How to Moisture Proof a Solar Panel

Photovoltaic cells on a panel with a voltmeter

Photovoltaic (PV) solar panel do-it-yourself guides contain helpful information that allows practically anyone with a free weekend on their hands to build good working solar panels that can help power a home. Many do-it-yourselfers find, however, that their solar panels degrade quickly when exposed to widely varying temperatures and elements. Moisture exposure especially, over several months, can accumulate, corrode and weaken connections between each of the solar cells that make up a solar panel. Fortunately there is at least one inexpensive way to protect your solar cells and panels from the corrosive and degrading effects of moisture.

Things You'll Need

• Wooden or Plexiglas backboard
• Pencil or marking pen
• Photovoltaic cells
• Clear-drying epoxy resin with urethane
• Thin rubber gloves
• Multimeter

Instructions

1. 

   Two photovoltaic cells

   Place, connect and arrange your photovoltaic cells on a Plexiglas or wooden backboard. The backboard should be the same size you plan for each of your solar panels. Use the pencil or marker to trace around each cell. Put the cells aside. Your backboard should now contain an outline of each of your photovoltaic cells.

2. Put on your thin rubber gloves, then mix the clear-drying urethane base epoxy resin on a base of clear hard plastic or wood for a minute or two with a stirring stick. Clear-drying epoxy resin with urethane is available at a reasonable price from every home improvement and hardware store. Spread even amounts of the clear epoxy resin inside the solar cell outlines on your backboard, then press your photovoltaic cells into their outlines on the backboard to secure them.

3. 

   A solar array panel

   Spread the epoxy resin evenly and smoothly all over each of the photovoltaic cells and the connectors between each of them on your panel. This will seal each of your photovoltaic cells, preventing moisture from forming and water from entering from outside the panel. Let it dry overnight.

4. 

   A standard multimeter

   Use your multimeter to test the connectors leading from each panel you made to make sure each panel is generating power.

Tips & Warnings

• Make sure your clear-drying epoxy resin has urethane in it. Urethane is UV resistant and will not yellow or fade in intense sunlight. Water-based clear coat epoxy resin is better for indoor projects. Urethane epoxy resin is for outdoor projects that will get lots of exposure to sunlight and the elements. Both products will dry clear but water-based epoxy resin will yellow and fade during prolonged exposure to sunlight. For longer-lasting solar panels, use urethane-based sealants.

• Plexiglas is a better, more durable material to use for your solar panel backboards than wood because it won't easily crack or break in extreme temperatures. It's a little more expensive but is worth it.

• Make sure that each of your solar cells are connected to one another and that they are working before you apply the clear epoxy sealant.

• Make sure there are lead (connecting) wires sticking out of each panel so you can join together each panel that you build. Cover each of the panel lead wires with epoxy after they have been connected and tested for power.

• Do not use urethane-based epoxy resin in a closed space, and always ensure that there is proper ventilation.

• Urethane is highly flammable so do not smoke or light flames around it before you mix and apply it to solar cells and connectors.

References

• YouTube: Make a Solar Panel Case
• YouTube: Clearcoat Application - Applying Your Clear Top Coat