Solar panels are mysterious. What does one hold inside? In this article, we’ll talk about how solar panels are made, what are solar panels made out of and what types of solar panels are there.
Key takeaways
A solar panel isn't just a single piece; it's a carefully constructed assembly of several key components working together.
The magic happens through the "photovoltaic effect." When sunlight (photons) strikes the silicon, it knocks electrons loose from the silicon atoms. These free electrons create an electrical current. This process is how solar cells made.
Solar cells are delicate. To protect them from the elements and ensure they last a long time, they're encased in protective layers. A sheet of glass covers the top, shielding the cells from impacts and weather. An encapsulant, often a plastic like EVA (ethylene vinyl acetate), surrounds the cells, bonding them to the glass and providing further protection. A back sheet, usually made of plastic or other durable material, forms the back of the panel, providing another layer of protection against moisture and other environmental factors. These layers are important for the panel's longevity and performance.
The entire assembly of cells and protective layers is housed within a sturdy frame, usually made of aluminum or other metal frame. This metal frame provides structural support and makes the panel easy to install. Wires connect the individual solar cells together, and a junction box on the back of the panel houses the electrical connections. This junction box is where the panel's electrical output is collected and sent to the rest of the solar power system. These components ensure safe and efficient energy transfer from the cells to your home or the grid.
Turning raw materials into a working solar panel is a complex manufacturing process involving several key steps. This is how solar panels are manufactured and how solar panels made.
The process starts with silicon, which is abundant in the Earth's crust (often found in sand). However, the silicon needs to be highly pure for silicon cells to work efficiently. The purification process involves several chemical steps to remove impurities. Once purified, the silicon is melted and formed into large ingots (cylindrical or square blocks) or into polysilicon, which consists of many small crystalline silicon crystals.
Read our article on solar panel recycling process!
The silicon ingots are then cut into very thin wafers, much like slicing a loaf of bread. These wafers are the foundation for the solar cells. This slicing process requires extreme precision to ensure the wafers are uniform in thickness and free from defects.
This is where the magic of electricity generation really takes shape. The silicon wafers are "doped," meaning small amounts of other elements (like phosphorus and boron) are added. This doping creates a "p-type" "n-type" junction within the silicon. This junction is essential for the photovoltaic effect. One layer of silicon is doped with phosphorus, creating an excess of electrons (n-type), and the other with boron, creating a deficiency of electrons (p-type). The junction between these two layers is where the electrical field forms.
The individual solar cells are then interconnected with thin metal strips (often copper). These connections create a series of cells called a "module" or "string." Multiple strings are then combined to form a larger array within the panel. Connecting the cells in series increases the power output of the panel.
The final step is assembling the complete solar panel module. The interconnected cells are encapsulated between the glass cover front sheet and the back sheet, with the encapsulant material filling the space. The aluminum frame is then attached, providing structural support. Finally, each panel undergoes rigorous quality testing to ensure it meets standards.
While most common solar panels use crystalline silicon (either monocrystalline or polycrystalline), there are other types, such as thin-film solar panels. Monocrystalline panels are made from single silicon crystals, making them more efficient but also more expensive to produce. This is the most common type today that you see on the roofs. Polycrystalline panels are made from multiple silicon crystals, making them slightly less efficient but with a more affordable price.
Thin-film panels are made by depositing thin layers of photovoltaic material onto a surface or substrate, making them flexible and lightweight but generally less efficient than crystalline silicon panels. Their manufacturing processes differ significantly, often involving deposition techniques rather than ingot slicing. Generally amorphous silicon is deposited onto a hard substrate, like glass or metal. These are types of solar panels that are manufactured in the solar panel manufacturers' facilities.
There are also bifacial solar panels, though they are not a separate type of panels. Bifacial panels can be monocrystalline, polycrystalline or even thin-film. The idea is that they have solar cells on both sides. Cells on the rear side capture reflected sunlight and contribute to the overall production of a module. Bifacial solar panels are generally used for building solar farms.
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