System and method for mobile solar generators

Features for a mobile solar generator. The system includes a deployable solar array using an actuator and torsion springs. The array can be locked into place after deployment. The array stows for transport of the system to remote locations. The solar panels of the array are unexposed when stowed, and secured into place using various locking mechanisms in both the stowed and deployed configurations. Tamper-resistant hardware is included in the solar array to prevent theft and damage.

BACKGROUND

Technical Field

The development relates to power generation, in particular to systems and methods for mobile solar-powered generators or “solar generators”.

Description of the Related Technology

Providing power to remote locations can enable life-sustaining and other vital systems. However, many remote regions in the world are without access to a standard energy grid and the power that comes from it. For example, it is expensive to run power lines from energy production factories to remote locations. There is therefore a need to provide power for remote and other locations.

SUMMARY OF CERTAIN INVENTIVE ASPECTS

The embodiments disclosed herein each have several aspects no single one of which is solely responsible for the disclosure's desirable attributes. Without limiting the scope of this disclosure, its more prominent features will now be briefly discussed. After considering this discussion, and particularly after reading the section entitled “Detailed Description,” one will understand how the features of the embodiments described herein provide advantages over existing systems, devices and methods for mobile solar power systems.

This section of the disclosure describes non-limiting examples of some embodiments. Other embodiments of the disclosed systems and methods may or may not include the features described herein. Moreover, disclosed advantages and benefits can apply only to certain embodiments and should not be used to limit the disclosure. The innovations described throughout this disclosure may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. Any of the below aspects can be combined with each other as suitable, and/or with any of the other features described in any of the sections herein. The present disclosure contemplates combining one or more features of each of the aspects in each and every suitable combination.

Described herein are features for mobile solar-powered generators or “solar generators.” The technology provides the necessary levels of efficient, sustained power supply along with the required safety and security needed in remote locations. Further, an economical and durable mechanical platform with mobility and secure storage capabilities is provided. The system includes solar panels that collect solar energy from the sun which are connected to power electronics, such as charge controllers and inverters to convert the energy to electrical power that is stored in batteries and used to run electrical components, for example to provide electrical power for lighting, well pumps, water treatment, and other systems in remote locations. The system includes a mobile platform, such as a trailer, for transport to and from remote locations. The mobility of the system allows for transportation over rough terrain and movement to where the power is needed on a daily, weekly or monthly basis. Various security and storage features of the system ensure the security, safety, and reliability of the unit, for example by mitigating risks of vandalism during transportation or storage. The solar panels deploy from a secure, protected, stowed configuration to a deployed configuration using spring-loaded hinges and other mechanisms. Some of the features of the system include a folding mechanism, solar panels that are secure and not exposed when stowed, solar panels that secure when deployed to prevent theft or damage, an integrated mobile platform, springs to offset the weight of the folding mechanism, a common hinge for both folding and tilting, and internal components such as the generator and others that are secured when the panels are deployed. Other features form part of this disclosure, as further described herein. Some of the prominent aspects are described below.

In one aspect, a mobile, solar-powered electrical generation system is described. The system comprises a mobile platform and a base. The mobile platform has two or more wheels and is configured to attach to a vehicle to tow the mobile platform. The base is carried by the mobile platform and comprises a closed volume enclosing power electronics, the base comprising a plurality of solar modules that at least partially form the closed volume. Each solar module comprises a base frame, two or more panel frames, and two or more solar panels. The base frame comprises frame members and sidewalls supported by the frame members, with each base frame supported by the mobile platform. The two or more panel frames are rotatably attached to each other and supported by the base frame. Each of the two or more solar panels is supported by a respective panel frame. The two or more panel frames are configured to rotate to deploy from a stowed configuration where solar energy collecting sides of the two or more solar panels are not exposed, to a deployed configuration where the two or more solar panels are exposed and form a planar solar array configured to collect solar energy from the sun. Each solar module is configured to connect with an other solar module to modularly expand the base to a desired size, with each base frame of each solar module supported by the mobile platform, and the two or more panel frames of each solar module forming a solar panel support frame that supports the planar solar array in the deployed configuration.

