Patent Publication Number: US-11381197-B2

Title: Modular solar power array

Description:
RELATED APPLICATIONS 
     This a continuation of U.S. patent application Ser. No. 16/677,589 filed Nov. 7, 2019 which is a non-provisional patent application claiming priority from U.S. Provisional Patent Application Ser. No. 62/756,867 filed Nov. 7, 2018, both of which are incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1) Field of the System 
     This invention is directed to a modular solar power array providing for swappable portable power units, solar generators, and existing circuit integrations. 
     2) Description of the Related Art 
     With the renewed effort to provide renewable energy, there has been much research into solar cells. Much progress has been made in increasing the efficiency of solar cells and decreasing the cost of production. With these improvements, there is an increasing use of solar cells for converting solar energy to electrical energy. However, there is much improvement needed to apply this power to multiple settings. 
     Solar power is a clean form of energy that is natural, renewable, and free. Using a transportable solar system allows you to deliver power to remote locations without sacrificing electrical items such as emergency equipment, fridges, lights, mobile devices and more. Additionally, eliminating the need for a generator removes the need for fuel, noise and significantly reduces costs. There have been attempts to provide for portable and transportable power supplies, but none at these attempts include the ability to have a base charge for sustained charging of a load, a set of portable power units that, when combined, provide aggregated power with removable portable power units from the set for deployed power supplies. These attempts include U.S. Pat. Nos. 5,522,943, 5,969,501 and 8,203,237 as well as United States Patent Application Publications 20050093514, 20080029153, 20090127933, 20110176256, 20120187761, 20120202094 and 20120205975. 
     It has been reported that when a natural disaster occurs, electricity is typically the first important service to be lost, which can have a devastating impact for days, weeks, or even months. Without electricity, many of our most basic needs go unfulfilled (e.g., power for homes, hospitals, food storage, heating) and emergency response teams cannot offer proper assistance. Traditional generators are used but suffer from the need to use fuel which is not readily available as fuel vehicles cannot transport fuel to the areas in timely fashion. Additionally, communication systems cease operations making relief and assistance even more challenging. 
     It is therefore an object of the present system to provide for a modular system for providing power using a base power storage, portable power units, solar power input, capacitors, and AC and/or DC output. 
     It is another object of the present system to provide power using a mobile platform to deploy power to remote locations or when power is unavailable such as with natural disasters. 
     It is another object of the present invention to provide portable renewable energy prior to regaining transitional power and to assist in providing clean drinking water, medical facilities, and communications. 
     BRIEF SUMMARY 
     The above objectives are accomplished by providing a system that is a scalable modular solar power array comprising: a solar panel; a solar power controller in communications with the solar panel configured to convert a first voltage to a second voltage; a DC to AC converter in communications with the solar power controller; a power input switch connected to the DC to AC converter and an external power source configured to switch between AC power from DC to AC converter and external power; a bus connected to the power input switch; a portable power unit connected to the bus, connected to a data network and connected to a power out bus; and, a load connected to the power out bus. 
     The modular solar power array system can include a mobile platform; a solar array carried by the mobile platform, connected to a distribution hub adapted to provide power to a base power source; an input controller having input computer readable instructions adapted to deliver power to a set of storage units from the base power source, the set of storage power units carried by the mobile platform; an output controller connected to the set of storage units having output computer readable instructions adapted to receive charge requirements from a load connected to the output controller, retrieving from a device lookup table included in the output controller a load type having charge specifications, and delivering power to the load according to the charge specifications; and, an external power source connected to the distribution bus for proving power to the base power source from the external power source. 
     The input computer readable instructions can be adapted to deliver power to a storage unit in the set of storage units according to the current charge of the storage unit. The solar power array can include a set of solar panels hingeably attached to each other having a retracted position and a deployed position. The solar power array can include a lowered position and a raised position. A port panel can be attached to the mobile platform. The set of storage units can include a portable power unit. The set of storage units can include a set of base power units, a set of delivery units and a set of portable power units. The output controller can be adapted to deliver power to an electrical junction box. 
     The system can be a modular solar power array comprising: a solar array connected to an input controller to provide power to a base power source; a set of storage units connected to the input controller adapted to receive power from the base power source to charge the set of storage units; a set of capacitors connected to the input controller adapted to receive power from the base power source to charge the set of capacitors; an output controller connected to the set of storage units and the set of capacitors for providing power to a load in electrical communications with the output controller; and, a portable power unit included in the set of storage units that are removably connected to the input controller and the output controller. 
