How are solar panels made?

As the world increasingly turns to renewable energy sources, solar panels for homes have become famous as they reduce their carbon footprint and save on energy costs. Understanding how solar panels are made can provide insight into the factors influencing their performance and sheet metal prices. This article will explore the manufacturing process of solar panels, focusing on the materials and components used, including galvanised (GI) sheet and galvalume steel. Interested in delving deeper into the world of solar panels? Register now to stay updated on the latest insights.

Raw materials and components 
Solar panels comprise several vital materials, each contributing to their efficiency and durability. The primary components include: 

• Silicon: silicon is the main ingredient in solar cells, and it is processed and purified to create photovoltaic (PV) cells.
• Conductive metals: silver and copper are used for electrical conductivity.
• Glass: a protective layer that shields the PV cells from environmental damage.
• Encapsulant: materials like ethylene-vinyl acetate (EVA) encase the cells to protect them from moisture and dirt.
• Backsheet: a layer at the back of the panel, often made from durable polymers.
• Frame: usually made from aluminium or steel, providing structural support. 

Steel in solar panel manufacturing 
Mild steel plays a crucial role in constructing solar panel frames and mounts. Companies like JSW Steel provide various steel products for use in this industry. Here's a closer look at the types of steel involved: 

Galvanised steel (GI sheet): galvanised steel is used for its corrosion resistance and is a popular choice for solar panel frames and mounting structures. The galvanisation process involves coating the steel with zinc to protect it from rust.

Galvalume: a combination of aluminium, zinc, and silicon, galvalume offers excellent corrosion resistance and is used in environments where enhanced durability is required. 

The manufacturing process 
The manufacturing of solar panels involves several key steps: 
 

• Silicon purification: the process begins with the purification of silicon, which is melted and cooled to form ingots. These ingots are then sliced into thin wafers.
• Cell formation: silicon wafers are treated to create an electric field, forming PV cells. These cells are tested for efficiency and sorted accordingly.
• Cell interconnection: the PV cells are interconnected using conductive metals like silver and copper, forming a solar cell module.
• Encapsulation: to protect it from environmental damage, the cell module is sandwiched between layers of EVA and a back sheet.
• Framing: the encapsulated module is fitted into a metal frame, often made from aluminium or galvanised steel, providing structural support.
• Quality testing: each solar panel undergoes rigorous testing to meet industry efficiency, durability, and safety standards. 
   

Factors affecting solar panel prices 
Material costs: the prices of raw materials like silicon, silver, and various metals directly impact the overall cost. For instance, fluctuations in sheet metal prices, such as steel plate and galvanised sheet prices, can affect manufacturing costs. 

Technology and efficiency: technological advances can lead to higher-efficiency panels, which may come at a premium price.

Manufacturing processes: streamlined and automated processes can reduce labour costs and production time, influencing the final price of the panels. 

Market demand: high demand for solar panels for home installations can drive prices up, whereas increased competition and mass production can lead to cost reductions. The price of solar panels varies based on the panels' type and efficiency, the installation's size, and regional factors. 

Conclusion 
The manufacturing of solar panels involves advanced technology and several types of steel and sheet metal. Companies like JSW Steel play a significant role in providing the raw materials necessary for this green technology. As the industry evolves, advancements in materials and manufacturing processes will continue to influence solar panel prices, making solar energy more accessible and affordable for homeowners. By understanding how solar panels are made, consumers can make more informed decisions about investing in this sustainable energy source.