Various embodiments of the various aspects may be implemented. For example, the system may further comprise a primary hinge rotatably connecting first and second panel frames of the two or more panel frames to each other, and where the primary hinge also is rotatably connecting the solar panel support frame to the base such that the deployed planar solar array can rotate about the primary hinge relative to the base. The primary hinge may further comprise rigid arms extending away from the base and comprising openings therethrough, and a tube extending through the openings of the rigid arms, such that the rigid arms are rotatably mounted to the tube to connect the primary hinge to the base. The primary hinge may further comprise a plurality of brackets attached to opposing edges of the first and second panel frames with each bracket having an opening extending therethrough, where the tube extends through the respective opening of the plurality of brackets to rotatably connect the first panel frame to the second panel frame. The first bracket of the plurality of brackets may be attached to the first panel frame, a second bracket of the plurality of brackets may be attached to the second panel frame, and the first and second brackets may be offset from each other in a direction parallel to an axis of rotation of the primary hinge. The system may further comprise a secondary hinge rotatably connecting the second panel frame to a third panel frame of the two or more panel frames, the secondary hinge comprising a plurality of brackets and a tube, where the plurality of brackets are attached to opposing edges of the second and third panel frames and each bracket has an opening extending therethrough, and where the tube extends through the respective opening of the plurality of brackets to rotatably connect the second panel frame to the third panel frame. The system may further comprise a linear actuator attached to the base and to one or more panel frames of the two or more panel frames, the linear actuator configured to extend a selected distance to rotate the planar solar array about the hinge to a selected angle to face the sun. The system may further comprise a locking mechanism comprising a pin and first and second brackets extending from respective opposing edges of two adjacent panel frames of the two or more panel frames, the brackets having openings configured to align and to receive the pin therethrough to lock the position of the two adjacent panel frames relative to each other in the deployed configuration. The base may comprise three solar modules, and the two or more panel frames of each solar module may comprise two solar panels.

In another aspect a mobile, solar-powered electrical generation system is described. The system comprises a mobile platform, a base, and a linear actuator. The mobile platform comprises two or more wheels and is configured to attach to a vehicle to tow the mobile platform. The base is carried by the mobile platform and comprises a closed volume enclosing power electronics, with the base comprising a plurality of solar modules that at least partially form the closed volume, where each solar module is configured to connect with an other solar module to modularly expand the base to a desired size. Each solar module comprises a base frame, two or more panel frames, two or more solar panels, and a torsion spring. The base frame comprises frame members and sidewalls supported by the frame members, with each base frame supported by the mobile platform. The two or more panel frames are rotatably attached to each other and supported by the base frame to form a solar panel support frame, with at least one of the panel frames of the two more panel frames rotatably connected to the base about a hinge. Each of the two or more solar panels is supported by a respective panel frame of the two or more panel frames, where the two or more panel frames are configured to rotate to deploy from a stowed configuration where solar energy collecting sides of the two or more solar panels are not exposed, to a deployed configuration where the two or more solar panels form a planar array configured to collect solar energy from the sun. The torsion spring is connecting two adjacent panel frames of the two or more panel frames, with the torsion spring configured to bias the two adjacent panel frames into the deployed configuration. The linear actuator is attached to the base and to a panel frame of the two or more panel frames, with the linear actuator configured to extend a selected distance to rotate the planar array about the hinge to a selected angle to face the sun.

Various embodiments of the various aspects may be implemented. For example, the hinge may be a primary hinge rotatably connecting first and second panel frames of the two or more panel frames to each other, and where the primary hinge also is rotatably connecting the solar panel support frame to the base such that the deployed planar solar array can rotate about the primary hinge relative to the base, and the system may further comprise a secondary hinge rotatably connecting the second panel frame to a third panel frame of the two or more panel frames. The system may further comprise a capture device projecting outward from opposing edges of the two adjacent panel frames, where opposite ends of the torsion spring attach to respective captures devices of the two adjacent panel frames. The capture device may comprise a central catch and a retainer, the central catch having an opening therethrough, the retainer extending about the central catch, and where the opening of the central catch is configured to receive and secure an end of the torsion spring therein. The system may further comprise two or more protective sheets and electrical wiring. Each protective sheet may be affixed to a rear side of a respective panel frame of the two or more panel frames, where the two or more protective sheets are mounted with tamper-resistant hardware on the rear side of the respective panel frame that is opposite from the solar panel supported by the respective panel frame. The electrical wiring may electrically connect the solar panel to a charge controller and battery, the wiring routed between the protective sheet and the respective panel frame to prevent access to the wiring or to solar panel mounting hardware. The system may include a locking mechanism to lock the position of the two adjacent panel frames relative to each other in a planar configuration.

In another aspect, a mobile, solar-powered electrical generation system is described. The system comprises one or more solar modules. Each solar module comprises a base frame, two or more panel frames, two or more solar panels, and a primary hinge. The base frame comprises frame members and sidewalls supported by the frame members. The two or more panel frames are rotatably attached to each other to form a solar panel support frame and are supported by the base frame. The two or more solar panels are each supported by a respective panel frame, where the two or more panel frames are configured to rotate to deploy from a stowed configuration where solar energy collecting sides of the two or more solar panels are not exposed, to a deployed configuration where the two or more solar panels are exposed and form a solar array configured to collect solar energy from the sun. The primary hinge is rotatably connecting first and second panel frames of the two or more panel frames to each other, and the primary hinge also is rotatably connecting the solar panel support frame to the base such that the deployed planar solar array can rotate about the primary hinge relative to the base.

