A solar panel is a set of interconnected construction of solar cells, also called Photovoltaic (PV) cells. The solar panel can be utilized as a constituent of a larger photovoltaic system to generate and distribute electricity for commercial and residential applications.

This post is a brief introduction to Do It Yourself (DIY) solar panel construction, which involves soldering of solar cells together. Although most people are already aware, it is better to know that solar cells are, basically, two types: “tabbed” and “un-tabbed”.

Even though tabbed cells are somewhat costlier, overall, it will work out much cheaper, if one intends to construct more than one solar panel. Besides use of tabbed cells will save a lot of time, the number of broken cells will be much less and because of this, there will not be any scope for irritations.

Solar cells are very delicate and the chances of breakages would be higher if they are handled more frequently or also not handled carefully. As solar cells are very brittle, soldering calls for careful handling and un-tabbed solar cells not only require soldering across a cell but also involves twice the amount of work than that of tabbed cells and the breakage of cells is likely to be much more in respect of un-tabbed cells.

Tabbed solar cells are provided with the metal connector strips connected to the front portion of “sunny side face” of the solar cells. This strip has a free end sufficiently long to position it across the subsequent cell.

These tabbed cell strips will link the front of one cell to the contact point on the subsequent cell and the process is repeated till all the solar cells are interconnected. While the front side of most of the solar cells is negative, the back portion is positive thereby, enabling the electric current to pass through between the cells in the solar panel. As mentioned earlier, the tabbed solar cells are preferred because considerable effort has to be put in to solder un-tabbed solar cells.

The first step in the construction of a solar panel is essentially to solder a new metal strip to the front of each cell before even thinking of interconnecting the solar cells. As the solar cells are delicate, it involves a lot of time to do the difficult job of soldering each cell, especially if these are un-tabbed cells. It is, therefore, advisable to purchase only tabbed solar cells for paneling.

Another important aspect in the construction of a solar panel is to choose a superior quality 65 to 75 watt regulating type soldering iron, which should be set to a temperature of around 700°F. The temperature control is very essential.

If the soldering iron is very cold, solder will not function properly and if it is too hot, the cells are likely to get damaged. However, if someone has purchased un-tabbed cells, one should, as a first step solder a tabbing strip to the “sunny-face” of each of the cells.

There are two methods of doing it; both are, of course, very tricky and difficult. One can either solder the strip directly to the cell using flux, pre-solder or “tin” each strip before soldering it to the cell. The main reason for adopting one of the two methods is to ensure a “solid connection” to the solar cell or otherwise, electric current will not pass through the cells.

Solar tabbing ribbon, normally, comprises 10 to 15 micrometers of solder alloy with 60% tin and 40% lead, known as SN60, coated on a copper strip. As the alloy contains lead, pre-soldering the tabbing strip is a cumbersome process and some people will, therefore, avoid this step.

Flux should be applied either way to the large glittery strips (the “bus bars”) on the front of “sunny face” of the solar cell. The next step is to place the tabbing strip along the fluxed bus bar and with a flat soldering iron, move gradually down the strip. This is a very delicate job. If it is not done properly, the tab strip will come off.

If it is done carefully; the tabbing strip will firmly connect to the bus bar. For this work, the help of an additional hand would be highly desirable. Sometimes, it may be better to practice on a broken cell using an extra strip in order to get an idea of the work involved in soldering.

As there are normally two of these strips on each solar cell, soldering is always a tricky and difficult job. From this, one can easily understand why it is highly desirable to purchase tabbed cells.

DIY Photovoltaic Panel Construction Guide

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This is a general introduction to the steps needed to tab and solder solar cells together. Also a brief definition as well as the distinct difference between un-tabbed and tabbed solar cells.

You may know that currently there are both tabbed and un-tabbed solar cells on the market. The tabbed solar cells are more expensive, however if you intend to build more than one solar panel, they will save you time, broken solar cells and future frustration.

Solar cells are quite fragile as a general rule, the more you handle or mishandle them, the greater the chances are of breaking them. The un-tabbed solar cells must be soldered, doing this to any solar cell requires great skill and care.

