Comments on: Phase Two DIY Solar Panel – It’ll Be Like This http://rantsville.com/archives/408 Not an angry rant blog (well maybe) Wed, 06 Jul 2011 03:58:39 +0000 hourly 1 http://wordpress.org/?v= By: Curmudgeon http://rantsville.com/archives/408#comment-53 Curmudgeon Thu, 07 Oct 2010 14:03:52 +0000 http://rantsville.com/?p=408#comment-53 I would really appreciate updates. Seems this will be an ongoing learning experience for all of us. I would really appreciate updates. Seems this will be an ongoing learning experience for all of us.

]]> By: edmond http://rantsville.com/archives/408#comment-52 edmond Thu, 07 Oct 2010 03:24:24 +0000 http://rantsville.com/?p=408#comment-52 I tried encapsulating cells using an 8mm thick plexiglas, sun exposed part of cells touching the plexiglas, I used EVA as encapsulant. Worked well when I tested the panel, getting about the same values as my commercially bought panels. Problem was after a while, the cells started heating up, almost too hot to touch from the back and then the volt and amp output started dropping significantly. I think what happened was the thick plexiglas acted like an insulator, not allowing the cells to radiate heat out, thereby cooling down. The plexiglas didn't feel hot to touch until hours under the sun, but the commercially made panels' glass started to feel hot almost immediately after getting sun exposure, the front and back felt about the same temperature, the one I made with the thick plexiglas felt very hot at the back and not as hot at the front. I was almost afraid the EVA would start melting. I am going to try making another panel using toughened glass and EVA. I tried encapsulating cells using an 8mm thick plexiglas, sun exposed part of cells touching the plexiglas, I used EVA as encapsulant. Worked well when I tested the panel, getting about the same values as my commercially bought panels. Problem was after a while, the cells started heating up, almost too hot to touch from the back and then the volt and amp output started dropping significantly. I think what happened was the thick plexiglas acted like an insulator, not allowing the cells to radiate heat out, thereby cooling down. The plexiglas didn’t feel hot to touch until hours under the sun, but the commercially made panels’ glass started to feel hot almost immediately after getting sun exposure, the front and back felt about the same temperature, the one I made with the thick plexiglas felt very hot at the back and not as hot at the front. I was almost afraid the EVA would start melting. I am going to try making another panel using toughened glass and EVA.

]]> By: Curmudgeon http://rantsville.com/archives/408#comment-50 Curmudgeon Fri, 01 Oct 2010 15:11:02 +0000 http://rantsville.com/?p=408#comment-50 Expansion and contraction may not be the problem. As you know the cells are rigid and quite brittle so flexing of the panel they are mounted to can be a problem. We get some pretty harsh winds in this part of the country so my panels are built using aluminum spacers between the rows of cells to both stiffen and prevent front and rear panels from squeezing the cells. There has been no problem with my cells breaking up. When building larger surface area panels I'll go a step further and add stiffeners to the external side of the rear panel at 90 degrees to the internal spacers/stiffeners. Then again there have been accusations of overkill thrown my direction. Expansion and contraction may not be the problem. As you know the cells are rigid and quite brittle so flexing of the panel they are mounted to can be a problem. We get some pretty harsh winds in this part of the country so my panels are built using aluminum spacers between the rows of cells to both stiffen and prevent front and rear panels from squeezing the cells. There has been no problem with my cells breaking up. When building larger surface area panels I’ll go a step further and add stiffeners to the external side of the rear panel at 90 degrees to the internal spacers/stiffeners. Then again there have been accusations of overkill thrown my direction.

]]> By: mike http://rantsville.com/archives/408#comment-48 mike Tue, 08 Jun 2010 00:42:41 +0000 http://rantsville.com/?p=408#comment-48 Hey i did a few DIY panels and had TONS of problems with the Acrylic/plexiglass. The plexi expands easily and attaches itself to the EVA and eventually through expansion and contraction pulls the cells apart and you are left with a bunch of broken cells that you have to gingerly separate the plexi and the EVA so that you can replace them. Another problem i have noticed reading online is that you need to vacuum the EVA with organic peroxide on it to ensure crosslinking. The machine to do this is about 750,000 bucks. I tried to fix my problems by going with tempered glass and sandwiching the cells between EVA and mounting it to the glass but the adherence is terrible. Any ideas? I would seem that your idea will produce the same result as the silicone is torn from the plexi as it expands. Hey i did a few DIY panels and had TONS of problems with the Acrylic/plexiglass. The plexi expands easily and attaches itself to the EVA and eventually through expansion and contraction pulls the cells apart and you are left with a bunch of broken cells that you have to gingerly separate the plexi and the EVA so that you can replace them. Another problem i have noticed reading online is that you need to vacuum the EVA with organic peroxide on it to ensure crosslinking. The machine to do this is about 750,000 bucks.
I tried to fix my problems by going with tempered glass and sandwiching the cells between EVA and mounting it to the glass but the adherence is terrible.
Any ideas? I would seem that your idea will produce the same result as the silicone is torn from the plexi as it expands.

]]> By: Curmudgeon http://rantsville.com/archives/408#comment-46 Curmudgeon Tue, 02 Mar 2010 05:10:42 +0000 http://rantsville.com/?p=408#comment-46 Hi Islandsolar, apologies for slow response time. DIY builders sometimes use two part crystal clear optical grade silicone painted onto the cells. One such product is from GE and another is from Dupont. The Dupont product is less expensive but my research indicates it works equally well. Because of cost one method uses it to coat the front side of the cells and standard silicone coats the back. Research regarding adhesives, sealants and encapsulation materials turned up information regarding silicones is making me rethink the use of silicone on cell backs either as a protective barrier or the means of holding them to the rear panel. Next post in the "Phase Two" series is being edited and deals with findings important to the issue. Ethylene-Vinyl Acetate (EVA) sheet is another product used for the purpose. Claims are made that it has the potential to provide 700 plus years protection. Guess I won't be hanging around long enough to learn if that's true. I'm also looking into possible use of an aerosol that could make encapsulation a snap if it is suitable. I don't know for sure but suspect if the cells are housed in a space with most of the air evacuated there may be little if any reason to encapsulate the panel cells. Hi Islandsolar, apologies for slow response time. DIY builders sometimes use two part crystal clear optical grade silicone painted onto the cells. One such product is from GE and another is from Dupont. The Dupont product is less expensive but my research indicates it works equally well. Because of cost one method uses it to coat the front side of the cells and standard silicone coats the back.

Research regarding adhesives, sealants and encapsulation materials turned up information regarding silicones is making me rethink the use of silicone on cell backs either as a protective barrier or the means of holding them to the rear panel. Next post in the “Phase Two” series is being edited and deals with findings important to the issue.

Ethylene-Vinyl Acetate (EVA) sheet is another product used for the purpose. Claims are made that it has the potential to provide 700 plus years protection. Guess I won’t be hanging around long enough to learn if that’s true.

I’m also looking into possible use of an aerosol that could make encapsulation a snap if it is suitable.

I don’t know for sure but suspect if the cells are housed in a space with most of the air evacuated there may be little if any reason to encapsulate the panel cells.

]]> By: islandsolar http://rantsville.com/archives/408#comment-45 islandsolar Mon, 01 Mar 2010 00:38:58 +0000 http://rantsville.com/?p=408#comment-45 Hey, I was thinking of building a similar (144w, from 6" cells) panel. Can you shed any light on the encapsulation of the cells and creating a weatherproof environment for the cells? Hey, I was thinking of building a similar (144w, from 6″ cells) panel. Can you shed any light on the encapsulation of the cells and creating a weatherproof environment for the cells?

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