Various embodiments of the various aspects may be implemented. Each solar module may be configured to connect with an other solar module to modularly form a base of a desired size. The primary hinge may further comprise rigid arms extending away from the base frame and comprising openings therethrough, and a tube extending through the openings of the rigid arms, such that the rigid arms are rotatably mounted to the tube to connect the primary hinge to the base frame. The primary hinge may further comprise a plurality of brackets attached to opposing edges of the first and second panel frames and each bracket having an opening extending therethrough, where the tube extends through the respective opening of the plurality of brackets to rotatably connect the first panel frame to the second panel frame. A first bracket of the plurality of brackets may be attached to the first panel frame, a second bracket of the plurality of brackets may be attached to the second panel frame, and the first and second brackets may be offset from each other in a direction parallel to an axis of the tube. The system may further comprise a secondary hinge rotatably connecting the second panel frame to a third panel frame of the two or more panel frames, the secondary hinge may comprise a plurality of brackets and a second tube, where the plurality of brackets are attached to opposing edges of the second and third panel frames and each bracket may have an opening extending therethrough, and the second tube may extend through the respective opening of the plurality of brackets to rotatably connect the second panel frame to the third panel frame. The system may further comprise a linear actuator attached to the base frame and to one or more panel frames of the two or more panel frames, with the linear actuator configured to extend a selected distance to rotate the planar solar array about the primary hinge to a selected angle relative to the base frame.

In another aspect, a mobile, solar-powered electrical generation system is described. The system comprises a mobile platform, lockable lifting supports and a base. The mobile platform has two or more wheels and is configured to attach to a vehicle to tow the mobile platform. The lockable lifting supports are configured to raise the mobile platform into a raised configuration such that the two or more wheels do not contact the ground. The base is carried by the mobile platform and comprises a lockable closed volume enclosing power electronics, such as a charge controller, an inverter, and a battery, with the base comprising a plurality of solar modules that at least partially form the closed volume, where each solar module is configured to connect with an other solar module to modularly expand the base to a desired size. Each solar module comprises a base frame, two or more panel frames, two or more solar panels, and two or more protective sheets. The base frame comprises frame members and sidewalls supported by the frame members, with each base frame supported by the mobile platform. The two or more panel frames are rotatably attached to each other by one or more hinges and supported by the base frame. Each of the two or more solar panels is supported by a respective panel frame, where the two or more panel frames are configured to rotate via the one or more hinges to deploy from a stowed configuration where solar energy collecting sides of the two or more solar panels are not exposed, to a deployed configuration where the two or more solar panels form a deployed planar solar array configured to collect solar energy from the sun. The deployed planar solar array is rotatably connected to the base via the one or more hinges to allow the deployed planar solar array to rotate relative to the base. Each of the two or more protective sheets is affixed to a rear side of a respective panel frame of the two or more panel frames, where the two or more protective sheets are mounted with tamper-resistant hardware on the rear side of the respective panel frame that is opposite from the solar panel supported by the respective panel frame, and electrical wiring electrically connecting the solar panel to the generator and routed between the each protective sheet and the respective panel frame to prevent access to the wiring or to solar panel mounting hardware.

Various embodiments of the various aspects may be implemented. The one or more hinges may comprise a primary hinge rotatably connecting first and second panel frames of the two or more panel frames to each other, and the primary hinge may also be rotatably connecting the two or more panel frames to the base such that the deployed planar solar array can rotate about the primary hinge relative to the base. The primary hinge may further comprise rigid arms extending away from the base, where each rigid arm comprises a first opening therethrough, a plurality of first brackets attached to opposing edges of the first and second panel frames, where each first bracket comprises a second opening therethrough, and a first tube extending through the first and second openings. The one or more hinges may further comprise a secondary hinge rotatably connecting the second panel frame to a third panel frame of the two or more panel frames, with the secondary hinge comprising a plurality of second brackets attached to opposing edges of the second and third panel frames, where each second bracket comprises a third opening therethrough, and a second tube extending through the third openings. The system may further comprise a locking mechanism comprising a pin and first and second brackets extending from respective opposing edges of two adjacent panel frames of the two or more panel frames, with the brackets having openings configured to align and to receive the pin therethrough to lock the position of the two adjacent panel frames relative to each other in the deployed configuration. The system may further comprise a torsion spring connecting two adjacent panel frames of the two or more panel frames, the torsion spring configured to bias the two adjacent panel frames into the deployed configuration, and a linear actuator attached to the base and to one or more panel frames of the two or more panel frames, the linear actuator configured to extend to rotate the planar array about the one or more hinges in a first direction and to retract to rotate the planar array about the one or more hinges in a second direction opposite the first direction.

In another aspect, a mobile solar generator comprises a mobile platform, a base, a charge controller, an inverter, a battery, a solar panel support frame, one or more solar panels, a hinge, an actuator, and a lock. The mobile platform has tires for transportation of the system. The base is secured to the mobile platform and includes a secure volume for storing the charge controller, inverter, and battery therein. The frame includes two or more panel frames, that each support one or more of the solar panels, and that are rotatably attached to each other and configured to deploy from a stowed configuration where the solar panels are not exposed to a deployed configuration where the solar panels form a planar array configured to collect solar energy from the sun. The hinge comprises a torsion spring attached to two adjacent panel frames of the two or more panel frames and biases the panel frames toward the planar or partially deployed configuration. The actuator tilts the horizontal planar array at an angle with respect to gravity. The lock secures the deployed array in the deployed configuration.

