A solar cell panel, solar electric panel, photo-voltaic (PV) module, PV panel or solar panel is an assembly of photovoltaic solar cells mounted in a (usually rectangular) frame, and a neatly organised collection of PV panels is called a photovoltaic system or solar array. Solar panels capture sunlight as a source of radiant energy, which is converted into electric energy in the form of direct current (DC) electricity. Arrays of a photovoltaic system can be used to generate solar electricity that supplies electrical equipment directly, or feeds power back into an alternate current (AC) grid via an inverter system.

In 1839, the ability of some materials to create an electrical charge from light exposure was first observed by the French physicist Edmond Becquerel. Though these initial solar panels were too inefficient for even simple electric devices, they were used as an instrument to measure light. 

Theory and construction

Photovoltaic modules consist of a large number of solar cells and use light energy (photons) from the Sun to generate electricity through the photovoltaic effect. Most modules use wafer-based crystalline silicon cells or thin-film cells. The structural (load carrying) member of a module can be either the top layer or the back layer. Cells must be protected from mechanical damage and moisture. Most modules are rigid, but semi-flexible ones based on thin-film cells are also available. The cells are usually connected electrically in series, one to another to the desired voltage, and then in parallel to increase current. The power (in watts) of the module is the mathematical product of the voltage (in volts) and the current (in amperes), and depends both on the amount of light and on the electrical load connected to the module. The manufacturing specifications on solar panels are obtained under standard conditions, which are usually not the true operating conditions the solar panels are exposed to on the installation site. 

A PV junction box is attached to the back of the solar panel and functions as its output interface. External connections for most photovoltaic modules use MC4 connectors to facilitate easy weatherproof connections to the rest of the system. A USB power interface can also be used. Solar panels also use metal frames consisting of racking components, brackets, reflector shapes, and troughs to better support the panel structure.

Technology

Most solar modules are currently produced from crystalline silicon (c-Si) solar cells made of polycrystalline or mono-crystalline silicon. In 2013, crystalline silicon accounted for more than 90% of worldwide PV production, while the rest of the overall market is made up of thin-film technologies using cadmium telluride (CdTe), copper indium gallium selenide (CIGS) and amorphous silicon (a-Si). 

Emerging, third-generation solar technologies use advanced thin-film cells. They produce a relatively high-efficiency conversion for a lower cost compared with other solar technologies. Also, high-cost, high-efficiency, and close-packed rectangular multi-junction (MJ) cells are usually used in solar panels on spacecraft, as they offer the highest ratio of generated power per kilogram lifted into space. MJ-cells are compound semiconductors and made of gallium arsenide (GaAs) and other semiconductor materials. Another emerging PV technology using MJ-cells is concentrator photovoltaics (CPV).

Mounting

Ground

Large utility-scale solar power plants usually use ground-mounted photovoltaic systems. Their solar modules are held in place by racks or frames that are attached to ground-based mounting supports. Ground based mounting supports include:

  • Pole mounts, which are driven directly into the ground or embedded in concrete.
  • Foundation mounts, such as concrete slabs or poured footings
  • Ballasted footing mounts, such as concrete or steel bases that use weight to secure the solar module system in position and do not require ground penetration. This type of mounting system is well suited for sites where excavation is not possible such as capped landfills and simplifies decommissioning or relocation of solar module systems.

Roof Top

Roof-mounted solar power systems consist of solar modules held in place by racks or frames attached to roof-based mounting supports. Roof-based mounting supports include:

 

  • Rail mounts, which are attached directly to the roof structure and may use additional rails for attaching the module racking or frames.
  • Ballasted footing mounts, such as concrete or steel bases that use weight to secure the panel system in position and do not require through penetration. This mounting method allows for decommissioning or relocation of solar panel systems with no adverse effect on the roof structure.
  • All wiring connecting adjacent solar modules to the energy harvesting equipment must be installed according to local electrical codes and should be run in a conduit appropriate for the climate conditions

Sunlight Tracking

Solar trackers increase the energy produced per module at the cost of mechanical complexity and increased need for maintenance. They sense the direction of the Sun and tilt or rotate the modules as needed for maximum exposure to the light.

Alternatively, fixed racks can hold modules stationary throughout the day at a given tilt (zenith angle) and facing a given direction (azimuth angle). Tilt angles equivalent to an installation's latitude are common. Some systems may also adjust the tilt angle based on the time of year.

On the other hand, east- and west-facing arrays (covering an east–west facing roof, for example) are commonly deployed. Even though such installations will not produce the maximum possible average power from the individual solar panels, the cost of the panels is now usually cheaper than the tracking mechanism and they can provided more economically valuable power during morning and evening peak demands than north or south facing systems.

Performance

Module performance is generally rated under standard test conditions (STC): irradiance of 1,000 W/m2, solar spectrum of AM 1.5 and module temperature at 25 °C. The actual voltage and current output of the module changes as lighting, temperature and load conditions change, so there is never one specific voltage at which the module operates. Performance varies depending on geographic location, time of day, the day of the year, amount of solar irradiance, direction and tilt of modules, cloud cover, shading, soiling, state of charge, and temperature. Performance of a module or panel can be measured at different time intervals with a DC clamp meter or shunt and logged, graphed, or charted with a chart recorder or data logger.

For optimum performance, a solar panel needs to be made of similar modules oriented in the same direction perpendicular to direct sunlight. Bypass diodes are used to circumvent broken or shaded panels and optimize output. These bypass diodes are usually placed along groups of solar cells to create a continuous flow. 

