How are panels made?

Solar panels are primarily made by integrating multiple solar cells in a matrix-like structure and then encapsulating them for protection and durability.

Here's a breakdown of the solar panel manufacturing process:

1. Solar Cell Production: The process begins with manufacturing individual solar cells. These are typically made from silicon wafers. The wafers are doped with impurities to create a semiconductor junction that generates electricity when exposed to sunlight.

2. Cell Interconnection: The solar cells are then soldered together using metal connectors to create a string of cells. This interconnection allows for the additive voltage required for practical applications.

3. Panel Assembly:

   • String Placement: The interconnected strings of solar cells are placed between layers of protective material. These typically include:
     • A backsheet (often made of polymer).
     • A layer of encapsulant (like Ethylene-vinyl acetate (EVA)) on both sides of the cells, to protect them from moisture and physical damage.
     • A front sheet, often made of tempered glass, to allow sunlight to pass through while protecting the cells.
   • Lamination: The layers are then subjected to heat and vacuum in a process called lamination. This bonds the layers together, creating a sealed, weatherproof unit.

4. Framing and Junction Box Installation:

   • An aluminum frame is added around the laminated panel to provide structural support and facilitate mounting.
   • A junction box is attached to the back of the panel. This box houses the electrical connections and wiring, allowing the panel to be connected to other panels or to an inverter.

5. Testing and Quality Control: Each panel undergoes rigorous testing to ensure it meets performance specifications and safety standards. This includes testing for power output, voltage, current, and insulation.

6. Panel Sizes: Panels come in various sizes, such as 48-cell panels suitable for smaller residential roofs, and larger formats for commercial and utility-scale installations.

In essence, solar panel manufacturing is a multi-stage process of creating individual solar cells, connecting them, encapsulating them for protection, and adding structural and electrical components for practical use.