In some embodiments, arms extend outward away from the base and rotatably receive a tube connected to the frame. The frame may rotate about an axis along the tube via the biasing force from the springs. The array may partially deploy to a flat, horizontal orientation. The lock, such as a locking pin, may be inserted through brackets that are rotatably connected to the tube and fixedly attached to adjacent panel frames to prevent relative rotation of adjacent panel frames. The actuator may be a linear actuator. The actuator may be a hydraulic manual linear actuator. Further locking devices may be included to secure the array in the stowed configuration and secure components stored within the base. Tamper-resistant hardware may be included in the panels to prevent theft and damage when in the stowed configuration.

DETAILED DESCRIPTION

The following detailed description is directed to certain specific embodiments of the development. Reference in this specification to “one embodiment,” “an embodiment,” “in some embodiments,” or similar phrases, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such phrases in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments necessarily mutually exclusive of other embodiments. Moreover, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but may not be requirements for other embodiments.

Various embodiments will now be described with reference to the accompanying figures, wherein like numerals refer to like elements throughout. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner, simply because it is being utilized in conjunction with a detailed description of certain specific embodiments of the development. Furthermore, embodiments of the development may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the invention described herein.

An embodiment of a mobile solar power generation system10, or solar generator, is shown and described with respect toFIGS. 1A-14C. In particular,FIGS. 1A-1Care various perspective views of an embodiment of the system10with solar panels110in a deployed configuration.FIGS. 2A-2Dare various views of the system10in a stowed configuration.FIGS. 3A-3F,FIGS. 4A-4C, andFIGS. 5A-5Dare various views of a solar module120used in the system10and shown respectively in stowed, partial deployed, and deployed configurations.

Further,FIGS. 6A-14Care various views of structures and components of the solar generator system10. In particular,FIGS. 6A-6Dare various views of a frame330for the solar module120having primary hinge arms334.FIGS. 7A-14Care various views of solar panel support frames and hinges used to support and deploy the solar panels110in the system10.

The system10is configured to supply power to both off grid and grid-tied systems. Power for the system10is provided by photo-voltaic solar panels110. The system10provides for simple and less expensive manufacturing of the parts and assembly and results in a robust, modular, and secure platform for providing power to remote locations. The power may be stored in one or more batteries for later use. In some embodiments, the system10may include electrical plugs or outlets for providing electricity to various electrical components, such as electrical devices, mobile phones, water treatment systems, etc.

The system10is towed by a mobile platform, such as the trailer400as shown inFIGS. 1A-2D, to the location of deployment. The trailer400includes a frame410that extends from a front end, configured for connecting to a vehicle, to a rear end to support the solar modules120. The trailer400includes tires420for mobility when being pulled by a vehicle. The trailer may include supports450for lifting the trailer400and tires420off the ground after the system10has been deployed to its destination. The supports450may include locking features to secure the system10off the ground and thereby prevent theft by prevention of towing the trailer400away. The locking features and supports450may include tamper-resistant hardware. The lifting supports450may selectively be raised and locked in position, for example hydraulically, mechanically, etc.

On the trailer400is affixed a base300made up of at least one, but typically multiple, solar modules, such as the three solar modules120,122,124in the embodiment described herein. Each solar module120is comprised of a at least partially enclosed base frame310, which holds the power electronics and is used to support a primary hinge230. The modules120connect together to form an enclosed volume, which may be continuous or portioned off by sidewalls312. Each solar module120is comprised of the base frame310, a portion of the primary hinge230and a portion of the solar panel support frame201. The base300can mount to the trailer400. In particular, the base300can be fixedly coupled to the frame410. The tires420can be mounted to the frame410. In some embodiments, the base300can be mounted opposite the tires420. The base300can be welded to the frame410. In some embodiments, the base300may be secured to the frame410using tamper-resistant hardware. The base300can be fixedly coupled to solar modules120,122,124. The base frames310can have frame members and sidewalls. The sidewalls can be supported by the frame members. The frame members can be supported by the trailer400and in particular by the frame410.

A solar array100is stowed on the system10with the panels110having the solar panel cells facing inward and not exposed to the outside. The solar array100deploys from the stowed configuration shown inFIGS. 2A-2D, to the deployed configuration shown inFIGS. 1A-1C, and can stow back from the deployed to the stowed configuration. The array100includes the solar panels110. As shown, there may be eighteen solar panels110, with six solar panels110per solar module120. There may be one or more solar panels supported by a single panel frame. As shown each panel frame supports two solar panels thereon. The solar panels110may deploy into six columns102,103,104,105,106,107as shown. There may be one, two, three, four, five, six, seven, eight, nine, or more columns. The panel frames110are each split into two groupings of solar panels per supporting panel frame210,212,214. In some embodiments, there may be one, two or more solar panels per panel frame210,212,214. The panel frames210,212,214define the three rows of solar panels110. In some embodiments, there may be one, two, three, four or more rows of solar panels. In some embodiments, the upper and lower panel frames210and214may be identical panel frames but oriented differently, to save on costs and simplify manufacturing.

