Epoxy for encapsulating cells (great DIY thread with photos!)

[Gravelsandwich]

Eva

How would this work. useing EVA.Build a box [air tight] large enough to put in the panel about 40x40, also install a heating element, and a connection for a vacuum hook up. now take your glass then a piece of EVA then the cells then EVA. put that in the box, start the vacuum pump let it runs till it pulls a vacuum on the gague,then turn on the heating element. let it heat up till I think it is 150 deg.

I've read where other people have done this and had a fair bit of success. I'm going to try this exact same method. I've got the EVA and some Tedlar backing in the post now. Building your own vacuum chamber would be difficult, i was going to use the elements from two electric frying pans for heating.

[conntaxman]

EVA vs Sylgard

How would this work. useing EVA.Build a box [air tight] large enough to put in the panel about 40x40, also install a heating element, and a connection for a vacuum hook up. now take your glass then a piece of EVA then the cells then EVA. put that in the box, start the vacuum pump let it runs till it pulls a vacuum on the gague,then turn on the heating element. let it heat up till I think it is 150 deg.
Has anyone tried this,besides a manufacturer co
John.
I think I send out and get some EVA if this sounds like it would work

[DeltaFox 25]

Sylgard is like real thick honey or STP. It will stick to the glass. I use PV 804 form Dow Corning to hold the glass to the frame.
Glass=sylgard=cells=sylgard=backing

[Mike90250]

To get the air bubbles out, you have to use a vacuum bag.

[conntaxman]

Sylgard-184

I would like to know if this Sylgard-184 " STICKS" to the glass also? I have encpasulated one test panel with Surf Board resin [ UV protective] and found out that it dose NOT stick to the glass of the front panel.Also if you have any air bubbles it seem to POP a hole in were the air bubble was,This is when it is 20 degrees.
How i did it was Make a frame, then put the cells on the glass Then solder all the rest of the pos and neg to the bus bars, Then POUR the resin over the whole back and let it seep under the cells. I used 2 quarts and it came out to be 1/16 of an inch thick.
I ended up taking out the HARDENED panel from the frame and glass. The front side of the panel looks just like glass VERY VERY smooth ,that is because it was modeled using the glass that I know.
I think were ever their was an air bubble after it cured, the frezzing temp. Froze the moisture in that air bubble and that is what caused it too pop., Not sure.
John
Back to the drawing board ------------

[solarchris]

DIY Encapsulated Solar Panels

I looks like I'm not the only one to come up with the idea of encapsulating solar panels. I've made a couple solar panels for my boat. Since they panel is routinely exposed to salt water, I decided to encapsulate them in UV stable fiberglass and resin.

I'd appriciate any feedback anyone cares to give on my DIY Solar Panels guide.

Cheers!

Chris Troutner

[DeltaFox 25]

I'm going to make a 5x5 72cell panel and I'll be useing a 3.9KG container of sylgard , ( $336.02) I'll put half on the glass then the cells and then the other half on the back and i'm going to have a lexen backing on top of that.

[Pylonman]

You definitely need two units of Slygard 184 to do a panel with (36) 3 x 6 cells. I used one and it left the back side of the cells exposed. Also, due to my crappy soldering, each string of cells wasn't totally flat. If I tried to tape the edges, the cells would crack.

[DeltaFox 25]

http://www.ellsworth.com/display/productlisting.html?ProductLineID=18&VendorID=138&SubcategoryID=58&Tab=Vendors

This is one of the places that I found that has sylgard. I know oversea's it's to exspensive to order and I'm very sorry about that because I think everyone that wants to buy this should not be punished with over exspensive shipping.

