Build a 60 Watt Solar Panel

Step 5 Prepare the solar cells

Now that I had the structure of the panel finished, it was time to get the solar cells ready

As I said above, getting the wax off the cells is a real pain. After some trial and error, I came up with a way that works fairly well. Still, I would recommend buying from someone who doesn't dip their cells in wax.

This photo shows the complete setup I used. My girlfriend asked what I was cooking. Imagine her surprise when I said solar cells. The initial hot water bath for melting the wax is in the right-rear. On the left-front is a bath of hot soapy water. On the right-front is a bath of hot clean water. All the pots are at just below boiling temperature. The sequence I used was to melt the bricks apart in the hot water bath on the right-rear. I'd tease the cells apart and transfer them one at a time to the soapy water bath on the left-front to remove any wax on the cell. Then the cell would be given a rinse in the hot clean water on the right-front. The cells would then be set out to dry on a towel. You should change the water frequently in the soapy and rinse water baths. Don't pour the water down the sink though, because the wax will solidify in your drains and clog them up. Dump the water outside. This process removed almost all the wax from the cells. There is still a very light film on some of the cells, but it doesn't seem to interfere with soldering or the working of the cells.

Don't let the water boil in any of the pans or the bubbles will jostle the cells against each other violently. Also, boiling water may be hot enough to loosen the electrical connections on the cells. I also recommend putting the brick of cells in the water cold, and then slowly heating it up to just below boiling temperature to avoid harsh thermal shocks to the cells. Plastic tongs and spatulas come in handy for teasing the cells apart once the wax melts. Try not to pull too hard on the metal tabs or they may rip off. I found that out the hard way while trying to separate the cells. Good thing I bought extras. More details on this step can be found on my web site at http://www.mdpub.com/SolarPanel/

Comments

[dontelmewatodo]

raisor blade it off

[speedstix]

 Not sure if you ever handled individual solar cells before but they are very fragile. Imagine a piece of paper but that piece of paper was made of glass. They break really easily. You could try a razor blade but you might end up with a bunch of broken cells. 

[sspence]

I've found that the heat of the soldering iron will melt the wax off the tabs, and the heat of the sun will get the wax off the cells, so separating the cells is the major concern. as you say, do it carefully.