A deployment system200deploys the array100. The deployment system200includes an actuator250, the primary hinge230, and the secondary hinge220. The system200may also include various locking features further described herein. The solar modules120each have three panel frames210,212,214(that together form part of the overall frame201) which rotate and stow such that the panels are secure and resistant to vandalism and defacing during storage and transportation. The top panel frame210orients the upper most panels110downward so that they are not exposed (cells not facing up) when the system10is in its folded configuration. The primary hinge230is used to rotate the lower panel frames214relative to the middle panel frames212. The secondary hinge220at the opposite side of the solar panel support frame201from the primary hinge230is used to rotate the top panel frames210relative to the middle panel frames212. The panel frames may be rotated inward to stow, our outward to deploy. By rotating inward, all panel frames210,212,214lay on top of one another for transportation and storage. This facilitates compactness and security of the mobile solar generators10for transportation and storage. By rotating outward, the panel frames form a planar array. The entire planar array can be rotated about the primary hinge230to orient the planar array as desired. The primary hinge230thus serves two rotation functions: rotating individual panel frames relative to each other, but also rotating the entire deployed planar array. The primary hinge230and secondary hinge220may have similar hardware for rotating the respective panels relative to each other, while the primary hinge230may have additional hardware to allow for rotation of the entire array, as further described herein.

The middle panel frame212is hingedly or rotatably attached to the lower panel frame214via the primary hinge230and hingedly or rotatably attached to the upper panel frame210via the secondary hinge220. In the stowed configuration, shown in FIGS.2A-2D, the panel frames210,212,214are folded together to form a flat “sandwich” orientation for a low-volume storage configuration.FIG. 4Ashows a partial deployed configuration of the panel frames210,212,214. During deployment, the lower panel frame214rotates outward from the middle panel frame212and then the upper panel frame210rotates outward from the middle panel frame212to the partial deployed configuration. In some embodiments, the upper panel frame210rotates outward from the middle panel frame212and then the lower panel frame214rotates outward from the middle panel frame212.

The system may include the primary hinge230rotatably connecting the first and second panel frames of the two or more panel frames to each other. The primary hinge230may also rotatably connect the solar panel support frame201to the base such that the deployed planar solar array can rotate about the primary hinge230relative to the base.

In the deployed configuration the solar energy collecting sides of the solar panels110are exposed. The solar panels can form a planar solar array when deployed. In the stowed configuration, the solar panels110face inwards. The inward facing panels110are thereby protected for transportation and storage. Each solar module120,122,124may be configured to connect with an other solar module120,122,124to modularly expand the base300to a desired size, with each base frame310of each solar module120,122,124configured to connect with an other base frame310of the other solar module120,122,124. The two or more panel frames of each solar module120,122,124may be configured to connect with respective panel frames of the other solar module120,122,124to form the solar panel support frame201that supports the planar solar array made up of the two or more solar panels of each solar module in the deployed configuration.

The actuator250tilts the deployed array100into the deployed orientation shown inFIGS. 1A-1C. As shown, there may be two actuators250. In some embodiments, there may be one, three, four or more actuators250. The actuator250tilts the solar panel support frames201. The actuator250is linearly actuated. The linear actuator250affixes to the base frame310of the module120on one end and the solar panel support frame201on the other end. The linear actuator250may be hydraulically, electrically, or manually actuated. A telescoping arm252is extended and retracted by the actuator250to respectively tilt and un-tilt the array100. As shown inFIG. 5B, the actuator250is connected to the base frame310via brackets320,322.

The actuator250may be installed on one or more of the modules120. The actuator250may be omitted from one or more modules120, for example if other means of tilting are provided or if the other panel frames provide the rotation. As shown, only the outer modules120have the actuator250installed, while the middle module120rotates along with the outer fame panels due to the mechanical connection of the frame members. Another example is if the system10comprised only two solar modules120. One of these solar modules120would include the actuator250or other tilting mechanism and the second module120would not require a tilting mechanism if the solar panel support frame is rigidly affixed to the first solar module120which includes the actuator250. This modularity allows for a reduction in cost due to the use of fewer tilting mechanisms when multiple solar modules120are used in a single system10. The actuator250used to raise and lower one end of the solar panel support frame201helps orient the solar panels110at an optimum angle of incidence with respect to the sun to improve solar panel energy capture efficiency. The use of two hinges220,230to connect the three panel frames210,212,214together reduces fabrication complexity.