     Output computer readable instructions can be included in the output controller adapted to receive charge requirements from a load connected to the output controller, retrieving from a device lookup table included in in the output controller a load type having charge specifications, and delivering power to the load according to the charge specifications. The system can include an external power connection adapted to connect an external power source to the set of storage units and the set of capacitors. The base power source can be a set of base power units. Input computer readable instructions can include in the input controller adapted to delivery power to a storage unit in the set of storage units according to the storage unit charge to provide for charge balancing across the set of storage units. A primary power unit can have primary power unit computer readable instructions adapted to determine the power level of a secondary storage unit in the set of storage units and direct power to the secondary storage unit when the secondary storage unit power level is below a predetermined level. 
     The system can include a mobile platform; a solar array carried by the mobile platform; and a set of capacitors in electrical communications with the solar array for receiving power from the solar array to charge the set of capacitors; and a port panel in electrical communications with the set of capacitors adapted to connect to a load to deliver power from the set of capacitors to the load. A base power source can be in electrical communications with the solar array and the set of capacitors and adapted to receive power from the solar array and delivery power to the set of capacitors. A set of storage units can be in electrical communications with the solar array for receiving power from the solar array to charge the set of capacitors and to deliver power to a load. The mobile platform can be a trailer having a solar panel support for supporting the solar power array wherein the solar power array includes a set of solar panels hingeably attached to each other having a retracted position, a deployed position, a lowered position and a raised position. An output controller can be connected to the set of capacitors having output computer readable instructions adapted to receive charge requirements from a load connected to the output controller, retrieving from a device lookup table included in the output controller a load type having charge specifications, and delivering power to the load according to the charge specifications. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The construction designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein: 
         FIG. 1  is a schematic of aspects of the system; 
         FIG. 2  is a schematic of aspects of the system; 
         FIG. 3  is a schematic of aspects of the system; 
         FIG. 4  is a schematic of aspects of the system; 
         FIG. 5  is a schematic of aspects of the system; 
         FIG. 6A  is a side view of aspects of the system; 
         FIG. 6B  is a top view of aspects of the system; 
         FIG. 7A  is a rear view of aspects of the system; and, 
         FIG. 7B  is a top view of aspects of the system. 
     
    
    
     DETAILED DESCRIPTION 
     With reference to the drawings, the system will now be described in more detail. Referring to  FIG. 1 , a solar power source such as a solar array  10  that can be one or more solar panels providing electrical energy. The solar panels of the solar array can be affixed to a structure such as a building roof, stand alone or portable. The solar array can be attached to a controller  12  that can transform the energy provided by the solar array to different voltage. For example, the solar array can convert produced 12-volt power to 48-volts. The solar power controller can be connected to a DC to AC converter  14  providing for the energy provided from the solar array to be converted into an alternating current. The DC to AC converter can be connected to a power input switch  16 . The power input switch can be attached to an external power source such as AC source  18 . The external power source can be the traditional electrical grid. The power input switch can include a power input controller that can be configured to allow power from the DC to AC converter, external power source or a combination thereof, to pass through to input power bus  20 . 
     Portable power unit  21  can be connected to the power in bus to receive power from input power bus  20 , which can charge the portable power unit. An example of a portable power unit is shown in U.S. Pat. Nos. 9,865,903 and 10,084,213 and U.S. application Ser. No. 16/110,947 incorporated by reference. Multiple secondary portable power units  22   a  through  22   d  can also be attached to input power bus  20  to receive power. Reserve portable power unit  24   a  through  24   c  can also be attached to input power bus  20 . The portable power units can be attached to the power in bus so that portable power unit  21  is first in line in the circuit and therefore would have the least amount of resistance on the power in bus. The portable power unit with the least amount of resistance can be designated the primary portable power unit. 
     The portable power units can include communication ports allowing data communications between the portable power units over data network  26  which can include data hub  28 . The data network can also include transceivers included in the portable power units and wireless communications between the portable power units. The portable power units can be hot swappable on and off the power bus or otherwise swappable on and off the mobile platform and its components. When removed, the portable power unit can separately be attached to an external power source such as solar panels, AC power, DC power, battery, generator, and the like. A shelf or other support unit can be used to support the portable power units and can include electrical contacts which engage with electrical contacts on the portable power unit when the portable power unit is placed on the storage unit, the storage unit contacts engage with the portable power supply contacts and provide power to the portable power unit. Therefore, a portable power unit can be removed from the power in bus and used to provide power to a location remote from the power in bus. The storage unit can include a storage unit controller configured to determine the primary portable power unit, detect the presence of a portable power unit on contacts, activate the contacts when a portable power unit is present or any combination. The storage unit controller can be in communications with the portable power units and the power input switch. The storage unit controller and the power input switch can cooperate to vary the power provided to the portable power units connected to the power in bus. 
