Cheap methods of encapsulating?

[DeltaFox 25]

No I just use glass , I use to use plexiglass not any more.

[kermitas]

No I just use glass , I use to use plexiglass not any more.

Wayne, why ?????
What is general problem with plexiglass ??
And if it were not plexiglass but soild polycarbonate would it change your decision ??

[Mike90250]

i don't build my own panels. Figured I'd just buy them.

[DeltaFox 25]

I can get a 62x32 peice if polycarbonate for $20.00 Plexiglass I have to buy a hole sheet and you have to have the UV type. Glass comes 100 miles and it's easer to use and get. I still have two plexiglass in my garage that I don't use.

[kermitas]

I can get a 62x32 peice if polycarbonate for $20.00 Plexiglass I have to buy a hole sheet and you have to have the UV type. Glass comes 100 miles and it's easer to use and get. I still have two plexiglass in my garage that I don't use.

Thats interesting. In my location polycabronate is cheaper than glass. It is also lighter so whole panel finally is not so heavy. But it is not as clear as glass. Now what is better for me ? I choose lighter panels (I am planning to have 10 or more so single panel should not be too heavy).

[kermitas]

I can get a 62x32 peice if polycarbonate for $20.00 Plexiglass I have to buy a hole sheet and you have to have the UV type. Glass comes 100 miles and it's easer to use and get. I still have two plexiglass in my garage that I don't use.

Wayne, did you garb any new information about Dow Corning PV-6100 & 6010 ? What is this ? Can it be used as encaplsulator ? Or maybe in front (if it is opticaly clear and hard after it coagulate) ? How much it costs ?

You know what ? I think I would be happy if I find sth like Sylgard but which could be placed on front of cells. Then I will just need to use strong backing and whole panel is ready !
(It should be like Sylgard, not like EVA foil because to use this second one you need high temperature and vaccum.)
Or maybe sth like sticker foil which will be glued on one side and you just stick it on front of cell...

PS : data sheet for PV-6010 http://www1.dowcorning.com/DataFiles...c88022cce0.pdf , I don't event catch what is difference to Sylgard 184 ? Where we can use this product ? Can it be used on front of cells (no glass, no plexiglass, just this product alone) ?

PS2 : there no data sheet for PV-6100, just "Optically clear silicone encapsulant providing high transmission of light to the solar cell." found at http://www.dowcorning.com/applicatio...=8095EN&bhcp=1

PS3 : Interesting info found at http://www.dowcorning.com/content/pu...06-1023-01.pdf : [I]% Quantum Efficiency comparison of Front Contact Mono-crystalline PV cells encapsulated with Dow Corning

[DeltaFox 25]

Is your polycardonate UV protected? If not it will yellow in acouple of years.
Wayne

[kermitas]

Is your polycardonate UV protected? If not it will yellow in acouple of years.
Wayne

Of course UV protected, soild one on front, and this one as backing.

Please look here http://mirror-uk-rb1.gallery.hd.org/...seup-1-DHD.jpg , it looks like eva/tedlar on front without glass.

(Check other photos here http://gallery.hd.org/_c/natural-sci...1-DHD.jpg.html .)

It is interesting who manufacture them and what is really on front.

PS : look here http://mirror-uk-rb1.gallery.hd.org/...eup-10-DHD.jpg , if I will know that is this I would be very happy man

[NeilTheCop]

Check out

http://www.freepatentsonline.com/4224081.pdf

It's from 1980 but it's assigned to Sharp in Japan, I'm assuming Sharp electronics.
They use a silicone SRX-920 from Toray Silicone Co. When I put that into Google it gave me Dow -Corning. So maybe they bought the Company/Patent/Rights
Have to admit the idea of sandwiching the cells between two sheets of glass and simply pouring a silicone in the gap is appealing.

[DeltaFox 25]

How about poring silicone one your cells top and bottom and use your extra glass for another panel

..

[kermitas]

Check out

http://www.freepatentsonline.com/4224081.pdf

It's from 1980 but it's assigned to Sharp in Japan, I'm assuming Sharp electronics.
They use a silicone SRX-920 from Toray Silicone Co. When I put that into Google it gave me Dow -Corning. So maybe they bought the Company/Patent/Rights
Have to admit the idea of sandwiching the cells between two sheets of glass and simply pouring a silicone in the gap is appealing.

