These days, solar panels seem to be everywhere: on solar farms, on the rooftops of residences, and even on automobiles and boats.
Solar panels are utilised to create power, but how are they manufactured?
Key takeaways
All solar panels consist of solar cells, a protective backsheet, a glass cover, and a metal frame.
Solar cells are the energy-generating component of a solar panel.
Silicon is the most significant raw element in solar panel production; it is utilised in nearly all solar panels manufactured today.
Solar panels are considered an environmentally friendly and sustainable energy source.
What parts are solar panels made from?
The primary components of a solar panel are as follows:
Solar cells for generating power from sunlight
A glass cover that sits atop the solar cells.
A backsheet that insulates and protects the underneath.
A frame made of metal to hold the panel together
Let’s examine each component in further detail below:
Solar cells
Solar cells are the energy-generating component of a solar panel. They are electrical components that utilise the photovoltaic effect to turn light into electricity.
Each solar panel is composed of several solar cells, often 60 or 72. Recently, however, the greatest solar panel models have incorporated sophisticated half-cut solar cells; because they are smaller, twice as many can fit on a panel.
The majority of solar panels include silicon solar cells comprised of crystalline silicon. Other forms of solar cells include thin-film solar cells, organic solar cells, and solar paint, however these are seldom employed.
Glass hood
Solar panels have a specifically constructed glass covering their front surface.
The glass has been tempered to render it exceptionally resilient. It can endure the impact of hail and hurricane-force winds, giving a high level of protection for the solar cells below.
Additionally, the glass must be extremely transparent to allow as much sunlight as possible to reach the solar cells.
Glass coverings can get soiled if they are coated in dust or soot; over time, this can hinder the generation of solar energy. If you reside in a dry region, you may need to clean the panels manually, since a little rain should be sufficient to remove the dirt.
Protective rearcloth
The backsheet is a protective blanket that covers the back of the solar panel, safeguarding the solar cells from the environment and any animals that may try to gnaw on them.
Backsheets also offer electrical insulation by limiting the unintended transfer of electric current from the solar panel to surfaces, such as your roof.
It also offers electrical insulation and stops electric current from travelling from the solar panel to objects, such as your roof, with which it comes into touch.
The backsheet is composed of polymer materials that are resilient, lightweight, and provide the required insulating qualities.
Usually, backsheets are white. Some all-black versions have black backsheets that contribute to the consistent look of the panels. However, dark backsheets tend to trap more heat and reduce the efficiency of solar panels.
Aluminum frame
The metal frame covers the panel’s edges and holds all layers together. They are intended to withstand adverse weather conditions without sacrificing portability. Because it creates a sleeker appearance and makes the panels less conspicuous on the roof, many panels currently have black anodized frames as opposed to silver ones.
Why is silicon used in most panels?
Silicon is the most prevalent element found in solar cells, the energy-producing component of a solar panel. According to the Department of Energy, it is utilised in almost 95% of solar panels manufactured today.
What is the manufacturing process?
Using modern manufacturing processes, solar panels are manufactured in big, highly-automated production facilities.
There are typically two main phases: solar cell production and solar panel assembly.
Let’s examine each phase in further detail:
Solar cell manufacture
The majority of solar cells consist of crystalline silicon. Typically, the production process looks like this:
First, molten silicon is combined with either gallium or boron before being reformed into a silicon ingot.
The ingots are then laser-cut into thin sheets known as silicon wafers, and an anti-reflective coating is then applied.
Individual solar cells are cut from silicon wafers, which are then ready to be installed in solar panels.
The precise manufacturing procedure will vary based on the type of solar cell being produced. Monocrystalline solar cells are composed of a single, solid silicon crystal, whereas polycrystalline solar cells are composed of a large number of small, square-shaped crystals.
The great majority of solar cells, including those utilised in locally sold panels, are manufactured in other countries, mostly in Europe and Asia.
Solar panel installation
Solar panel assembly is the process of combining solar cells and all other solar panel components to make the finished product.
Soldering the required number of solar cells together.
Next, the cells are surrounded by protective layers. The glass cover is affixed to the panel’s upper surface, the backsheet is secured to the panel’s underside, and the metal frame is fitted around the entire panel.
The panel is completed by installing a junction box to safeguard the electrical cables from harm. If it’s an AC solar panel, a microinverter will also be installed.
Several solar manufacturers assemble solar panels in the United States; below are the top five.
Are solar panels sustainable and eco-friendly?
Indeed they are! Solar panels are a very sustainable and environmentally friendly source of electricity. This is why:
They provide clean, renewable energy: Solar panels require only sunshine to function, and they produce electricity without emitting any hazardous pollutants or waste products. Consequently, solar panels help to cleaner air and decrease climate-damaging carbon emissions.
Having an abundance of materials: There is no deficiency in the availability of materials required to build solar panels. Silicon, the second most prevalent element on earth, is used to create both the solar cells and the glass cover. Aluminum, which is utilised to construct the metal frame, is also available.
They have a lengthy lifespan: Sustainable living entails avoiding the use of disposable objects, sometimes known as things that are used for a little period of time and then discarded. Solar panels exceed these requirements; they can endure up to 30 years without requiring repair or maintenance.
Recycling initiatives are expanding: The majority of retired solar panels are now taken to landfills, and numerous organisations, including SolarReviews, are urgently advocating for expanded solar panel recycling programmes.
Far superior to fossil fuels: Unfortunately, the majority of the energy we consume today originates from fossil fuels, which contribute to air pollution and global warming. Governments, utility companies, and households are all making the move to clean and sustainable solar energy because it is a superior choice.