How to make a homemade solar panel that works

How to Make a Homemade Solar Panels the Easy Way

Before I start I want to explain what you'll find in this article, even though I think the title pretty much gives it away. You will find all the tools necessary to build a homemade solar panel, all the parts that go into putting it together, and a plan of attack to have a working solar panel. This is obviously just a short version, some part won't be explained because it takes more than just this article, but at the end you'll find where to get more information if you're serious about doing it yourself.

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To make solar panels at home, you need to prepare the following materials and tools:

Material

• Light-receiving cell panels
• There are 3 types of cells on the market today: 3×6 inches; 5×5 inches; 6×6 inches (1 inch = 2.54 cm). Note when buying cell panels that the maximum power is Pmax in standard conditions of 25C temperature and 1000 Lumen light.
• The base frame fixes the cells, usually made of metal
• Case to hold the frame for the panel: Can be made of steel or wood. Should be painted with 3 layers of protection to prevent rust
• The bar around the frame protects the cell sheet
• Welding wire: There is a small solder wire to serially weld the cells together and a large solder wire to connect the strings of solder wires together.
• Soldering pen: is a pen containing Flux used for soldering wire to stick well to cells
• EVA glue: Works to increase the capacity of the battery, against adverse effects from the environment. High strength glue
• Tempered glass covered with anti-shatter panels: Glass is usually 4mm thick. Using glass can resist external influences such as hail, ... But at the same time, glass reduces the performance of the battery. However, factories have used TPT to overcome this shortcoming.

Tools

• Drill
• Wood saws
• Pliers
• Iron soldering tools
• Screwdrivers
• Table

Instructions on how to make solar panels at home

The process of making solar cells at home includes the following steps:

Step 1: Create a frame for the panel

The first is to create a panel for the base plate of the panel. The size of the frame is estimated by the number and layout of cells.

For example: It will take 36 battery cells to meet the voltage number of 0.5V. We will arrange into 4 horizontal and 9 vertical rows to correspond to each 3×6 inch cell sheet. Including the distance between cells and the distance between cells and frame borders, the panel will have the following corresponding dimensions:

	Longs	Width
Background	88.9 cm	68.58 cm
Thickness	81.28 cm	60.96 cm
Borders	88.9 cm	63.5 cm

First, use the saw to cut the material to the size you have calculated before. Then use glue to attach the frame covers to the case. To prevent the foundation from being worn and rusted, cover the base frame with 3 layers of paint.

Once again double-check that the panels with the cut-out frame and back cover fit snugly.

Step 2: Attach the solder wire to the cell panels

We will use solder wire and solder pen to attach the solder wire to the cell panels. There is a small note for you that the cells are very thin, so when mounting be careful not to damage the cells.

Place the panel on a clean flat surface, front facing up. Use a soldering iron to follow the 2 contact strips. Then use solder wire to put on 2 straight lines. Heat up the solder wire and then gently press on the surface of the adhesive wire to the white line on the cell. At this step requires meticulousness and care so that the wire does not drift to the white line. You do these steps continuously in the remaining cells

Step 3: Connect the cells into a large panel

If the panel has a 4×9 structure, we will connect 9 cells into 1 chain. At this time, the excess wire on the front of cell 1 will connect to the back of cell 2 and continue like that until the string runs out.

Specifically, proceed as follows: Put 2 cell panels next to each other and in opposite directions (cell 1 front, cell 2 back) use a solder pen containing Flux chemical to 6 white points on the back of cell 2. For each point white let me put a metal solder. Put the solder wire cell 1 into the 3 white points in cell 2, and press down with your hand to stick the solder wire to the white point. In the following cells we do the same until the end. To make row 4, we do the same as above.

Step 4: Install the cells in the frame

We will use silicon solder to attach the cells to the frame. But we have to understand how to mount the cell chains on the base frame. As a rule of thumb, the negative electrode of string 1 must be connected to the positive terminal of string 2 with a large solder wire.

Perform:

Attach the strings to the base frame: Insert the strings into the frame (as shown above) and then place a small amount of silicon in the center of each cell. Flip the cell chain back to the original, and then gently push the cell chain down so that they are firmly attached to the base frame.

Next glue them together: Use a large solder wire to connect the chains. We cut the large solder wire into pieces. Place a large solder wire along the first 2 cells of the string to be joined. You take the small solder wire of these 2 cells and wrap it in the large solder wire and re-solder the wraps tightly. The rest of the chains do the same.

Step 5: Install the back cover for the base frame and install the battery cover

Adjust the base frame to fit the back of the panel and then screw it tight to secure them. On the last cell on the left of the negative pole and the last cell on the right of the positive pole, we connect 2 small solder wires with copper wire. Make sure the two wires are long enough to be able to pull out the back of the panel to connect to the external receivers. Next, you put a blocking diode in the anode conductor, preventing the battery from self-discharging at night. Alternatively, charge control can be used.

Use a drill to drill a hole in the middle of the cathode and anode and then let the wire thread through the hole and then behind the panel. Check the battery panel to make sure it's still working properly before installing the tempered glass.

Secure the solder wire to the base frame with silicon solder. Still use silicon to fill the solder holes to ensure safety. Install the tempered glass on top of the panel and secure it with screws. The openings in the case, the frame edge are all filled with silicon so that the battery panel is completely protected.

Step 6: Check the operation of solar panels

Move the panels to a sunny location. Then connect the multimeter to the terminals of the battery panel (the positive pole is connected to the positive pole - the negative pole is connected to the negative pole). Check power lines and meters are working properly.

Check the voltage and the corresponding amperage.

With the above step-by-step instructions on how to make a solar battery, you can completely make yourself a simple solar panel at home. However, this homemade solar battery will not work for a long time and can pose a fire safety risk. Therefore, you should use quality solar panels at reputable companies, installed by experts to ensure long-term operation and use. Wishing you success!

Also See: DIY Solar Power - How to Generate Your Own Solar Power From Home