The primary hinge230supports the folding solar panel support frame201. As shown inFIGS. 4A-4C, the primary hinge230includes a tube234rotatably mounted to rigid arms334which are oriented downward (toward the base frame310) to connect the hinge230to the solar module120between the solar panel support frames212,214. The arms334include projections336extending away from the frame330with circular retainers338on the end thereof, as shown inFIG. 6E. The tube234extends through openings of the retainers338. The projections336may have a length configured to rotate the panel frame214on top of the stowed panel frames210,212. Brackets232having openings211and215, for respectively panel frames210and214, are rotatably attached to ends of the tube234and fixedly attached to the frame212,214. The brackets232may be offset laterally from each other to avoid interference when the panels rotate. “Lateral” may refer to a direction parallel to the axis of rotation, which may be a central axis defined by the tube234. For example, as shown inFIG. 5C, a first bracket232A of the plurality of brackets232may be attached to the first panel frame210, a second bracket232B of the plurality of brackets232may be attached to the second panel frame212, and the first and second brackets232A,232B may be laterally offset from each other in a direction parallel to an axis of rotation of the primary hinge230. Similarly, as shown inFIGS. 4B, 4C, and 5D, a first bracket232A of the plurality of brackets232may be attached to the second panel frame212, a second bracket232B of the plurality of brackets232may be attached the third panel frame214, and the first and second brackets232A,232B may be offset from each other in a direction parallel to an axis of rotation of the primary hinge230. A pin213may be inserted through a diameter at the ends of the tube234to axially restrain the tube234in place.

This orientation allows the solar panel frame201to pivot around the hinge230and also tilt when the system10is deployed. The solar panel support frame201holds at least one, but typically multiple, solar panels110. The primary hinge230defines the axis around which the deployed solar panel support frame201tilts in order to place the panels at an angle to face the array at the sun based on the geographical latitude and time of year of the solar installation. In some embodiments, the tube234can be sized to correspond to the total length of the assembled modules.

The brackets232may connect to edge frame members217, as shown inFIGS. 8B and 8C. There may be four frame members217that form an outer perimeter of the panel frame212. The frame members217may be metallic and extend along edges of the panel frame212. The frame members217may support a panel, protective sheet, etc. The frame members217may extend beyond the edge of an adjacent frame member, as shown inFIGS. 8B and 8C. The brackets232may be positioned on inner (FIG. 8B) and outer (FIG. 8C) sides of the frame member217. The panel frames210,214may include the frame members217and brackets232as described, as well. Adjacent panel frames, for example panel frames210and212, or panel frames212and214, may have opposing brackets232laterally offset to accommodate rotation of each bracket relative to each other. For example, the bracket232on the upper end of the frame member217of the panel frame212may be located on the outer side of the frame member217, while the opposing bracket232on the lower end of the frame member217of the panel frame214may be located on the inner side of the frame member217of the panel frame214, etc.

The panel frames may include central frame members218, for example as shown inFIG. 7Bwith respect to panel frame214. The frame member218may extend between edge frame members217along the length of the panel frame214. The frame member218may have similar features as the frame member217except for its location. The frame member218may extend beyond the ends of adjacent frame members217, as shown in FIG.7B. The protruding end of the frame member218may attach to the bracket232, which may be laterally offset from a bracket232on the opposing panel frame212. Similar arrangements of the central end edge frame members may be included for the panel frames210and212.

The one or more modules120,122,124may connect together to form a base of a desired size. This allows for customizing the amount of solar energy collected and corresponding amount of electrical power produced for a given application. The tube234may extend continuously through each primary hinge230of the plurality of solar modules. As shown, for example inFIG. 2B, a single, long tube234extends through the primary hinges of the solar modules120,122,124. Similarly, an additional tube234extends through the secondary hinges of the solar modules120,122,124. Each solar module120,122,124may have a larger-diameter tube into and through which the tube234extends.

In some embodiments, there may be separate tubes234for each solar module. For example, the ends of the tubes234in the primary and secondary hinges230,220may connect to adjacent end brackets232, such as the bracket232A shown inFIGS. 4B and 4C. The pin213may secure adjacent tubes234together. The end of one of the tubes234may have a relatively larger width and receive therein the other tube234having a relatively smaller width, with the pin213rotatably securing the tubes234together. In some embodiments, a fitting may connect the ends off the tubes234together.

The individual solar modules120,122,124may be deployed and stowed independently of each other. For example, the base frames310may be connected together, but the panel frames of a first base frame310may not be connected to the panel frames of an adjacent base frame310. Thus the solar panels on each base frame310may be deployed and stowed independently of each other.

In some embodiments, adjacent panel frames may stow and deploy together. The panel frames may be connected along the length of the frame edges that are adjacent each other. For example, opposing edges of adjacent panel frames210,210at the upper part of the array (e.g. shown inFIG. 1A), may attach together at one or more locations along the opposing edges. In some embodiments, the upper most opposing edges of edges of the frames210may connect together and lower most opposing edges of the frames214may connect together. The edges may connect similarly to the tubes234that connect at the hinges220,230, as described. Brackets, fittings, or other suitable mechanical attachments may be used as well.

