent tape, or expensive metal module. These two ways can keep the cells straight. About the machine, no perfect one in the market. Because dealing with small cells is too complicated and troublesome. Here's a video, you will find more.

https://youtu.be/i30zqvwh4MM

SidM16 (author)Lucio Liang2017-07-27

Hi, I hope you are fine

I saw your message

I'm looking for a training course that includes how to make a solar panel starting with solar cells, meaning after the training course I can make a solar panel using solar cells.

i hope you help me

thank you

Lucio Liang (author)SidM162017-11-01

Sorry, it's been a long time to visit instructables.com.

I'm glad if I can help you. If you have questions about the course, please contact me: 332418931@qq.com (Perhaps it is blocked).

If you know the principle, you can make a solar panel yourself.

TechFrags (author)2015-11-16

This looks really cool and I would like to make it, but I don't get anything about this?! Nice subject doe!

Lucio Liang (author)TechFrags2015-12-01

Open your mind, find something like iron, tempered glass. But I don't know how to cut a cell well without a laser machine. Perhaps it's not expensive in your country. See the video, you will find something more: https://youtu.be/i30zqvwh4MM

tomatoskins (author)2015-11-16

That's really cool! Thanks for sharing and welcome to the community!

About This Instructable

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Bio: Handmade panels maker. Various specifications you can choose or reasonable design for new products, I will work with you.
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