What Are Solar Panels Made of in 2023

If you are wondering to yourself, “what are solar panels made of?”, you came to the right place. The materials, parts, and manufacturing of solar panels, right here in an easy to understand format.

Harnessing the power of the sun has been a dream since mankind first discovered fire. I doubt those cavemen were pondering how to use the power of the sun to power their iPhones, but you get the point.

Solar panels are the modern-day realization of that dream, providing clean, renewable energy without the need for fossil fuels. But what are solar panels made of, and how are they made?

In this article , we’ll take a look at solar panel technology and explore the materials that go into their construction, as well as the process of making solar panels. Read on to learn more about this technology that is helping us get off our fossil fuel addiction.

Types of Solar Panels

Before we can answer what are solar panels made of, we first must understand the different types of solar panels, as each one is made differently. There are three major types of solar panels: monocrystalline, polycrystalline and thin-film.

All three types are made of photovoltaic (PV) cells, AKA solar cells, which are the basic components of a solar panel. Here’s a breakdown of what each type is made of and how they work:

1. Monocrystalline Solar Panels: Monocrystalline solar panels are made from a single, continuous silicon crystal. They provide the highest efficiency, meaning they can convert more sunlight into energy, but also the highest cost.

2. Polycrystalline Solar Panels: Polycrystalline solar panels are made from several small silicon crystals connected together. They offer slightly lower efficiency than monocrystalline panels, but are still effective at capturing and converting sunlight into energy. As of now, they are more cost effective than Monocrystalline solar panels.

3. Thin-Film Solar Panels: Thin-film solar panels, also known as flexible solar panels, are made from a thin layer of a single material, usually a mix of various chemicals. They are the most affordable type of solar panel, but offer lower efficiency than monocrystalline and polycrystalline panels. They are best used for smaller applications.

If you want to learn more about the types of solar panels, click the link.

What are Solar Cells and What Are They Made Of

Simply put, solar cells are devices that convert sunlight into electrical energy. They are made of a semiconductor, usually silicon, that absorbs sunlight and then releases energy in the form of electrons.

Solar cells are like little ray-catching superheroes, using their silicon superpowers to absorb sunlight and turn it into electricity to power our homes and cities.

Solar panels are made of many individual solar cells connected in a specific order. The cells are arranged in a grid pattern and mounted on a frame. Each cell is composed of two layers of semiconductors. The cells are coated with a material that helps capture sunlight and convert it into electricity.

When sunlight hits the cells, the electrons in the semiconductor absorb the photons, releasing energy in the form of electricity. This electricity is then transmitted to other components of the solar panel, like the inverter.

The electricity produced by the solar panel is then able to be used to power appliances, lights, and selfie toasters (yes, that’s a thing). Solar cells are typically made of a variety of materials, including crystalline silicon, amorphous silicon, and cadmium telluride.

Each type of material has its own advantages and disadvantages. Crystalline silicon cells are highly efficient but expensive, while amorphous silicon cells are cheaper but not as efficient. Cadmium telluride cells are the least efficient but are the least expensive.

The Parts of a Solar Panel

In order to better answer the question, what are solar panels made of, we first must discuss the parts of a solar panel. Solar panels are made up of several different parts, each with its own purpose and composition. Here’s the meat and potatoes of what you need to know about the components of a solar panel and what they are made of:

• Solar Cells: As previously discussed, solar cells are the key component of a solar panel, and are made of semi-conductive materials like silicon. When light from the sun hits the solar cells, electrons are set in motion and create an electrical current.
• Interconnects: The interconnects are the wires that connect the individual solar panels together to form a larger array. These are usually made of copper, but can also be made of other metals like aluminum.
• Glass: To protect the solar cells inside, most solar panels are covered with tempered glass (meaning it has been treated to increase its strength, not it gets angered easily). This glass is designed to be strong and shatter-resistant, while also allowing the sun’s rays to pass through.
• Frames: The frames of solar panels are usually made of aluminum, which provides a sturdy structure and ensures that the panels last longer.
• Cabling and Junction Boxes: The cabling and junction boxes are the components that connect the solar cells to the inverter and other components. These are usually made of copper, aluminum or a combination of the two.
• Inverters: The inverter converts the direct current (DC) power generated by the solar cells into the alternating current (AC) power that can be used to power our homes. These are usually made of plastic or metal.