In some embodiments, the hinges220,230may support the respective panel frames210,212,214in a planar orientation for a given solar module. For example, the module120may include supports at the hinges220,230to support the panel frames210,212,214of that module120in a planar orientation. There may be hard stops preventing rotation of the panel frames210,212,214beyond a planar configuration. The modules122,124may have similar features. The hinges220,230may support the weight of the deployed panel frames such that attachments of the panel frames to each other may not be necessary except at the hinges220,230, as described.

The base frames310may attach to each other to form the base300. As shown inFIG. 1C, each base frame310may include frame members311and sidewalls312. The frame members311may frame the base frame310and support the sidewalls312. There may be multiple edge frame members311along the edges of the base frame310. There may be one or more central vertical frame members311supporting the sidewalls312between the edges. The sidewalls312may be located on the top, bottom, and/or sides of the base frame310. Some of the sidewall312are removed in the figures for clarity. The sidewalls312may completely enclose the base frame310to prevent access therein. In some embodiments, adjacent sidewalls312of adjacent base frames310may be removed to create a continuous inner volume of the base300. The base frame310may also include central longitudinal frame members, as shown inFIG. 6A.

The base frames310may be welded or bolted together. The frame members311may be welded or bolted together. The base frames310may share frame members311to rigidly affix the modules120,122,124together. A single frame member311may extend across two or more base frames310. The panel frames may be connected at their rotational axis by way of the tube234which extends through all of upper or lower panel frame brackets232. The panel frames may be connected with the tube234extending inside an axis tube of each module. The upper and lower panel frames may only be connected at the hinges230,220. Each of the three modules may open and close independently.

In some embodiments, the base frames310may be connected together by the tubes234extending between the respective hinges220,230. The base frames310may be supported by the mobile platform and only connected by the tubes234.

The primary and secondary hinges230,220include torsion springs236. There are four springs236per hinge, as shown. There may be one, two, three, five or more springs236per hinge. The springs236are used to offset the weight of the solar panel support frame201to provide assistance in opening and closing. The torsion springs236are affixed to panel frames210,212,214that are adjoined by way of the hinges220,230. A capture device238connects to ends of the torsion spring236. The capture device238projects outward from opposing outside surfaces of opposing panel frames. As shown inFIG. 7B, the capture device238includes a central catch237surrounded by two retainers239. The catch237receives therein and fixedly attaches to an end of the spring236. There are two capture devices238for each spring236. The capture device238may connect to edge frame members217of the panel frame214. There may be three capture devices238along an edge of the panel frame214. The panel frames210,212may include similar arrangements of the capture devices238thereon. The torsion springs236installed between the panel frames210,212,214provide rotational biasing forces which counteracts the weight of gravity of the solar panels110and support frame201. This makes the system10easier and faster to deploy and stow. The torsion springs236can be arranged to store energy. The torsion springs236can be arranged to release energy as the panels are rotated. The force exerted by the torsion springs236can tend to lift the panels frames210,212,214. The torsion springs236can bias two adjacent panel frames into a deployed configuration.

All solar panel wiring is protected from external vandalism by routing it through the panel frames201and/or metal conduit. When the panel frames210,212,214are opened to the deployed position (solar panels all facing outward), they are locked into place by a locking mechanism240(shown inFIGS. 4A-5D) to avoid inadvertent closing or excessive vibration from weather. The locking mechanism240includes a pin that extends through an opening in the bracket232to prevent relative rotation between adjacent panel frames. The pin can extend through two or more openings, each opening fixed to a different panel frame. When the panel frames210,212,214are folded into the stowed position (solar panels not exposed outward) they are locked into place by mechanical means to prevent tampering, theft, and vandalism. As shown inFIG. 2C, the panel frames may be locked in the stowed position using aligned lugs having openings therethrough. A first lug may extend from a first panel frame and a second lug may extend from a second panel frame, with openings in the lugs aligning and configured to receive a pin therethrough to lock the panel frames together. A padlock or other lock may secure to the pin to prevent removal of the pin.

The power electronics are secured inside the enclosed base300by way of locking doors313. (For clarity, some of the doors313and walls312of the base300are removed inFIG. 1B.) The power electronics may include: solar charge controller(s)350, batteries360, and/or other components such as inverter(s), supporting wiring and electronics, etc. The enclosed base300can be formed from one, two or more base frames310. The base frames310can have locking door313on one or more exterior sides. The number and location of locking doors313on the base frame310can vary between various modules. For example, a central module, such as module104may have a single locking door313. The locking door313can be positioned on either side of the module104. The module104can have multiple locking doors. The outer modules102and106can have locking doors313on one, two or three sides. The outer modules102and106can have one or more locking doors313.

Each of the modules102,104, and106can have one or more open sections. The open sections can be positioned adjacent when the enclosed base300is assembled. The assembled solar modules can form a partly (e.g., completely) closed volume. This volume can be accessible through the locking doors313. The locking doors313can be positioned around the perimeter of the closed volume.

