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Ask an Expert Forum Repair Cracked Conductive Epoxy
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  • conductive epoxy
  • alta pv cells
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Repair Cracked Conductive Epoxy

ralphjy
ralphjy over 1 year ago

I'm currently working on a road test of an ADI Energy Harvesting Eval board kit.  I was experiencing a lot of intermittent readings from the PV cells and I noticed that they are mounted with what I believe to be conductive epoxy and that it was cracked all along one end.  Not sure why they used conductive epoxy - maybe the contacts aren't solderable.  

image

The good news is that Randall was able to get me a replacement board quickly (I mentioned it to him Saturday and had a replacement on Wednesday - amazing!! ) Relaxed.

This board is using Alta GaAs PV cells which are somewhat unique, so I thought that I'd ask if and how experienced users would repair this board.  I have no experience with conductive epoxy and it seems expensive to just try if you don't know what you're doing.  The material seems pretty conductive just probing the surface, so maybe just adding more epoxy along the surface would work?  Any recommendations for what brand to use?  I've seen single use stuff on Amazon that costs about $20 which is probably more than this board costs.

On a related note, does anyone know what happened to Alta?  They were acquired by Hanergy in 2013 and sounds like the US office might have been shut down in 2019.  Haven't been able to find specs on the cells used on this board.  It's possible they were only produced for demonstration purposes.  Randall is checking with his ADI contact.

TIA

Ralph

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Top Replies

  • ralphjy
    ralphjy over 1 year ago in reply to Gough Lui +7
    Thanks Gough Lui for the suggestion to use a clip. I printed a push on clothespin style clip and it is working well for testing.
  • ralphjy
    ralphjy over 1 year ago in reply to Gough Lui +3
    Here is the whole board. You can see the split plane - so the attach is on both ends. J4 is the cracked connection. I assume the solder mask is open under the epoxy. Maybe plated like J2 and J3 so the…
  • Gough Lui
    Gough Lui over 1 year ago in reply to ralphjy +2 suggested
    That's a lot clearer, thanks. I wonder if some PCB trace repair pen could fix it. Not cheap though ... and probably not a permanent repair. Seems like conductive epoxy isn't a good choice between rigid…
  • anniel747
    0 anniel747 over 1 year ago

    MasterBond is good. 

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  • Gough Lui
    0 Gough Lui over 1 year ago

    Hmm. I'm not sure how that's connected but I can't seem to see any traces. That epoxy may not be used for contacts ... or perhaps is it shorting together two cells in series. Hard to tell from the photo ... I thought the Alta cells were all connected from one side.

    Perhaps you can use a kind of conductive metal filler by packing it with graphite ...

    - Gough

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  • ralphjy
    0 ralphjy over 1 year ago in reply to Gough Lui

    Here is the whole board.  You can see the split plane - so the attach is on both ends.  J4 is the cracked connection.  I assume the solder mask is open under the epoxy.  Maybe plated like J2 and J3 so the copper doesn't oxidize before assembly.

    image

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  • Gough Lui
    0 Gough Lui over 1 year ago in reply to ralphjy

    That's a lot clearer, thanks.

    I wonder if some PCB trace repair pen could fix it. Not cheap though ... and probably not a permanent repair. Seems like conductive epoxy isn't a good choice between rigid to rigid connection - bending or differential thermal expansion and contraction would probably damage it over time.

    Perhaps clipping the broken side down using a bulldog clip and a piece of paper as an insulator to apply pressure evenly across the cell is a quick way to move forward with the minor loss of cell area due to shading ...

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  • anniel747
    0 anniel747 over 1 year ago in reply to ralphjy

    Proper epoxy is hard to damage, the cell would have cracked before the joint. 

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  • ralphjy
    0 ralphjy over 1 year ago in reply to anniel747

    The MasterBond product looks good, but their website indicates that it is not available for “personal use” applications.  I didn’t realize that their products were not available for retail sale.

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  • anniel747
    0 anniel747 over 1 year ago in reply to ralphjy

    There is also Chemtronics CircuitWorks that is available everywhere.

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  • ralphjy
    0 ralphjy over 1 year ago in reply to Gough Lui

    Thanks Gough Lui  for the suggestion to use a clip.

    I printed a push on clothespin style clip and it is working well for testing.  

    image

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