How To Make Solar Light Bulbs From Plastic Bottles

In today’s world, the importance of sustainability is widely recognized, leading more and more people to reduce their carbon footprint actively. Adopting an eco-friendly lifestyle has become crucial with growing awareness of our environmental impact.

One practical approach is repurposing materials that would otherwise end up in landfills. This blog post will explore the benefits of creating solar light bulbs from plastic bottles, offering a step-by-step DIY guide to embracing this eco-friendly and cost-effective solution.

What materials do you need to build a solar bottle bulb?

To construct a solar light bulb using a plastic bottle, you will require the following materials:

1. PET soda bottle: The PET soda bottle serves as the main component of the solar light bulb. It acts as a container and housing for the other materials and helps create a diffusion effect for the light emitted by the bulb.
2. Galvanized Iron (GI) sheet: The GI sheet creates a reflective surface inside the plastic bottle. It is cut and shaped to fit the inner surface of the bottle. The reflective surface helps maximize the light emitted by the bulb by reflecting and directing the light toward the desired area.
3. Epoxy or rubber sealant: Epoxy or rubber sealant secures the GI sheet inside the plastic bottle. It helps attach the reflective surface firmly to the inner surface of the bottle, ensuring it remains in place and doesn’t move around.
4. Bleach: Bleach removes any residue or impurities from the plastic bottle before starting construction. This helps ensure a clean and sanitary environment inside the bottle.
5. Filtered water: Filtered water fills the plastic bottle after construction. It acts as a medium through which sunlight can pass and get dispersed by the reflective surface. The water helps create a diffusion effect, enhancing the brightness and spread of the light emitted by the bulb.

10 Steps to assemble a solar light bulb:

Step 1: Cut a GI sheet

Create the reflective surface for the solar bottle bulb by accurately cutting the GI sheet to the specified size.

1. Measure and mark the GI sheet to a size of approximately 9 x 10 inches using a ruler or measuring tape.
2. Carefully cut along the marked lines using a pair of tin snips or metal shears. Take your time to ensure precise and clean cuts.
3. If you are using a corrugated GI sheet, align the cuts with the corrugations. If you use a flat GI sheet, maintain a rectangular shape while cutting.
4. Double-check the dimensions of the cut GI sheet to ensure it fits properly inside the plastic bottle.

Step 2: Mark and cut a circle on the GI sheet

Next, you will need to accurately mark and cut the circles on that GI sheet:

1. Place the GI sheet on a clean, flat surface, ensuring it is secure and stable.
2. Locate the center of the GI sheet. You can measure and mark the halfway point on the sheet’s length and width, then draw a small cross where the lines intersect.
3. Using a compass or a round object with a diameter similar to the soda bottle’s circumference, position the compass’s center at the marked center of the GI sheet.
4. With the compass open to the desired radius, carefully draw the outer circle by rotating the compass 360 degrees while keeping the center fixed. This will create a circle that matches the circumference of the soda bottle.
5. Reduce the radius of the compass by approximately 1 cm to create the inner circle. Keep the center fixed and draw the smaller circle inside the previously drawn outer circle.
6. Once both circles are marked, take a pair of sharp scissors or tin snips and carefully cut along the line of the inner circle. Pay attention to maintaining the circular shape and make precise cuts.

Step 3: Create radial strips and bend them upwards

Starting from the inner circle you have cut, cut them radially with a 1 cm difference like strips, and then bend them upwards perpendicular to the GI sheet:

1. Locate the previously marked inner circle on the GI sheet.
2. Starting from the outer edge of the circle, use a sharp pair of scissors or tin snips to cut the circle’s center. Make the cut approximately 1 cm wide.
3. Repeat step 2 around the circumference of the inner circle, ensuring that each cut is evenly spaced and parallel to one another.
4. After completing the cuts, gently lift each strip and bend it upwards, perpendicular to the surface of the GI sheet. Use your fingers or a pair of pliers to help create the desired angle.
5. Continue this process until all the strips within the inner circle are cut and bent upwards.

Step 4: Create a slightly roughened surface on the soda bottle

To ensure optimal adhesion between the GI sheet and the soda bottle, you will need to prepare the surface of the bottle:

1. Select a piece of medium-grit sandpaper, preferably between 120 to 180 grit, to create the desired texture on the bottle’s surface.
2. Carefully hold the sandpaper and begin by lightly scratching the upper third portion of the PET bottle where the GI sheet will be placed. Use a circular or back-and-forth motion to ensure even coverage.
3. Apply moderate pressure while sanding to create a slightly roughened surface. This helps the epoxy or rubber sealant adhere better.
4. Pay close attention to the scratched area, ensuring it extends around the entire upper third portion of the bottle where the GI sheet will be attached. This provides sufficient surface area for the sealant to bond effectively.
5. After sanding, wipe the bottle surface with a clean cloth or tissue to remove any debris or dust particles.

Step 5: Attach the bottle to the GI sheet with rubber sealant

When you have both the bottle and radially cutten GI sheet ready, securely attach the bottle to the GI sheet:

1. Take the prepared GI sheet and carefully insert the soda bottle until it reaches the upper third portion. Ensure a snug fit between the bottle and the GI sheet.
2. Apply a generous amount of rubber sealant on the strips above the area where the bottle is inserted and around the area below. Use a rubber sealant applicator or a small brush for precise application.
3. Make sure to cover the strips completely with the rubber sealant, creating a thick and even layer. This will provide a strong bond between the GI sheet and the bottle.
4. Allow the rubber sealant to dry as per the manufacturer’s instructions. This usually takes a few hours, but waiting overnight for a fully cured bond is advisable.
5. During drying, ensure the bottle remains stable and upright to prevent any movement affecting the sealant’s effectiveness.