The soldering iron should be of a good quality with a 65 to 75 Watt adjustable unit with the temperature set at about 700F. You must find the temperature that is perfect for your specific solder.

If you run the soldering iron too cold, the solder will not run properly, too hot and you risk damaging the solar cells. Doing this to un-tabbed solar cells effectively means soldering right across a solar cell, having to solder a new metal tab strip to the front of each solar cell before you can even start to connect your solar cells together.

You can solder the strip directly to the solar cell with flux or, pre-solder or “tin” each strip and then solder it to the solar cell. The goal is to get a solid solder connection to the solar cell or it will not transfer current.

Solar tabbing ribbon typically consists of 10 -15 micrometers of solder alloy, commonly SN60 (60% tin and 40% lead) coated on copper strip, note this contains lead.

Apply flux to the big shiny strips (the bus bars) on the front “sunny-face” of the solar cell. Lay the tabbing strip along the fluxed bus bar and with a flat tipped soldering iron, run slowly down the strip. If done with skill and extreme care, the tabbing strip will bond to the bus bar.

I highly suggest you practice on a broken solar cell with some spare strip to get a feel for the soldering. There are usually two of these on each solar cell. This makes twice the work with the chance that you will break some of the solar cells.

Tabbed solar cells come with the metal connecting strips already attached to the front face side of the solar cells, this strip is long enough to lay across the next following solar cell. The tab strips will connect the front of one solar cell to the contact points on the back of the next.

In general, the solar cells are negative on the front and positive on the back which allow the electricity current to flow between the solar cells in your solar panel. Tabbed solar cells are in my opinion the safe option if you want efficiently installed solar cells that do the job you need them to do.

I love going to Starbucks. One of the reasons I hang out there is for the good coffee and also for the free wi-fi. I get to look at people walking around and do my work there. It’s a great experience.

Sometimes I would spend a whole day there working on my laptop.

If you think about it, our laptop has become as common as our cell phone. With broadband wireless signal available free in most area, we can now use our notebook to work from anywhere we choose to.

There is one drawback though and it is the battery lifespan. We can only work on your laptop as long as the battery can last. Sooner or later, we will need to use our power cable to recharge the battery.

Starbucks realize this and they prepare power outlets for their customers. At some other places, it will be quite challenging to find a power outlet to recharge.

All of our mobile devices are held back by its battery life. How do we overcome this? One good solution to the battery life issue is with a portable solar panel.

If you are planning to shop for a personal solar power generator, the following are 6 factors you may want to consider.

1) Light Weight.

Weight is sexy, or rather the lack of weight is sexy. Just look at the Apple MacBook Air. It weights practically nothing.

If you are looking for a personal solar panel, why not get the lightest product. Hauling a notebook plus other accessories in your backpack can be quite heavy. You want to minimize weight as much as possible.

2) Water resistant.

I live in a country where it rains most of the time. Sometimes, I do get caught in a thunderstorm and get myself drenched. As a safety precaution, get a solar panel which is water proof. You don’t know when you’ll be caught in a heavy rain or even snow. If it is water proof, you don’t have to worry even if you were accidentally spill coffee on it.

3) Toughness.

Durability is an important factor. A flimsy solar panel may break if you were to pack it in a suitcase or stuff it in an airplane overhead compartment. You want it to be able to handle all the bumps and shocks of executive travel.

4) Reverse flow protection.

Reverse flow is a technical aspect of the solar film. When the sun is shining, the solar cells will generate power and charge the battery unit.

Without the reverse flow protection, the power from the battery will flow back into the solar cells when the sun is out.

5) Foldable.

Get a solar panel which is foldable. This feature makes the panel very easy to be packed into a bag or briefcase. The panel can be either folded like an origami or rolled into a tube for easy storage.

6) Amorphous solar cells.

Again, this is another technical aspect of the solar panel. Amorphous solar cells works even under low sun light. You will get a constant power output even if the panel is under cloud cover.

Related web pages:
1) Brunton Flexible Solar Module from Amazon.com

2) Powertraveller SM-GREY Gray Solarmonkey Solar Power Charger – Suitable for cell Phone, iPod, PDA, MP3 player and many other digital devices.

3) Ambigrid Review – Reviewing The Ambigrid E-book.