12V Solar Panel

It is easy to build a 12V solar panel if you know how. This step-by-step guide is designed to teach you if you want to build one but are clueless on how to start.

This article also illustrates the sequence to building a 12V solar panel so you’ll have the least trouble.

After reading the 5 steps, I’m confident no matter how confused you are, you’ll be able to move along to begin designing your first photovoltaic panel:

Step 1 – Source for solar cells.

There are a total of 3 ways you can get a solar (photovoltaic) cell — you can buy them, you can salvage used or broken solar cells or you can even make them.

If you intend to use your solar panels for long, I recommend you buy them. Although they’re more expensive, they yield more power and can last longer. Thus you won’t need to make another solar panel a few years down the road.

If you intend to make a solar panel just for fun, you can join pieces of used or broken solar cells to make up a complete solar panel. They won’t be the most professional looking photovoltaic panels around, but who cares, they’re just for fun!

And if you feel more adventurous, you can even make your own solar panel by heating up copper plates to form cuprous oxide, which is a form of semiconductor by itself. These homemade solar cells are inefficient at best and only produce microwatts of power per cell. But if you’re just having some fun are feeling adventurous, why not?

Step 2 – Soldering the solar cells

To form a 12V supply, we have to solder the photovoltaic cells in series so they add up to 12V collectively. While many solar cells are rated at 0.5V each, you’ll have to check its specification before buying and using them. Some may not rated at 0.5V.

With 24 solar cells connected in series, we can easily make an array of solar cells that produce 12V supply.

However voltage is only part of the equation. We also have to consider the current output of the solar cells. With the correct voltage and sufficient current, we’ll have enough power to drive the application of your choice.

Step 3 – Pasting solar cells onto a substrate

After soldering the solar cells, you can prepare to paste them onto a substrate. Many hobbyists prefer to use silicone caulk to do this. However you’ll need to employ the correct technique to paste the solar cells using silicone caulk. Otherwise the cells may crack just after a short period of use.

Step 4 – Put the array of solar cells with a protective box

After the substrate is done, you’ll have to make a box to contain the substrate. This can be made of wood, plastic or metal. Each has its unique advantages and disadvantages.

The protective box is done last. This is because you can then be flexible to alter your solar panel design if you need to add more solar cells to the setup. This will free you from some worrying.

After the box is completed, you can hold down the substrate in the protective box using blobs of silicone caulk.

Step 5 — Cover the solar panel box

Finally, you’ll have to cover the box with a transparent plastic or glass. This will keep precipitation and dew from destroying your solar cells and metallic joints. Many hobbyists choose plexiglass because it’s not as fragile as glass. The choice is entirely up to you.

After completing these 5 steps, your solar panel is ready to produce electricity for you.

Continue Reading:

1. How To Build Solar Panel (Part 1 of 3)
2. How To Build Solar Panel (Part 2 of 3)
3. Used Solar Panels – How To Use Them To Build Cheap DIY Solar Panels

Since the primary voltage used in an automobile is 12 volts, the solar panel you build will most likely be of this rating.

There are a few items you need to purchase in order to make this project:

1. Solar cells
2. Silicon caulk
3. Aluminum frame
4. Perspex cover
5. 2-gauge wires
6. Soldering iron
7. A piece of substrate

You can either use broken cells or new/used ones. What I recommend (if you have the budget) is to use new PV cells. This is because you’ll get the most power. Since an automobile doesn’t have a lot of surface area, you need more power per square feet for your PV panel.

First, you have to position the solar cells on the substrate to make sure you’ve got your spacing correct. Next, check that the PV cells are orientated according to the correct polarity.

Once this is done, you can flip the cells and start soldering them. Use 2-gauge wires or tabbing wires so the electrical resistance is as low as possible. After this, put the cells under the sun and test to see if you’re getting the correct voltage and current output.

Then put the PV cells back on the substrate again. Row by row, put a blob of silicon caulk at the back of the solar cell. Then paste the solar cell gently on the substrate. Do not cover the entire cell with silicon caulk. Otherwise you will leave the material with little space for expansion and contraction. When sufficient stress builds up in the material (glass), it may crack.

You’ll usually have to wait at least 24 hours for the silicon caulk to dry completely. Otherwise it will leave deposits at the Perspex surface. This will hinder sunlight from entering the solar panel.

Immediately after pasting your solar cells, you may want to take some time to waterproof the solar panel frame. This prevents moisture and rain from entering your PV panel. Thus you’re protecting metallic connections and components from corrosion.

Finally, you can also build a small charge controller into the solar panel frame if space allows. However this depends on what you want to use your solar panel for.

Continue Reading:

1. How To Build Solar Panel (Part 2 of 3)
2. Step-By-Step Guide To Build A 12V Solar Panel
3. Building a Solar Panel Frame By Using Aluminum Angles