How to Light Photo Cell Panels

Encase one or more photocells and their electrical connections in a sintered powder of thermoplastic resin. The photocells may either be arranged in a parallel or in a series connection type. The photocells work best when they are encased either on their lower faces or their side faces. They should be arranged carefully because they are very brittle.

Enclose the encased photocells and their connectors between two rigid sheets. The first sheet to be placed on the uppermost level should be transparent. A good material may be a sheet made of transparent polycarbonate. The bottom layer may also be identical to the topmost one but not in a mandatory sense. Melt the resin carefully without interrupting the thermoplastic resin material by unnecessary movements of the sheets.

Perform the fusion of the vacuum lamination process by placing the set up in a flexible bag and inserting it in an autoclave. Apply vacuum in the flexible bag to remove the entrapped air bubbles in the network of photocells. While still maintaining the vacuum in the flexible bag, apply high pressure at the same time to the outer side of the flexible bag.

Increase the temperature and the pressure of the autoclave while observing the thermoplastic resin. You should continue to increase the temperatures until thermoplastic resin softens and fuses itself. This is usually followed by progressive cooling. The thickness of the thermoplastic resin between the photocells and the upper sheet is determined by the amount of thermoplastic resin material. In case more materials are used, the thickness equally increases.

Release the vacuum and decompress the autoclave. Wait for the photocell panel to cool down before getting it out of the autoclave.

Test the effectiveness of the panel by exposing it to sunshine and attaching its power output cables to an ammeter. The number of photocells should determine the estimated power output.