How Are Solar Panels Created?
Manufacturing solar panels is a delicate process. For this reason, major advancements in the solar power industry didn’t occur until the late quarter of the last century. At that time, advances in photovoltaic design and semiconductors allowed for the development of more affordable, more efficient solar cells. While most people know what solar panels are and what they do, most don’t know how they are made.
Crystalline Silicon Panels
Creating solar panels usually involves cutting crystalline silicon into very small disks that are less than a centimeter in thickness. These wafer like disks are treated and polished to repair any damage from the cutting process and make them glossy. After they are polished, materials called dopants are added which alter the electrical charge in a photovoltaic solar cell or semiconductor. Then, metal conductors are installed across the disks.
These conductors are then aligned into a grid like pattern on top of the solar panel and are spread out in a flat, thin sheet on the side of the panels that face the earth. To protect the panels after they are processed, a think layer of glass is bonded to the top of the photovoltaic cell. After the protective glass is added, the almost complete panel is attached to a substrate by a thermally conductive cement that is very expensive.
The thermally conductive properties of the cement keeps the panel from overheating. Overheating is caused by energy that is leftover and can’t be converted by the solar panel. Without the thermal cement, this energy would cause the panels to overheat and greatly reduce their efficiency. Even with these protective measures, other steps need to be taken to ensure that the panels are kept cool. For instance, the panels should be elevated about the ground so that air can flow underneath the device to help keep it cool.
Amorphous Silicon Panels
Amorphous silicon panels are a very powerful line of photovoltaics that are now emerging in the industry. These solar panels differ in structure and output and are created with a different manufacturing process. Known as A-si cells, Amorphous solar panels are developed using a continuous roll to roll process. During this process, silicon alloys are deposited in multiple layers. Each of these very thin layers specialize in absorbing different parts of the solar spectrum.
The result is reduced costs for materials and record breaking efficiency levels. Some of these solar panels are even equipped with shade resistant technology or multiple circuits within each cell that prevents the circuit from being broken even when a whole row of cells are in complete shade. Because of this development process, A-si solar panels are also less susceptible to damage or breakage during transportation or installation.