Thank you

[NeilTheCop]

How about poring silicone one your cells top and bottom and use your extra glass for another panel

You still need something to support the cells. So a sheet of tempered glass on top for protection and a sheet of cheap window glass on the bottom for support. A layer of tape http://www.shop3m.com/3m-aluminum-fo...MSpec6_Prod425
round the edge to give it an added moisture seal then a simple aluminum or vinyl frame to finish it all up.

[DeltaFox 25]

I have made 6 solar panels like I said and have not had any trouble with them at all.

Put your cells on top of the glass = put sylgard ontop of this and it will hold to the glass and the cells. The thing wrong about tape is it will crack with heat the panel will make , and it will fail in the long run. You have to have tape that will take the heat andweather like Kapton tape.

[mdmiller1]

through the roof for encapsulant

I'm a newbie, assembling the knowledge to fabricate a panel, and see one obvious stumbling block, the encapsulant. The Dow Sylgard is a no-brainer but expensive. As an architect, I've always been pleased with Lexel sealant. More transparent and flexible than silicone. I know some guys who seal fabric kayaks with it. I see the manufacturer now has a brushable product called 'through the roof'. If it's brushable, it is probably pourable, or at least screed-able. And it's designed for roof exposures.
It is $13 at Amazon for a quart.
It appears the base is toluene, instead of acetoxy cure, so hopefully electrical corrosion from acids should not be an issue. ??
Anyway, if anyone has any thoughts, or experience with this product, I would appreciate them. - thanks - Duane

[mdmiller1]

thru the roof

I bought a quart of thru the roof by sashco. $14.95. Ace Hardware.
The viscosity is very thick, thicker than honey.
I called their tech line and asked about thinning and they said no, that it could not be thinned. I realized after the call what else could they say, really. They guarantee the product, and have no control of any thinning process.
The product out of the can would be great to spread on a roof to seal a problem spot. It looks like lexel (which they also make) but not gun-grade, if you stick a screwdriver into it, and hold it for a bit, it will finally drip off but slowly.
So, I thinned it. The product has a base of toluene, which I didn't have, so I used some paint thinner made of white spirits. A pretty standard thinning agent.
I mixed it 50% by weight. I think it could be a bit thicker than that, possibly 2:1 sealant:thinner. If this works then I imagine toluene would work for sure if I can find it. I poured my thinned mix on a piece of scrap glass with a chunk of a broken cell. I'll let it age outside for awhile to get an idea of performance. Here's a picture.


Day 2:
The Thru the Roof encapsulant test has a bit of tack but the edges are dry. Golly it is tough, it looks like it has become one with the glass. A couple of mini-bubbles but no way can I even start to get the edge to come loose with a fingernail. I had taped around the cell fragment, but not well, and a lot leaked under the cell, so maybe that is good to know, it means it will capillary well. Perusing the msds at sashco, this is just Lexel. Thru the roof MSDS says it is packaged under several names, one is Lexel. The MSDS on the brushable can says that it's active ingredients are the same as the tube, but has been thinned with mineral spirits. Go figure. Looks like mineral spirits are the right thing to use to thin it a bit more. The product brochure touts that it is 19 times clearer than silicone and stays clear. If this quart is mixed with mineral spirits, that would make half-a-gallon of encapsulant. Testing continuing.

Day 3:
The Thru the Roof is dry except under the cell. Pushing on the cell it is apparent that material that was sucked under will be wet for some time. After reading about Dr. Komp's similar problems with bubbles under the cell using Sylgard, I am considering some technique of buttering the cells like you would butter a ceramic tile for setting. If anyone has ideas, I'm open.

Day 6:
The Thru the Roof cured nicely on my samples, is incredibly tough and very nice and clear. They claim no yellowing. Everything looks good so I fabricated a dam to do 1/4th of the panel. The mix ratio I decided on was by weight 6 parts Thru the Roof to 4 parts mineral spirits. I laid 9 soldered cells into place, put a slight tilt on the board and poured at the space between each cell to minimize bubbles. So the space between the cell and the front was capillary filled from one direction using gravity to flow it into and across the space, effectively forcing the air out the other side.