Cheap methods of encapsulating?

[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

[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.

[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.

[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

[DeltaFox 25]

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

..

[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.

[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

[DeltaFox 25]

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

[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

[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).

[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.

[Mike90250]

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

[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 ??

[DeltaFox 25]

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

[kermitas]

The sylgard 182 you have to heat treat it to cure it. The sylgard 184 will cure itself. Loo at me last thread here and click on the diagram and really look at it. Buying sylgard at $36.85 is alokm cheeper then E-Bay. What's your price ( at Cost ) you would crarge for the sylgard.

DeltaFox, Mike90250, are you one of them who used glass and solid polycarbonate on front in your panels ?? How solid polycarbonate works ??
It is not so clear as glass but can you see/fell the difference on output power ??
And what about cooling ? It is also not so good as glass. What did you used as backing ? Does heat is enemy of non-glass panels ??

@bladerunner - I am thinking to buy Sylgard, what would be your final cost that you can offer to me ?

Thanks,
Arthur.