My DIY Solar Panel FAB
I decided I wanted to build my own solar panels. The main reason was that I suspected I could do it cheaper and with the use of less energy compared to importing panels from China. Bare minimum cost of solar panels hovers around 1,20 USD/Watt, which is very cheap, but that is if you can get them in China. Retail prices in Holland are 2 Euro/Watt. With the squeeze in panels these days the prices are often higher, not everybody tries to scan the whole market.The cost components of panels
1. The Cells
These can be ordered online, or bought from chinese manufacturers directly (usually in significant quantities). There are a number of Ebay sellers who do not guarantee their wares. Cells can easily yield less than advertized. Cost (aug 2010) is about 1 Euro/Watt. A nbit about cells here.
2. The tabs and resin
To connect the cells you need tabbing wire and resin to clean the tracks. Aceton works well in removing solder acid stains. Watch out with it, use it in a ventilated space cause it will wreck your lungs.
3. Encapsulation
Encapsulation is what protects the cells against corrosing and kinetic damage. It can be anything, but in this well organized world it is not always easy to get that anything. EVA, Ethyl Vinyl Acetate, most commenly used, is not for sale for real prices, all the other parts you need to make a regular panel are priced such that you end up on a par if you don't count labour cost.
Look for links to materials supplier here
Choosing either silicone or EVA both require heating and compressing (using vacuum). So I had to build a vacuum oven.
The oven is made of a wooden box with a heater I took from a paint remover.
I used a picaxe micro controller to monitor temperature.
It drives a ralais switch to switch the heater on and off.
I also control the vacuum pump (as the vacuum bag leaks) using the picaxe. The microcontroller switches the pump on and off based on a time interval controlled by analog input. Another method is using a small switch in the vacuum bag. If the vacuum is reduced, the switch is triggered.
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