How Are Solar Panels Made?

Solar energy is the cheapest source of energy in the world. You’ve probably seen solar panels before as they are becoming increasingly popular and affordable each year. Maybe you’ve even wondered how solar panels are made. In this article, we’ll focus on how solar panels are made and the different components that are used.

Solar Panel Components

A solar panel comprises a rectangular structure. It has a bluish-silvery surface with a glass cover.  A solar panel has the following components:

• Aluminum frame. It keeps the panel intact once it is mounted and protects the structure from damage.
  
• Glass sheet. It is 6-7 millimeters thick and protects the solar cells inside the panel.
  
• Silicon cells. These comprise a matrix-like structure that converts sunlight into electricity.
  
• Back sheet. Its function is to regulate humidity and temperature in the panel. It also insulates the module and protects against UV radiation.

Inside a solar panel are a series of photovoltaic (PV) silicon cells. There are usually between 60 and 70 cells. Rays from the sun hit and bounce off these cells. Then, electrons—tiny particles with a negative electric charge—start moving around. Between the silicon cells is a bond comprising phosphorus and boron material.

Phosphorus helps generate more particles with a negative charge. Boron reduces the electrons and introduces protons—particles with a positive electric charge. Sunlight hits the panel and causes the electrons to flow to the cell junctions. 

Next, we’ll focus on the specific process of how solar panels are made.

How Are Solar Panels Made?

Here are the steps for making solar panels:

• The Manufacture of Solar Cells

The manufacturer makes solar cells consisting of silicon mixed with boron and phosphorus. The mix is also called silicon ingot. Machines cut it into thin sheets coated with a layer of anti-reflective material.

• Soldering

Soldering follows by introducing metal connectors to link the solar cells. The process merges 60 or 72 cells, depending on the solar panel size. A standard panel has 60 cells, while a commercial use panel has 72 cells.

• Back Sheet Installation

Next, the installation of the back sheet—made from durable plastic—occurs. Manufacturers install it at the bottom of the panel. The glass sheet at the top follows, whose function is to filter sunshine. A special glue holds these components together.

• Metal Frame Installation

A metal frame confines the components and gives shape to the panel. Mounting clamps—where the panel will fit—have latches that hold the frame in place. A mounting system keeps the solar panel secured on the roof or the ground. The mount helps keep panels tight in place. 

• Junction Box Installation

Finally, the manufacturer installs a junction box. This device prevents the reverse flow of electricity. It ensures that electric current flows from the solar panel to the inverter used in the system. The junction box also protects the panel's wiring from electrical damage. 

Testing and Dispatch to the Market

Once complete, solar panels must undergo quality testing. Manufacturing technicians simulate Standard Test Conditions (STC). Each panel that passes this test is ready for shipment to consumers.

The Elumis Foundation believes that no child should be left in the dark. Our goal is to use solar kits to bring light to families and children around the world who don’t have access to electricity. With the renewable power of the sun, we can change the lives of people all around the world, give them opportunities they wouldn’t have without access to electricity, and help our planet in the process. Find out how you can get involved and help us make a difference today!

About the Elumis Foundation

The Elumis Foundation is a certified non-profit organization that was created in 2018 by siblings Eva and Michael Sakellakis (ages 15 and 13), looking to make a difference. Their father, who has his own successful solar business Elumis, helped and inspired them to form the foundation. Together they formed a Non-Profit 501(c)3 organization. This allows all donations to be tax-deductible by the donors. 100% of all donations received will fund the distribution of solar kits to be given to families who do not have electricity in impoverished areas of the world.

Elumis’ goal is to bring light to families and kids without that privilege through solar kits. These solar kits are powered through solar panels and can provide light and electricity for a family for up to 24 continuous hours. The Foundation has already made its first donation of 1000 solar kits in Vietnam and plans to distribute more kits to third-world countries throughout Africa, South East Asia, Central America, and India. Our goal is to distribute at least 100,000 kits to families in need.