How to Produce Solar Screens
- 1). Research and order solar cells online. Each 3x6" cell is capable of producing about half a volt. The standard panel outputs 18 volts and 3-4 amps of power, which means you will need 36 solar cells for each panel. Be aware that grade B cells are less expensive but are often damaged and may not work as efficiently as grade A cells. Do not buy cells unless they are pre-tabbed. These cells are extremely delicate and may come packed in wax, in which case you will have to melt the wax off them in a pot of boiling water on the stove. Handle solar cells with care.
- 2). Plan and build the container. Most containers are simply a flat wooden box with Plexiglas in front. Draw your design first showing the dimensions; try not to make it too heavy if you are mounting it on your roof. You can make the box 18x36x3/4" or any size that will fit 36 solar panels inside it. Use plywood and planks or whatever scrap wood you have. Measure it, cut it and nail or screw it together, making sure it is square. Finish it with polyurethane to protect it from the weather. Do not install the glass at this stage.
- 3). Cut a flat piece of masonite peg board or fiberboard to just fit inside the box. This will form the base or substrate to hold your cells in place. Measure and draw a grid showing where each cell will fit on the substrate. Line up a row of 6 cells on the substrate and solder the negative tabs at the top of one cell to the positive tabs at the bottom of the next cell to form a "string" of six cells. Repeat to make six strings of six cells each.
- 4). Glue each cell to the substrate using a blob of silicone caulk in the center of each cell. Do not place the caulk anywhere else because the substrate and the cells may expand and contract differently from one another. Rotate alternate strings so you will be able to join them in series and glue all six strings to the substrate.
- 5). Solder the first and second strings together at one end with BX electrical wire and the second and third strings at the other end and so on. Solder a blocking diode to each of the wires in series. This will prevent the current from running backwards into the solar panel at night. Anchor the wire and diodes to the substrate with caulk. Drill a hole on the side of the panel for the wires to exit, and drill a series of holes along the sides to allow hot air to circulate inside the box.
- 6). Glue the substrate into the panel with wood glue and also screw it in. Thread the wires out through the hole and seal the hole with caulk. Stand it in the sun for a while. Test the power output with a meter; if your meter shows 18 volts you will know it is working. When the caulk has fully dried, screw the Plexiglas in place. Attach a 2-pin jones plug - female side to the wires. Build a series of these panels and wire them together in series.
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