Step 6: Fill the soda bottle with filtered water and bleach

Filling the soda bottle with filtered water and bleach is vital to maintain a clean and hygienic environment, inhibit algae growth, and enhance light diffusion for optimal functioning of the solar bottle bulb as a sustainable light source.

1. Take the PET soda bottle that has been attached to the GI sheet and remove any existing cap or closure.
2. Fill the bottle with filtered water until it reaches the top, leaving a small gap to prevent overflow.
3. Add approximately 10 mL of bleach to the water. This is equivalent to about two capfuls, ensuring the proper concentration for disinfection.
4. Carefully cover the filled soda bottle with its original cap or closure, ensuring a tight seal to prevent leakage.
5. Gently shake the bottle to ensure the bleach is evenly distributed within the water.

Once you have completed the aforementioned steps, the solar bottle bulb is now prepared and ready for installation!

Install the solar bottle bulb into the roof:

To install the solar buttle bulb, it is recommended to install it in a suitable area that allows for maximum exposure to sunlight, such as the roof or an elevated position. Alternative locations may not provide the optimal conditions for harnessing solar energy and producing light.

Due to its design and intended purpose, the solar bottle bulb is primarily suitable for installation on roofs or overhead structures where it can capture sunlight effectively.

Step 7: Create a hole in the Roof

It is necessary to cut a hole into the roof to install the solar bottle bulb and apply rubber sealant around it.

1. Choose the ideal location on the roof where you want to install the solar bottle bulb. Ensure it is an area that receives ample sunlight throughout the day.
2. Measure the circumference of the soda bottle carefully using a measuring tape or ruler. This measurement will guide you in cutting the appropriate hole size on the roof.
3. Using a pencil or marker, mark the outline of the measured circumference on the roof. Double-check the markings to ensure accuracy before proceeding.
4. Wear appropriate safety gear, such as gloves and safety goggles, to protect yourself during cutting.
5. Carefully cut along the marked outline with a suitable cutting tool like a reciprocating saw or jigsaw, following a steady and controlled motion.
6. Take caution while cutting to avoid damaging any underlying structures, electrical wiring, or plumbing.
7. Once the cut is complete, inspect the hole to ensure it matches the bottle’s circumference and is free from any sharp or jagged edges.

Step 8: Place the solar bottle bulb into the hole

Gently and carefully position the solar bottle bulb inside the prepared hole. Ensure it is placed securely and fits properly within the opening.

1. Gently lower the solar bottle bulb into the hole on the roof, aligning it with the opening. Be cautious not to force or drop it, which may cause damage.
2. Check the alignment and positioning of the bulb within the hole. Make any necessary adjustments to ensure it is centered and level.
3. Press down firmly on the edges of the bulb to create a tight fit with the roof material. This helps secure the bulb and prevent any movement or dislodging.
4. Inspect the surrounding area to ensure no gaps or spaces between the bulb and the roof. If any gaps are present, apply additional sealant or adhesive to fill them and enhance the seal.
5. Test the stability of the bulb by gently applying pressure and ensuring it remains in position without any wobbling or shifting.

Step 9: Drill 4 holes on each side of the solar bottle bulb and apply rubber sealant

To ensure a secure and leak-free installation of the solar bottle bulb, it is crucial to focus on proper fitting and applying rubber sealant.

1. Select an appropriate drill bit size for the rivets and set up the Bosch Lithium-ion Cordless Drill or a compatible drilling tool.
2. Carefully drill four evenly spaced pins on each side of the solar bottle bulb, ensuring they align with the corresponding holes on the GI sheet. Take caution to maintain the structural integrity of the bulb and sheet.
3. Insert the rivets into the drilled holes on both sides of the bulb. Use a rivet gun or appropriate tool to secure the pins, ensuring they are tight and firmly holding the components together.
4. Apply rubber sealant generously on all sides of the GI sheet, covering the drilled holes and the rivets. Use a brush or applicator to spread the glue evenly and ensure it forms a complete seal. Pay special attention to the edges and corners to prevent any potential leakage.
5. Allow the rubber sealant to dry and cure entirely per the manufacturer’s instructions. This ensures a strong and durable seal that can withstand environmental factors.

Step 10: Apply rubber sealant to the bottle cap with a protective plastic tube

By placing a protective plastic tube over the bottle cap and applying rubber sealant, you can reinforce the seal and enhance the longevity of the solar bottle bulb. This additional measure ensures optimal protection and minimizes the risk of water penetration or damage.

1. Take a protective plastic tube that fits securely over the bottle cap. This tube protects against water infiltration and helps maintain the seal’s integrity.
2. Place the plastic tube over the bottle cap, ensuring it covers the cap completely. The tube should fit snugly and extend slightly beyond the cap’s edges.
3. Apply rubber sealant generously around the base of the plastic tube where it meets the bottle cap. Cover the entire junction to create a secure and watertight seal.
4. Smoothly out the rubber sealant using a tool or your finger, ensuring it is evenly distributed and forms a seamless seal. This will further enhance the protection against moisture and potential leaks.

Conclusion

By following these, you can create a solar light bulb using a plastic bottle as a sustainable light source for your outdoor space while reducing waste.

FAQ

You can also read the following:

1. How To Wash Cloth Using Solar Power
2. Best Solar Flood Lights with Motion Sensor
3. The Best Street Lights With Solar Panels You Can Buy
4. Solar Outdoor Pathway Lights: A Guide to the Best Brands and Options
5. Safe Indoor Cooking Without Electricity