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

[DeltaFox 25]

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.

[mrnewbie]

How do you like those 5x5 cells as compaired to the 6x6's.

Are they thicker..stronger..still curl up...easier to work with?

[DeltaFox 25]

I really like them better , there are easer to work with and there not as fragel. I'm ordering 120 grade A today from evergreen. the ones that I have worked with seam not to curl up that much. I'm still going to lay the sylgard down first then cells then sylgard. I don't care how long it takes to dey just so there are no air pockets there.

[mrnewbie]

Well if you beat me to it (laying cells on sylgard)..keep us updated.

My work table is a pool table..so its as level as I can get..
The only problem I see with putting the sylgard down first..is the cells FLOATING on top of sylgard..and squirting out of place..

Perhaps a weight on ends..or maybe even a piece of tape or something to keep em from sliding around..

If you try it before me...(I'm about a week away)..
Do post and let us know how it worked out..

[DeltaFox 25]

No NO I think the sylgard is thick enough to keep the cells from moving around. Sylgard is like STP maybe a little thicker. I have made several panels with Sylgard and my cells didnot move around.you do it like me and put the sylgard ontop of the cells and let it dry
and you will be happy.

[mrnewbie]

I don't understand..

I was thinking of..pooring the sylgard first..onto the glass then lay the strings of cells (blue side down) on top of the sylgard puddle..

Is this not what you were gonna do?

[DeltaFox 25]

yes and then put slygard on top of the cell that are already there. so you will have glass , slygard , cells , slygard , no air bubbles.

[mrnewbie]

Ok thats the plan..

Make Sylgard puddle
Lay in Strings of cells

Wait 3/4 days.

Solder strings of cells together.
coat back with 2nd real thin coat of sylgard covering buss wires.

Add that rubber paint or plastic panel to provide extra coverage when dry

[DeltaFox 25]

No No put all the cell togeather , sodler all , lay them on something else like card board or somthing else. Make sure they will fit in the space you are going to put them in. Now put sylgard on the glass , now get your fully assambled cells and put them ontop of slygard that is on the glass, OK now put more slygard on top on the cells you just layed down, let it set untill dryed.

[mrnewbie]

Wow..that sounds hard to do using 6x6 cells..so fragile

This is a pretty big setup 55 6x6 cells...

Thinkin on it...

[DeltaFox 25]

can you get a 1/4 " piece of plywook . Mark off the area that the cells need to fit in.
sloder your cells , put them on the plywood. once you get the slygard on the glass . all you have to do is slide ( probly with help) the cells onto the slygard thta is on the glass.
then put the other slygard on top of that.


..

[mrnewbie]

I could just use another glass panel...

I just poored the sylgard around edges of cells..(back of) and let it flow around to the Front(blue side/glass side)...to many air bubbles left..at least I'm not happy with it.


So you have used this method, and It gets rid of most of the air bubbles correct?

I'll be doing it or something real close to your method...

[DeltaFox 25]

I'm sorryn but I have to stick with the way I do it. i have to many panels that have airbubles in it up till now.can you get a 1/4 " piece of plywook . Mark off the area that the cells need to fit in.
sloder your cells , put them on the plywood. once you get the slygard on the glass . all you have to do is slide ( probly with help) the cells onto the slygard thta is on the glass.
then put the other slygard on top of that.
.. put all the cell togeather , sodler all , lay them on something else like card board or somthing else. Make sure they will fit in the space you are going to put them in. Now put sylgard on the glass , now get your fully assambled cells and put them ontop of slygard that is on the glass, OK now put more slygard on top on the cells you just layed down, let it set untill dryed.

[mrnewbie]

I don't understand why your sorry..

I was lookin for a better way to do it and you replied..Thank you

I'm not trying to convice you to do it a different way.
In fact I think your way (The Delta puddle method) is better than simply pooring around the cells like I had done before..not happy with results


".. put all the cell togeather , solder all , lay them on something else like card board or somthing else. " Yes I understand

I plan to do this on a second piece of panel glass like mentioned above..its already the right size.

[DeltaFox 25]

Thank you , i have several panels ( I call it the old way) with just one pore thats over the back and hope it would go around the frount , untill I see a guy that did it the way i said. I plan to use more slygard this way but I'll have a better panel for it.

Keep in touch and let me know how everything is going and don't forget take pictures.