Knowing what solar panels are made of helps you better understand their function and better assess their efficiency. With advances in technology, solar panels are becoming more and more efficient, making them a great, renewable option for powering your needs (if you really “need” a selfie toaster).

How Solar Panels Are Made

The construction of solar panels is a fascinating, highly-specialized process. If you are a visual learner, the video below is shows the step by step process. If you would rather read about the process, read on.

Solar panels are made from a variety of materials and the manufacturing process can vary slightly as well. Most solar panels are made using the following steps:

1. Special silicone: The process of making pure silicone from sand is time consuming and energy intensive. First, the sand must be heated to extremely high temperatures, up to 2,500 degrees Celsius or more (the surface of the sun is just under 6,000 degrees for comparison).
   
   This requires a specialized furnace or kiln. When the sand is heated, oxygen and hydrogen are added to it, allowing the silicone to form. After this, the mixture is cooled, filtered and purified. The result is a pure silicone compound.
   
   Photovoltaic cells, which are constructed with a special type of silicone called polycrystalline silicone, are used to create solar panels. To create this silicone, pure silicone is combined with boron, which strengthens the silicon’s bonding.
   
2. Ingots- The process of creating an ingot begins with the raw material, typically silicon chunks. The chunks are heated until molten, like lava, before being poured into a mold. The mold is removed once the molten metal has cooled and solidified, and the ingot is ready to be used in the manufacturing process.
   
   The ingots are then cut into thin slices, which are then heated again and subjected to a process called doping (not the Lance Armstrong type). This process adds impurities to the silicon, allowing it to conduct better electricity and more efficiently convert sunlight into electricity. The doped silicon is then cut into even thinner slices and further refined to create individual cells.
3. Wafers- The ingot is cut with a diamond saw into thin slices called wafers. These slices are currently .16 millimeters thick, but researchers believe that they will be as thin as .04 millimeters in the near future. The wafers are then polished to remove any sharp edges and reduce surface roughness. Next, to further reduce surface roughness and increase light absorption, the wafers are textured or etched. Finally, the wafers are inspected for any cracks or other defects.
4. Solar Cells– The following processes will convert a wafer into a solar cell capable of converting solar power into electricity. Each wafer is treated, and metal conductors are added to their surface. Phosphorous is diffused across the surface of the wafers in a thin layer. This will charge the surface with a negative electrical orientation. The combination of boron and phosphorous will give the positive – negative junction, which is vital for the proper function of the cell.
5. From Solar Cells to completed solar panels- The first step in the process is to solder the cells together. The cells are placed side by side in a pattern, and then a special flux is applied to the cells. This flux helps to drive the solder into the cells, creating a strong electrical connection between them.
   
   Once the cells are soldered together, the panel is then encapsulated in a protective material that helps to protect the cells from the outside environment. This protective material also helps to ensure that the cells remain electrically connected. The material used to encapsulate the cells is usually either a type of epoxy resin or polyurethane.
   
   Once the solar cells are encapsulated, they are then connected to the circuit board. The circuit board actually serves as the backbone of the solar panel, and it connects all of the cells together. This allows the cells to be connected in a series, which allows for the solar panel to be able to produce electricity.
   
   The circuit board in a solar panel is like the conductor of an orchestra, connecting all the individual cells (or musicians) and allowing them to work together to produce electricity, just like how a conductor leads an orchestra to make beautiful music.
   
   Finally, the panel is then tested to make sure that it is working properly. This is done using a visual inspection and electrical tests. The visual inspection ensures that the cells are properly connected and that the panel is not damaged in any way. The electrical tests help to make sure that the cells are able to produce the maximum amount of energy.

Conclusion

Solar panels are made up of a variety of materials in a number of specialized processes. As this technology evolves, we hope the construction process becomes less complicated and more energy efficient.

We hope we were able to answer your question of, “what are solar panels made of”. If you enjoyed this article, please consider sharing with others. Thanks for reading!!!