Journal #1

For Week 3 ~ November 6-8 ~ Caleb Rider

Goals
My goals for Week 1:
● To update my website to the best of my ability so that it contains all information I
can currently provide.
● To begin my research on the materials and methods needed to construct a
photovoltaic cell.
My goals for Week 2:
● To continue my research on materials and skills for photovoltaic (PV) cell
construction.
● To begin ordering materials for the construction of the PV cell
● To begin construction of the PV cell if ready
My goals for Week 3:
● Continue obtaining materials to build the PV cell
● ​Continue research on construction of the PV cell

Research and What I Learned

I will have parenthetical citations that just include numbers. Please refer to my bibliography at
the end for sources.

For this past journal period I have researched materials and methods used in the
construction of photovoltaic(PV) or solar cells. Many people are familiar with solar
panels, but not solar cells. Solar panels are much larger devices made by connecting
many solar cells together.

The way a solar cell works is by absorbing photons, or light particles, and
converting their energy into electric current. Most solar cells are made out of wafers of
silicon, a material adept at this process. Solar cells use two different types of silicon:
N-type and P-type. Silicon wafers are made by melting silicon in an induction
furnace(7,8) and slowly extruding it into a single crystal through the use of a small seed
crystal(5). While the silicon is being extruded, because it is porous while molten, it is
exposed to the gaseous form of certain elements, depending on the type of silicon
desired. This process is commonly referred to as “doping.” To produce N-type silicon,
the molten crystal is usually infused with phosphorus(9), occasionally arsenic. To
produce P-type silicon, the crystal is infused with boron. The reason both types are
required to produce a solar cell is because of the properties of the elements used for
doping. Phosphorus doped silicon carries an extra valence electron, or electron in the
outer energy level, that can be used to produce current(9,17). Boron doped silicon lacks
enough electrons to fill the outer energy level, and has “holes” in its structure where
there would be electrons(17). After the two types of silicon are layered together,
electrical contacts, usually made of aluminum, are placed on the front and back of the
silicon layers. When photons hit the N-type silicon, they transfer their energy to the extra
valence electron, causing it to become excited and jump to a higher energy level. This
allows it to be easily detached from its molecule, and then flows into the front electrical
contact, creating current. If the circuit is complete, the electron travels through it to the
rear electrical contact and into the P-type silicon layer, where it passes through a “hole”
and moves back into the N-type silicon to repeat the process.

I completed research on how to produce my own silicon wafers, but as the

process was both time-consuming and costly, I instead opted to simply purchase silicon
wafers online. This process would include having to extract silicon from sand using
acid(14), which would be difficult to obtain and hazardous to use; building and operating
my own induction furnace to melt the silicon(7,8); slowly drawing it out to create a single
crystal, which can take up to three days(5); doping my silicon crystal to create one of
the two types of silicon(17); cutting the silicon into wafers using a diamond saw; then
repeating the entire process to create the other type of silicon.

To make the PV cell actually able to produce current, it needs electrical contacts
for the flow of electrons. These are most commonly made of aluminum, as it is a great
conductor of electricity and is much cheaper than the few, more conductive, metals
such as copper and silver. Compared to these it also has a relatively low melting point,
making it much easier to use. A common method of applying front electrical contacts is
screen printing, where the aluminum is pushed through a stenciled screen and applied
only on unblocked areas of the PV cell’s surface(12). Since a screen printer would again
take more time to create, I will likely try to simply paint the aluminum on. After the
electrical contacts are placed, it is simply a matter of wiring the PV cell to a pre existing
phone charger.

Accomplishments
● Complete research of how to build a PV cell and the materials needed
● Order materials used for construction of the PV cell
My accomplishments list is small, but this is because I have been in a research-heavy
phase of my project. Once I start moving into actually building my PV cell, my research
will be smaller and my accomplishments list will be longer.
Reflection on Goals and Timeline
I feel as though my project is going very smoothly thus far. I have been able to
complete each of my goals each week, all of which are in line with my timeline.
Following the period of this journal, I should be ready to construct my PV cell, in order to
stay on schedule. This should not be difficult, as I have been for the duration of my
project up to this point.
1. “Aerospace Engineer.” ​Graphic Design Degree - CollegeGrad.com,​
collegegrad.com/careers/aerospace-engineers.

2. AGCAS Editors. “Aerospace Engineer.” ​Prospects.ac.uk​, Birkbeck, University of London, Jan.

2018, ​www.prospects.ac.uk/job-profiles/aerospace-engineer​.

3. AGCAS Editors. “Electronics Engineer.” ​Prospects.ac.uk​, Birkbeck, University of London, Apr.

2018, ​www.prospects.ac.uk/job-profiles/electronics-engineer​.

4. Aggarwal, Vikram. “2018 Most Efficient Solar Panels on the Market | EnergySage.” ​Solar News​,
EnergySage, 22 Oct. 2018,
news.energysage.com/what-are-the-most-efficient-solar-panels-on-the-market/.

5. “Czochralski Process.” ​Wikipedia,​ Wikimedia Foundation, 22 Oct. 2018,

en.wikipedia.org/wiki/Czochralski_process.

6. “Electrical and Electronics Engineers.” ​Graphic Design Degree - CollegeGrad.com​,

collegegrad.com/careers/electrical-and-electronics-engineers.

7. “Induction Furnace.” ​Wikipedia​, Wikimedia Foundation, 3 Nov. 2017,

en.wikipedia.org/wiki/Induction_furnace.

8. “Induction Heating.” ​Wikipedia,​ Wikimedia Foundation, 4 Oct. 2018,

en.wikipedia.org/wiki/Induction_heating.

9. Laube, Philipp. “Semiconductor Technology from A to Z.” F​ abrication of Oxide Layers - Oxidation - 
Semiconductor Technology from A to Z - Halbleiter.org​, 
www.halbleiter.org/en/fundamentals/doping/.

10. Learn How to Become. “Electrical Engineering Careers |.” ​How to Become,​
www.learnhowtobecome.org/engineering-careers/electrical/​.

11. “Mechanical Engineer.” ​Graphic Design Degree - CollegeGrad.com​,

collegegrad.com/careers/mechanical-engineers.

12. “Solar Cell.” ​How Products Are Made,​ Advameg, Inc.,

www.madehow.com/Volume-1/Solar-Cell.html.

13. “Solar Photovoltaic Cell Basics.” ​Energy.gov,​ Office of Energy Efficiency &Renewable Energy,
www.energy.gov/eere/solar/articles/solar-photovoltaic-cell-basics.

14. Staples, Peter. “How to Make Silicon Crystals from Sand.” ​Sciencing​, Leaf Group Education, 24
Apr. 2017, sciencing.com/make-silicon-crystals-sand-11367401.html.

15. “Technology.” ​Wi-Charge​, 30 Sept. 2018, ​www.wi-charge.com/technology/​.

16. “Types of Electrical Engineering.” ​School of Mechanical and Manufacturing Engineering​, 1 Nov.
2016, ​www.engineering.unsw.edu.au/electrical-engineering/types-of-electrical-engineering​.
17. https://academics.uccs.edu/rtirado/PV_Resources.pdf