[Gravelsandwich]

Newbie

Hi all,
I'm new to this game and over the last few weeks i've read a novel of posts and watched a movie length of youtube vids!!! Its clear the holy grail for the DIYer is the encapulation. I've just built my first panel, 12x5 (60)cells the 3x6"ones, I used 30x30x3mm aluminium frame with 6mm(1/4") Plexiglass.
I made the frame the same way that Mark bloke on youtube does but i glued the corners and the Plexiglass down Sikaflex instead of silicone.Sikaflex is much stronger and durable than silicone but as you cant get it in clear you've got to be carefull where you put it. All the cells are soldiered and in place ready for encapulation. This is where i came to a halt.
I've read a lot about differant encapulation materials and methods.(lets leave EVA aside for now) but every time i keep coming back to Sylgard. i wouldn't use polyurathane's, my experience with it is after a while it goes cloudy, Epoxy's yellow and are to rigid.I've mucked around with gells, oils etc but just end up back at Silgard. The big problem with Silgard how expensive it is and then you add the freight. Especially for us humble Aussies
I did find this stuff which i've ordered 3 lots of, its heaps cheaper so i hope it works ok.

http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=290519348271&ssPageName=STRK:MEWNX:IT

http://cgi.ebay.com/SOLAR-TITE-LIKE-SYLGARD-184-DIY-solar-cell-solar-panel_W0QQitemZ270689611511QQcategoryZ41981QQcmdZViewItemQQ_trksidZp4340.m263QQ_trkparmsZalgo%3DSIC%26its%3DI%252BC%26itu%3DUCI%252BIA%252BUA%252BFICS%252BUFI%26otn%3D10%26pmod%3D290519357053%26ps%3D63%26clkid%3D6269129803114984975

On getting the bubbles out from under the cells has anyone tried sucking them out with a flatened bendable straw?

[conntaxman]

Slygard184

BilljustBill,

Yes that is the same stuff but it goes for $53.00. If you can find it cheeper that that tell me please. The amount of the Slygard is about 20 oz.
567g. It's just enough to do a panel with 36 3x6 cells . I think I'm going to have to buy two for my 6x6 panel that I'm making.

.
I would like to know how you did Both sides of the cells with Only 22 oz. that comes out to about .03 oz for each cell. I just made and used 2 qts of resin for one 36 cell panel of 3x4 cells.
Also I found out that you can also use the resin that they use for Surf Boards,and it has the uv protection. I buy it from a guy in Florida, one gallon ends up to be $50.00 . I did some panels and they came out good and its holding up in the cold 20 deg. outside, and then I bring them indoors to about 70 deg. And every thing is fine.
John
The glass area is 26x31

[DeltaFox 25]

I haven't tryed it this way but I have 5 panels and I have tryed different ways to do it. All panels had air. I read somewhere to try it the way i said. I'm useing 5x5 cells now . I have tried 3x6's 4x4;s 6x6's and now 5x5's . I like these better.
i'm in the prosses of making my own frames. Welding them at the 45% angle.
Slygard has been used by manufactures befor EVA came along. I am making a 72 cell also. I have some sylgard on hand now but I want the larger container so I'll know i'll have enough to do the job.

[solarrules]

Sylgard air bubbles

Solarules,

I have had some panels that I used sylgard with and to me it is a learning lesson. i think if you can put sylgard on your glass first then put your cells down then pore sylgard ontop on the cells you will not have any air.

Thank you for the response. Have you tried this yet and with what kind of luck?

Incidentally, I have my cells and have pre-tabbed the entire lot. As for the painting the aluminum, it could be a thread of its own, but man my frame (ordered from Markp0177) looks BEAUTIFUL with the paint job. Next paint job will be even better..

One more disparate thought -- I agree with Markp0177 -- I'm trying to make all workmanship last a long, long time. Taking my sweet time on my first build. Next build can go a lot quicker.

[DeltaFox 25]

Solarules,

I have had some panels that I used sylgard with and to me it is a learning lesson. i think if you can put sylgard on your glass first then put your cells down then pore sylgard ontop on the cells you will not have any air.

[russ]

Hi Solarrules - Welcome to Solar Panel Talk!

Several of the guys are on projects like your at present - let us see what they have to say.

Russ