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