The number of modules used can be varied during assembly. The inner modules can have a first configuration. For example the inner modules may have one locking door313. The outer modules can have a second configuration. For example, the outer modules could have one or more (e.g., two) locking doors313and an actuator250.

Each solar module, such as the depicted solar modules102,104, and106is configured to connect with one or more other solar modules. Assembling the modules can include welding, riveting, mechanical fasteners and other means of fastening. The base frames310of the solar modules can be affixed to the adjacent base frame(s)310of other modules. Solar panel support frames201can be affixed to adjacent panels.

As shown inFIG. 6A, the base frame310may include central longitudinal frame members311B. The base frame310may be framed by the members311,311A, and311B. The members311,311A, and311B may be welded together or attached together using fittings or other attachments. The base frame310is shown without any sidewalls312for clarity. Adjacent members311of adjacent base frames310may connect together to form the base300. Various fittings, brackets, or other suitable mechanical attachments may be used to connect adjacent base frames310. The members311A and/or311B of adjacent base frames310may also attach to each other.

A protective sheet117of material (metal in this embodiment) is affixed to the rear121of the solar panel support frame201by way of tamper-resistant hardware113, shown inFIG. 14B. This protective sheet117is installed to protect the back side of the solar panels110. The purpose of this sheet117is to make access to the solar panel wiring and solar panel mounting hardware difficult. This will reduce risk of theft and vandalism of the panels and wiring. The sheet117may be installed using numerous tamper-resistant hardware113as shown inFIG. 14A. The hardware113may include non-standard screws or bolts in an attempt to deter access. The hardware113may be bolts with 5-sided heads, or a standard Torx screw head made in a tamper-resistant form with a pin in the center. The sheet117can be supported by the solar panel support frame201, such as by the edge and central panel frame members. Electrical wiring, for example wiring connecting the solar panel110to a charge controller and routed between the protective sheets117and the respective panel frames201, can prevent access to the wiring. The power inverter, or inverter, may be a power electronic device or circuitry that changes direct current (DC) to alternating current (AC). The inverter may be used to convert battery power into alternating current. A charge controller may be included having instructions stored on a non-transitory computer readable medium that, when executed by a processor, controls the solar power collection process such as charging of the batteries.

As shown inFIG. 13C, the sheet121may be connected to the panel frame210, such as to the frame member217, via the clip118. The clip118may be L-shaped and attach the sheet121to the frame member217. A fastener119may be used to secure the clip119to the sheet121. The clip119may secure to the sheet121and/or to the frame member217via mechanical attachment, adhesive, friction fit, or other suitable means. Multiple such clips119may be used along the outer edges of the sheet121. Such arrangements may be used for the panel frames212,214as well.

Some uniquely desirable features of the system10include portability, security and robust design. A multitude of solar panels are folded into a thin, flat space. There are no exposed wires that can be easily pulled or cut with a knife. The solar panels are enclosed in the hard solar panel frame201and protected from exposure to weather, vandalism and theft during transportation and storage when not deployed. When the system is deployed, the protective sheeting117is used to hinder access and reduce risk of theft of the solar panels. The system10may be used by towing the system to a remote site, lifting the wheels off the ground to prevent theft, tilting the solar array(s) using the linear actuator(s), deploying the lower solar panel(s) using the primary hinge(s), deploying the upper solar panel(s) using the secondary hinge(s), turning on the power electronics, collecting solar energy, converting and storing the energy in batteries, and/or providing electrical power to one or more electrical devices. The steps may be carried out in a variety of orders, and some steps may be omitted. For example, the solar panels may be unfolded first, and then the planar array tilted. Or the upper solar panels may be deployed prior to the lower panels, etc.

Thus, any method sequences are illustrative only. A person of skill in the art will understand that the steps, decisions, and processes embodied in the flowcharts described herein may be performed in any suitable order other than that described herein. Thus, the particular methods and descriptions are not intended to limit the associated processes to being performed in the specific order described.

While the above detailed description has shown, described, and pointed out novel features of the invention as applied to various embodiments, it will be understood that various omissions, substitutions, and changes in the form and details of the device or process illustrated may be made by those skilled in the art without departing from the spirit of the invention. As will be recognized, the present invention may be embodied within a form that does not provide all of the features and benefits set forth herein, as some features may be used or practiced separately from others. The scope of the invention is indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

All numbers expressing quantities of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding approaches. For example, terms such as about, approximately, substantially, and the like may represent a percentage relative deviation, in various embodiments, of ±1%, ±5%, ±10%, or ±20%.

The above description discloses several methods and materials of embodiments of the present invention. Embodiments of this invention are amenable to modifications in the methods and materials, as well as alterations in the fabrication methods and equipment. Such modifications will become apparent to those skilled in the art from a consideration of this disclosure or practice of the invention disclosed herein. Consequently, it is not intended that this invention be limited to the specific embodiments disclosed herein, but that it cover all modifications and alternatives coming within the true scope and spirit of the invention as embodied in the attached claims.