Homebrews

Solar Panel built with cells

I used flat aluminum sheet that they use to cover the trailers on the big trucks. It’s about 1/16 of an inch thick and is white powder coated on one side. The powder coating is very tough and works very well for insulating the cells from the aluminum. I used a 27”x34”x1/8” inch piece of tempered glass for the front and I used 100% silicone caulk to seal ¼ inch aluminum channel that I purchased from Lowe’s hardware between the front and back. The size could be probably knocked down to 26”x32” but I left enough room in between every thing so I could easily make repairs if I ever needed to do so. I faced the channel to the outside of the panel so I could cut slots in it and the back sheet so I could slide ¼ inch SS bolts in to mount it. I thought the silicone alone would hold it together but my roof is warped and it put the first one in a bind that eventually caused the glass to pull away from the frame. So I found some ½ inch aluminum channel which fit over the edge of the panel with a small gap and cut 1 inch pieces and clipped about a dozen of them around the frame with a thin piece of cork in the gap between it and the glass. The clips are probably temporary until I work something else out. I also used the silicone to attach the strings of cells to the aluminum back. I have two of this design on my roof for several months now and they are functioning great. Once I have perfected this I plan on posting a how-to on the site with step by step pics. I also have samples of some encapsulate ordered which should work to make panels of commercial quality. I will experiment with this and if it works out the way it is suppose to I will start to sell it on the site and post a how-to on making panels using it.  

Here’s a link to a small inexpensive eBook that I purchased that would give you more ideas in designing your panels http://www.goodideacreative.com/solarpanel.html.

When I get time I am going to sort through my bookmarks and post links to other sites with homebrewed panels.