Electrical characteristics include nominal power (PMAX, measured in W), open-circuit voltage (VOC), short-circuit current (ISC, measured in amperes), maximum power voltage (VMPP), maximum power current (IMPP), peak power, (watt-peak, Wp), and module efficiency (%).

Open-circuit voltage or VOC is the maximum voltage the module can produce when not connected to an electrical circuit or system. VOC can be measured with a voltmeter directly on an illuminated module's terminals or on its disconnected cable.

The peak power rating, Wp, is the maximum output under standard test conditions (not the maximum possible output). Typical modules, which could measure approximately 1 by 2 metres (3 ft × 7 ft), will be rated from as low as 75 W to as high as 600 W, depending on their efficiency. At the time of testing, the test modules are binned according to their test results, and a typical manufacturer might rate their modules in 5 W increments, and either rate them at +/- 3%, +/-5%, +3/-0% or +5/-0%. 

Maintenance

Solar panel conversion efficiency, typically in the 20% range, is reduced by the accumulation of dust, grime, pollen, and other particulates on the solar panels, collectively referred to as soiling. "A dirty solar panel can reduce its power capabilities by up to 30% in high dust/pollen or desert areas", says Seamus Curran, associate professor of physics at the University of Houston and director of the Institute for Nano Energy, which specializes in the design, engineering, and assembly of nanostructures. The average soiling loss in the world in 2018 is estimated to be at least 3% – 4%.

Paying to have solar panels cleaned is a good investment in many regions, as of 2019. However, in some regions, cleaning is not cost-effective. In California as of 2013 soiling-induced financial losses were rarely enough to warrant the cost of washing the panels. On average, panels in California lost a little less than 0.05% of their overall efficiency per day.

There are also occupational hazards with solar panel installation and maintenance. A 2015–2018 study in the UK investigated 80 PV-related incidents of fire, with over 20 "serious fires" directly caused by PV installation, including 37 domestic buildings and 6 solar farms. In 1⁄3 of the incidents a root cause was not established and in a majority of others was caused by poor installation, faulty product or design issues. The most frequent single element causing fires was the DC isolators.

A 2021 study by kWh Analytics determined median annual degradation of PV systems at 1.09% for residential and 0.8% for non-residential ones, almost twice that previously assumed. A 2021 module reliability study found an increasing trend in solar module failure rates with 30% of manufacturers experiencing safety failures related to junction boxes (growth from 20%) and 26% bill-of-materials failures (growth from 20%).

Cleaning methods for solar panels can be divided into 5 groups: manual tools, mechanized tools (such as tractor mounted brushes), installed hydraulic systems (such as sprinklers), installed robotic systems, and deployable robots. Manual cleaning tools are by far the most prevalent method of cleaning, most likely because of the low purchase cost. However, in a Saudi Arabian study done in 2014, it was found that "installed robotic systems, mechanized systems, and installed hydraulic systems are likely the three most promising technologies for use in cleaning solar panels".

Waste and Recycling

There was 30 thousand tonnes of PV waste in 2021, and the annual amount was estimated by Bloomberg NEF to rise to more than 1 million tons by 2035 and more than 10 million by 2050. Most parts of a solar module can be recycled including up to 95% of certain semiconductor materials or the glass as well as large amounts of ferrous and non-ferrous metals. Some private companies and non-profit organizations are currently engaged in take-back and recycling operations for end-of-life modules. EU law requires manufacturers to ensure their solar panels are recycled properly. Similar legislation is underway in Japan, India, and Australia. 

A 2021 study by Harvard Business Review indicates that, unless reused, by 2035 the discarded panels would outweigh new units by a factor of 2.56. They forecast the cost of recycling a single PV panel by then would reach $20–30, which would increase the LCOE of PV by a factor 4. Analyzing the US market, where no EU-like legislation exists as of 2021, HBR noted that without mandatory recycling legislation and with the cost of sending it to a landfill being just $1–2 there was a significant financial incentive to discard the decommissioned panels. The study assumed that consumers would replace panels half way through a 30 year lifetime to make a profit. However prices of new panels increased in the year after the study. A 2022 study found that modules were lasting longer than previously estimated, and said that might result in less PV waste than had been thought. 

Recycling possibilities depend on the kind of technology used in the modules:

  • Silicon based modules: aluminum frames and junction boxes are dismantled manually at the beginning of the process. The module is then crushed in a mill and the different fractions are separated – glass, plastics and metals. It is possible to recover more than 80% of the incoming weight. This process can be performed by flat glass recyclers since morphology and composition of a PV module is similar to those flat glasses used in the building and automotive industry. The recovered glass, for example, is readily accepted by the glass foam and glass insulation industry.
  • Non-silicon based modules: they require specific recycling technologies such as the use of chemical baths in order to separate the different semiconductor materials. For cadmium telluride modules, the recycling process begins by crushing the module and subsequently separating the different fractions. This recycling process is designed to recover up to 90% of the glass and 95% of the semiconductor materials contained. Some commercial-scale recycling facilities have been created in recent years by private companies. For aluminium flat plate reflector: the trendiness of the reflectors has been brought up by fabricating them using a thin layer (around 0.016 mm to 0.024 mm) of aluminum coating present inside the non-recycled plastic food packages.

Since 2010, there is an annual European conference bringing together manufacturers, recyclers and researchers to look at the future of PV module recycling.

*Source-Wikipedia.