Solar energy is one of the greatest technological advances of the last hundred years. You probably know that solar panels collect energy from sunlight and convert it into electricity, but you may not understand how that process happens and what components make it possible. Understanding the manufacturing process of solar panels can be a great help when deciding on a solar system.
A quick guide to solar panel manufacturing
Solar technology is always advancing, making solar panels more efficient and durable. Solar technology research and development is a competitive and complex field, but here are the basics of how all solar cells work.
How do solar panels work?
Solar radiation, the light from the sun, is a powerful form of energy, even after traveling 93 million miles in 500 seconds to reach Earth. The US Department of Energy estimates that the amount of sunlight that warms the Earth in 90 minutes is enough energy to power the entire world for a year.
Photovoltaic cells inside solar panels absorb sunlight just like a dark car interior on a sunny day. The interior of the car burns as atomic-level particles are filled with solar energy.
Unlike the interior of your car, photovoltaic (PV) cells put that energy to good use. The layers inside a solar cell contain alternating positive and negative charges. This creates an electric field that activates and activates when enough sunlight is absorbed into the PV cell.
Energy from the sun pushes electrons out of the layers of the PV cell. These now charged particles move along the current. The metal in the grid lines along the solar panels allows electricity to flow from the cells and into the wiring of a home or business.
What are solar panels made of?
Manufacturing solar cells starts with the element silicon, a semiconductor found naturally in sand. Semiconductors are materials that conduct electricity better than insulators such as rubber and glass, but not as well as metals. They are useful in electronics because they can hold current without overwhelming the system with too much electricity at once.
One of the properties of silicon is that it can hold a positive or negative charge, making it ideal for placing electric fields inside photovoltaic cells. This discovery was made in the 1940s, and silicon solar cells have been around since 1954.
How are solar panels manufactured?
Of course, the manufacturing process of modern solar panels is not the same as the first panels. Here is a basic step-by-step overview of solar panel manufacturing.
- Raw silicon is melted at 2000 degrees Celsius and goes through a refining process.
- The resulting high-quality silicon is formed into ingots, which are then cut into thin sheets.
- The plates receive a coating of silicon nitride. This surface coating is roughened to make the plates less reflective. So the plates hold more sunlight instead of bouncing off like a mirror.
- The sheets are inspected, any cracked sheets are diverted for less intensive use. Testing with artificial sunlight ensures that approved plates will perform at maximum efficiency.
- The machine applies a layer of glue to the large glass. This forms the “canvas” of the solar cell.
- More machines smooth the silicon sheets and thin metal mesh over the glass. An extra layer of glue seals all the components together. As the plates can crack during this process, the panels are re-inspected on a lighted surface for small breaks.
- Once the panels are fully installed and double-checked, laminating machines compress the adhesive and components in a heated vacuum sealing process. This process, along with coatings, protects the solar cells from the weather.
- An aluminum frame surrounds the delicate panels, providing structure for easier portability and overall durability.
- A junction box runs along the back of the panel. This piece collects and manages the electricity produced by the panel.
After final testing, the production of solar cells is complete. The panel is ready to provide clean and reliable power.
Where are solar panels manufactured?
Unbound Solar’s solar panels are built in America. It is important to buy solar panels from a reliable source because the silicon sheets inside are delicate. They can be damaged at many points in the solar cell manufacturing process. Several rounds of precise testing are vital to verifying the efficiency of a solar panel.
How to recognize a quality solar panel
Not all solar panels are created equal, so pay special attention to efficiency and cost per watt to choose the best solar panels. A good solar panel efficiency rating will fall somewhere between 14% and 22%. You can find the cost per watt by simply dividing the price by the watts provided by the solar panel.
Climatic factors can slightly reduce the efficiency of your solar cells, as silicon is slightly worse at conducting electricity at higher temperatures. To find out how much this will affect your solar panels, look at the temperature coefficient. This number will tell you how much the efficiency will decrease for each degree the temperature is raised from factory conditions.
Many solar panel manufacturers offer long warranties because modern solar panels are so durable. You will want to check not only the length of the warranty, but also the lifetime of the manufacturer. Although solar technology is a growing field, not all companies survive, so choose established manufacturers.
What does high quality solar panel manufacturing mean to you?
There’s never been a better time to go solar. The US Department of Energy has invested more than $125 million to fund solar research and development and promote American manufacturing of solar panels.
Many steps in the solar cell manufacturing process, such as extensive testing, improved wire mesh layout, and innovative weather insulation, ensure high-quality solar cells that can meet the demands of modern life. Solar panels are a sustainable, cost-effective and environmentally friendly energy solution. Contact us at Unbound Solar for a quote and expert guidance on choosing and installing the best solar system for you.
