Simplified encapsulation of solar cells using glass fibre reinforced polymers

This paper presents a simplified method of solar cell encapsulation using glass fibre reinforced polymers (GFRP). The method investigated is focused on affordability, efficiency, the use of basic equipment and a fast turn around time for manufacture with basic skill requirements. The fast and inexpensive method was put to the test when a full scale, 6 m², solar array was implemented on a solar-powered electric vehicle. The method has been developed using half cells in raw form, assembled in uniform modules. A number of electrical, thermal and mechanical tests have been conducted to determine the comparative durability and output of the encapsulated cells prior to implementation on the solar vehicle. The tests aided in characterising the benefits of composites for this application, and ultimately to finalise the composite layup and tweak the process. Since then, the vehicle competed in the 2012 South African Solar Challenge (SASC), a biennial endurance event spanning 4900 km of South African roads over a period of two weeks. Exposed to ambient temperature variations of between 5 and 40 °C, rain, road vibration and shock from the odd pothole, the race proved to be an adequate test for the durability and reliability of the array. The method proposed in this paper could be used to encapsulate cells for other applications where a lightweight and inexpensive array is required, such as portable power generation.