Flexible Solar Panel Mounting Solutions

Flexible Solar Panel Issues

Flexible Solar Panels get hot

Solar panels get hot from normal operation upwards to 160ºF! The hotter they get, the less efficient, and the shorter their life span. Our flexible solar panel mounting solution using our twinwall polycarbonate solution solves this issue!

Flexible Solar Panel Crystals can Crack

Placing of a Solar Panel across Bimini or Dodger bows without additional support is not recommended by panel manufacturers. Doing so can crack the cell crystals leading to failure or even catch fire.

Additionally, when flexible solar panels that are affixed directly to canvas without support, oscillation induced by high winds causes is crystal cracking. Think of a flag flapping. How many times have you seen your Bimini flap during a summer squall, or frontal gale? That flapping is transferred directly to the flexible solar panel and subsequently causes crystal cracking. Our flexible solar panel twinwall polycarbonate mounting solution solves these issues!

Our Solution

Here at Potomac Sailmakers we are boaters first. We sat down with a major Flexible Solar Panel manufacturer and discussed the matter at the Annapolis Boat show last fall. The result was a design that meets the following specifications:

Is lightweight
Supports Flexible Solar Panels Across Bows
Provides cooling which increases efficiency and panel life longevity
Quickly removable
Secure in heavy wind and sea conditions
No Leaks
No Screw hole penetration through canvas
Makes handling and stowage safe (solar affixed to backer as “one” unit)
Modular
Provide Chafe Protection

Solar Panel Mounting Assembly

Meet the Potomac Sailmakers’ flexible Twinwall Polycarbonate bolt-on Flexible Solar Panel Mounting Kit. We are now entering our third year of providing this solution!

It starts with a vented lightweight & strong twinwall polycarbonate substrate that is custom cut to the exact dimensions of the Solar Panel.

It is affixed to the panel by mechanical and special high temperature adhesive tape. In essence it becomes a single solar panel assembly that is nearly impossible to “over flex” which would cause damage to the solar panel crystals.

Next we fabricate side rails for both “long” edges of the panel assembly. These serve the dual function of securing the unit to the canvas and providing chafe protection. The side rails are sewn to the canvas. The side rail rails wrap around the long edge of the panel assembly and are fastened to the edge solar panel assembly by mechanical snaps.

On both short edges, we fabricate screens which provide chafe protection and allow panel ventilated cooling while keeping small insects out of the air vents. This kit is offshore ready and strong enough to securely hold panels in gales, rough sea conditions, summer squalls. We use Top-Gun® fabric on the rails which provides excellent chafe and UV protection.

We previously had an off-shore and in-shore model, but decided to standardize on a design that can both handle off-shore gales and in-shore thunderstorm winds which can exceed hurricane force at times.

One of the great benefits of our system is that the solar panel assembly is quickly installable & removable by one person.

Here is a picture on an O’Day

Mounting Options:

1. Turnkey – Send us your Canvas and Solar Panel or drop both off at our loft and have us fabricate and sew the rail kit on. We will return it all and it is ready to install on your boat.

2. Our Kit, you sew – Since there are so many different sizes, panels and mounting considerations, this is not being offered as it takes too much time on our part and it is less expensive to simply have us do it all in our shop where we can control quality and ensure an exact fit.

3. DIY – This “non-sew-on” installation an be via a through-bolt kit such as is offered by Custom Marine Products or your own method. These use bolts to penetrate the canvas which can cause issues with the Bimini later on. It is also not easily removable (think hurricanes or winter layup) as our snap-on solution.

Other Options

Storage Bag – custom made storage bag for PSOLMA© when it is not mounted.

Batten supports – These are custom sized battens that go underneath the canvas and rest on top of the bows. They keep the panels from depressing the canvas thereby preventing pooling of water and associated debris and providing a more professional streamlined look. The battens are held in place by chafe resistant straps that wrap around the bows. The battens are strong laminated vinylester pieces with end caps that we also use on our small boat racing sails.