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Step 5Preparing Glass (Amorphous) Cells
I received a surplus glass cell with instructions on how to use copper mesh
to make a connection to the glass cell. The glass cell was pre-scratched in
the area where the mesh and wires were supposed to go. But... even with
the copper mesh, it didn't stick. It was doable, but hard to do, and not very
strong. All the wires pulled off. Some of you may have had success with
using copper mesh soldered to scratched areas of glass cells, but there is an
easier way.
Perhaps you have a broken / damaged glass cell. You may still be able to use it,
unless the damage has made the glass transparent, in which case there is severe
damage to the photovoltaic part of the cell.
One interesting thing about the glass cells. Looking at them, you see lines, just
as you may on "broken" or "crystalline" cells, but those lines are not current-
collecting conductors. They are gaps between areas of the glass cell that each
make about half a volt. So, glass cells can be expected to have 2 lines for every
volt of output. And they can make 6 or 9 or 12 or 20 volts.
So, we want to connect the wires to places with the most amount of lines between them
to get the highest voltage. And out the wires on the silver side, of course.
Scratch the silver (probably aluminum) near the edges and test the voltage and polarity,
for your information. I usually use a red wire for Plus and a black or green for Negative.
Easy connection method:
You need two brass extrusions, carefully cut with a dremel (safety goggles!),
and wires soldered on this side of the extrusions ---> C
The extrusion must have enough space inside it for the glass cell to fit.
The extrusion is then crushed a little (before putting it on the glass)
so that it will bite the glass with some pressure and make contact with the scratched edge.
Slide the crushed extrusion onto the glass. If it's too crushed it won't go on, so pry
it open. If it's not crushed enough it falls off, so crush it more. When it bites, and
there is voltage in the light across the two extrusions, put stickytape or
just a little plastic cement over the extrusion to help it stay there.
The Glass cell is now ready to use.
The long one shown is actually two 9-volt ones on one glass, and is the one
that I put extruded contacts on because the copper mesh wouldn't stick..
to make a connection to the glass cell. The glass cell was pre-scratched in
the area where the mesh and wires were supposed to go. But... even with
the copper mesh, it didn't stick. It was doable, but hard to do, and not very
strong. All the wires pulled off. Some of you may have had success with
using copper mesh soldered to scratched areas of glass cells, but there is an
easier way.
Perhaps you have a broken / damaged glass cell. You may still be able to use it,
unless the damage has made the glass transparent, in which case there is severe
damage to the photovoltaic part of the cell.
One interesting thing about the glass cells. Looking at them, you see lines, just
as you may on "broken" or "crystalline" cells, but those lines are not current-
collecting conductors. They are gaps between areas of the glass cell that each
make about half a volt. So, glass cells can be expected to have 2 lines for every
volt of output. And they can make 6 or 9 or 12 or 20 volts.
So, we want to connect the wires to places with the most amount of lines between them
to get the highest voltage. And out the wires on the silver side, of course.
Scratch the silver (probably aluminum) near the edges and test the voltage and polarity,
for your information. I usually use a red wire for Plus and a black or green for Negative.
Easy connection method:
You need two brass extrusions, carefully cut with a dremel (safety goggles!),
and wires soldered on this side of the extrusions ---> C
The extrusion must have enough space inside it for the glass cell to fit.
The extrusion is then crushed a little (before putting it on the glass)
so that it will bite the glass with some pressure and make contact with the scratched edge.
Slide the crushed extrusion onto the glass. If it's too crushed it won't go on, so pry
it open. If it's not crushed enough it falls off, so crush it more. When it bites, and
there is voltage in the light across the two extrusions, put stickytape or
just a little plastic cement over the extrusion to help it stay there.
The Glass cell is now ready to use.
The long one shown is actually two 9-volt ones on one glass, and is the one
that I put extruded contacts on because the copper mesh wouldn't stick..
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