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How to build a solar energy panel

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So you’ve decided to reduce your dependence on your local electric company, lower your carbon footprint … and increase your dependence on The Big Power Company – the sun.

It’s a great idea. (But then you probably already know, right?) Assuming, of course, that you can capture enough sunlight to offset the cost over time. There are areas of the country where it is simply not feasible to use solar power, so before you begin, you may want to check the U.S. Energy Information Administration (EIA) website to determine how suitable your Location.

However, once you are ready to begin construction, you will find that building a solar energy panel is not rocket science and once the initial cost is offset, it can certainly save you a lot of money on your energy bills.

While many consumers view solar power as an “all or nothing” proposition, the truth is that you can start small, see how it works and add if you like it and find that it is energy efficient.

Today, “prefabricated” solar energy panels are becoming more profitable. But … they are still far from cheap. Plus, it’s fun and interesting to create your own. And … if you’re a DIYer with a little extra time and short on money, you can save a lot of change.

I discovered that there is more than one recipe for building solar energy panels. There are books, e-books, and tons of articles on the internet on how to build solar energy panels. A little research can help you find what will work best for the way your solar energy will be used and what materials are most readily available to you.

Using what research shows as currently available technology and readily available building material for a photovoltaic (PV) panel, here is what you can expect as the necessary ingredients for a basic recipe:

1. Solar cells

2. A shallow box made of plywood.

3. Perforated masonite board or similar substrate

4. Plexiglass to protect cells

5. Screws and hardware

6. Wire

7. Silicone putty

8. Diode

9. Jones plug

You solder the cells together in a series with a blocking diode placed inside the solar panel, then you plug a polarized two-pin jones plug into the ends of the wires. Make sure the cells are connected and protected inside the box, and seal it with a silicone caulk so that water can’t get in and damage it. Once everything is connected and sealed, you just need to connect it to a battery pack or an inverter and you have the beginnings of a small solar power system.

One of the interesting points of this article is a reminder that there are many types of solar cells, but cells of the same type produce the same voltage, regardless of size. So … if you use bigger cells, you will get more power, but the panel will be heavier.

One of the key considerations, I think, is keeping the panels manageable for one person to operate. Most DIY’s (do-it-yourselfers) not only build, but also install whatever they’re building, so unless you’re making a permanent installation, and will have plenty of help getting it up, keeping the panel small and light is a More. You can add multiple solar panels and a larger battery bank, with more inverters to expand your system if you decide the whole process is worth it … and I’m talking about it worth so much for the energy saving costs as per the IDIM (I did it myself) factor.

As I mentioned earlier, solar cells are currently relatively expensive. However, new technology in solar energy panels is advancing rapidly. I found some fascinating innovations coming to the fore at www.treehugger.com. They include CIGS (copper indium gallium disselinide thin film solar cells being developed by the US National Renewable Energy Laboratory that will be extremely competitive with current silicon-based cells. And … there’s the Inflatable Balloon Cool Earth, designed to focus more direct sunlight on smaller solar panels. Not to mention growing Thin ‘hairy’ solar panels using nanowires? How cool is that.

Regardless of what you use to build your solar energy panel, you can feel good about it … really good. You are decreasing your own dependence on a non-renewable energy source, decreasing the overall negative environmental impact of man, and doing so with the most profitable method: as a DIYer.

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