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

[scheek]

[QUOTE=wjgrisham;12942]I am sure would like to see you pictures also. I haven

[DeltaFox 25]

Here is just one of mine and there were some mistakes and thats how i learn

[wjgrisham]

I hope I get longer life out of cells by encapsulating them in epoxy. I will have pics later. Since all the chatter about corrosion and such, I decided to use a 2 part epoxy.

How I did it: After completing my soldering I had my cells facing down on my glass. I then finished my wiring. I used scotch tape to cover all edges of the cells going both ways, horizontal and vertical. I then ran a strip around the outer edge. My goal was to prevent any epoxy running between my cells onto the front side of my glass.

I used a 2 part epoxy that required (1) small styrofoam coffee cup of one and (2) cups of the other. I mixed the two and poured over the cells making sure that I had overlapped onto the glass to make a good seal.

It's dry now after a few hours and it appears to have sealed it all. NOW I'm not as worried about air getting to my cells and corroding them. Still, I'm not sure whether to leave an air vent or not, since my cells are protected. Maybe Mike has a idea.

Anyway, I'm ready to put this sucker to bed.

I am sure would like to see you pictures also. I haven

[smoothbrad]

Epoxies are NOT UV stable....

[cby016]

Not sure about my epoxy name. We use it in highway construction to encapulate the road surface and then apply a small gravel for friction (used on bridges,curves). I will search for the name. UV resistant, I would think so... since it is designed to work on roads.

Scheek great job on the panels. Did you ever find out the name or where to buy this epoxy? Also do you still recommend encapsulating with this method?

[DeltaFox 25]

I ment in the mail type of send. I could get a picture but it wouldn't really show you what ti is really like.

[Pennguy]

Yes sure if you have pics or video it'll be great to watch.

[DeltaFox 25]

It is kind of rubbery but it's silicone. I had to tare a 4x4 panel i had down and scrap all the cell's off and I have some peices of the slygard covered cell's I could send you if you want to see for yourself.

[Pennguy]

Fascinating conversation! How does this Slygard184 encapsulate hardens does it feel rubbery when cured or hard like plexi glass? I once found a youtube posting of a DIY'er applying a substance that when it cured it felt like rubber. I think that substance would be the best but I didn't get the name of it. I'll try in finding the link and I'll post it here so give me some time to find it again.

[DeltaFox 25]

Well , let me think. My 72 cell is 64x34 and to do a panel half that size would take one slygard ( 20oz) I think that is what that size is. so I'm going to do two slygard then the cells and then two more. You know this is all kind of exsperamental. This will be the first time that I have done this size of a panel.

[charlie_ruizpr]

That would be a good way of doing it, how many bottles of slygard do you think I would need for a 108 cell panel?

[DeltaFox 25]

Im was thinking about puting the cell's on a piece of plywood that is alittle biger then the frame and glass and make sure that these are tied togeather just like when you have them on the glass. put that aside , get your frame and glass ready and put your sylgard on the glass, now slide the cell's on the plywood off onto the slygard you already have on the glass , You probly will have some time to move thew cell's around if needed. Then add the other slygard , your done , let everything dry. I'm going to make a 72 cell 5x5 and I'm going to use this method.

[charlie_ruizpr]

Thats a real good deal on the glass, Everytime I called Superior Essex they told me I had to buy 3 of them or they could not sell it to me. I'm going to put the Sylgard down on the glass and then the cell's and then Sylgard on top of that . It will take the air out.
I had alot of trouble with the 6x6's so I;m working with 5x5's now and I'm making a 72 cell panel. Good luck on your project.

Hey guys, let's say you put the frame on a table, put the cells in the frame with the glass of course, place the sylgard and let it set for a while and possibly add a litttle vibration with a motor to the table to see if it helps with removing the bubbles. Let me kno what you guys think

[charlie_ruizpr]

Oh ok. Thats interesting to know. I was thinking of doing it exactly how he was, but maybe i should think about it. It sounds like it would be difficult to handle the cells once all connected though if putting them down after the sylgard. for example, the solar panel im making is a 72 cell (4 columns x 18 rows), and soldering the bus wires together while the sylgard is wet sounds too tricky, which means i'd need to somehow hold the entire array of cells and place it on the sylgard...which i can't see how it would work.

I remember the youtube guy poured the sylgard so that only 3 edges of each cell had sylgard poured on it, allowing the sylgard to seep under without creating bubbles, but i guess if you tried it four times and it didnt work...

Also, do you think 2 Sylgards will be sufficient for a 72 cell panel? Im thinking of getting them off ebay, unless that superioressex website can send international? im from australia.

I will be making 108 cell panel, how much sylgard would I need?

[charlie_ruizpr]

I have don that but with sylgard. I'm going to start a new way, First put sylgard on to the glass , then put the cells ( already tyed togeather and bussrar also) on top of the sylgard , then put more sylgard ontop of the cells. this way it will completly take any air out.

That's a good idea, try it and let us kno.