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Step 2Assembling the Cells
In this step we're going to cut out the aluminum electrode and construct the cells which will be used to provide power.
Each cell contains a sandwich composed of an aluminum foil electrode, a porous non-conductive layer (we use paper towels but almost any material may be used) and a carbon electrode.
As noted in the bill of materials almost any non-conductive shallow container may be used, so I measured the bottom of my pans and cut an electrode from the foil, leaving a significant lead approximately 1" wide and several inches long (see picture). This is folded over the end of the pan and is used to secure the lead cable for the cell.
In my case the pans measured 6"x10" across the bottom so I chose to make the foil electrode 5" wide and 9" long with a 1" lead to be trimmed after assembly . Then I cut out the porous layer from the paper towels and made them 5.5"x9.5" long. This insures that the foil will never come into direct contact the carbon brush and short out the power supply.
Even though the lid was slightly larger than the two bottom pieces I chose to keep the same dimensions in all cells. With the same surface area and electrolyte concentration each cell should produce approximately the same output.
I found it easiest to layout the electrode on the foil with a ball point pen and ruler then carefully tear the foil along the edge of the ruler. Alternatively scissors can be used to cut out the final shape. Make sure the power lead is long enough to reach easily over the edge of the pan and bend over the lip to firmly secure the foil. If using the ruler method always place the ruler so that it protects the electrode portion during the tear.
Once the foil has been cut out assemble the cells by placing the aluminum foil in the bottom anchored to one edge by the foil lead which is gently formed around the lip. Place an insulating layer of paper towel on top of the foil so that it is completely covered. Place one of the Fluval carbon filters on top of the paper towel and the cell assembly is complete.
In a later step we will wire these cells in series and charge them using a saltwater electrolyte.
For now let's set these aside and turn out attention to solar powered yard light and its mysterious inner workings....
Each cell contains a sandwich composed of an aluminum foil electrode, a porous non-conductive layer (we use paper towels but almost any material may be used) and a carbon electrode.
As noted in the bill of materials almost any non-conductive shallow container may be used, so I measured the bottom of my pans and cut an electrode from the foil, leaving a significant lead approximately 1" wide and several inches long (see picture). This is folded over the end of the pan and is used to secure the lead cable for the cell.
In my case the pans measured 6"x10" across the bottom so I chose to make the foil electrode 5" wide and 9" long with a 1" lead to be trimmed after assembly . Then I cut out the porous layer from the paper towels and made them 5.5"x9.5" long. This insures that the foil will never come into direct contact the carbon brush and short out the power supply.
Even though the lid was slightly larger than the two bottom pieces I chose to keep the same dimensions in all cells. With the same surface area and electrolyte concentration each cell should produce approximately the same output.
I found it easiest to layout the electrode on the foil with a ball point pen and ruler then carefully tear the foil along the edge of the ruler. Alternatively scissors can be used to cut out the final shape. Make sure the power lead is long enough to reach easily over the edge of the pan and bend over the lip to firmly secure the foil. If using the ruler method always place the ruler so that it protects the electrode portion during the tear.
Once the foil has been cut out assemble the cells by placing the aluminum foil in the bottom anchored to one edge by the foil lead which is gently formed around the lip. Place an insulating layer of paper towel on top of the foil so that it is completely covered. Place one of the Fluval carbon filters on top of the paper towel and the cell assembly is complete.
In a later step we will wire these cells in series and charge them using a saltwater electrolyte.
For now let's set these aside and turn out attention to solar powered yard light and its mysterious inner workings....
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