     The portable power unit controller can be configured to determine the primary portable power unit. The primary portable power unit can be configured to determine the power level of each of the other portable power units in the data network. If a secondary portable power unit in the data network is lower than a level determined by the primary portable power unit, the primary portable power unit can instruct the secondary portable power units to charge. The primary portable power unit can balance the charging across the secondary portable power units. 
     Referring to  FIG. 2 , the portable power units can provide power to various loads individually or collectively. The portable power units can be connected to a power out bus  30 . The portable power units can be hot swappable on and off the power out bus. If a secondary portable power unit is removed from the bus, the primary portable power unit can be informed and power from the remaining secondary portable power units can be delivered to the power out bus. If the primary portable power unit is removed, the next inline secondary portable power unit can assume the role of the primary portable power unit. 
     The system can include an external power controller  32  in communications with the portable power units. The external power controller can be configured to allow power to be delivered to a load, such as to a junction box  34 , from an external power source  18 , from the solar array  10 , from the portable power units, individually, in combination, in series or in parallel, or any combination thereof. In the example of the junction box  34 , the junction box can be included in a circuit  36 . The circuit can include outlets, switches, and lights. When the external power controller prevents external power from entering the junction box, circuit  36  is unpowered. When unpowered, one or more portable power units can be connected to the circuit, such as by plugging the portable power unit into an outlet as shown by direct connection  38 , to provide power to the circuit resulting in an “off the grid” power supply for the one or more circuits. Therefore, this system can be configured to have solar power, external AC power, portable power supply power or any combination thereof. 
     Referring to  FIG. 3 , an example of a portable power unit  40  is shown. The enclosure  42  can include an interface plate  44  with various output and input connectors which can include AC power, DC power and varying voltages and amps. A battery module  46 , fan  48 , transformer  50  for AC to DC, DC to AC, voltage, or amperage changes, display  52  and portable power unit controller  54  that can be in electrical communications in the enclosure. The enclosure can include a handle  56  and supports  58 . Status indicators  60 , such as lights, can be included. A door panel can cover the interface plate. 
     Referring to  FIG. 4 , a solar array  10  and external AC power source  18  can be connected to a controller  12 . The controller can be connected to an AC output  62  and a DC output  64 . The controller can be connected to a power bus  66  that can be connected to a storage unit such as portable power unit  21 . The controller can include computer readable instructions that can determine if an AC load or a DC load  67  is connected and based upon the power requirements of the load, draw power from one or more storage units according to the load. A device lookup table can us used to determine the amount of power to draw from the storage units and deliver to the load. For example, if the controller determines that the load is drawing 1 amp and about 5 volts, the controller can use this information, access a device lookup table, and determine that the device is likely a smartphone. A smartphone with a depleted battery can charge in about an hour with a 1 amp, 5-volt charge course. Therefore, the controller can deliver 1 amp and 5 volts to the load for an hour at which point saturation can be reached such as when voltage peaks and the current decreases. At that point, the controller can deliver a topping charge after a certain period of time such as after 3 hours and occasionally apply the topping current until the load is removed. If the controller determines that the load is drawing 1 amp and about 10 volts, the controller can use this information, access a device lookup table, and determine that the device is likely a tablet. A laptop can be as high as 25 volts. By understanding the load charge specifications, the controller can deliver the appropriate power to the load, avoid unnecessary power delivery, extend the life of the storage units, and prolong the time the system can delivery power. 
     The portable power units can be designed in sets. A set of base power units  68  can be used to receive charging power from the controller and delivery Charing power to other storage units such as  70 . One or more units from a set of delivery units  72  can be used delivery power to a load. A set of portable power units  74  can be removably connected to the power bus  66 . A unit in the set portable power units can also be included in the base power set or the delivery set. A portable power unit  76  can be connected to the power bus by direct connection, cable, contacts, or induction. Wireless power transfer (e.g., induction, wireless power transmission, wireless energy transmission, or electromagnetic power transfer) allows for the transmission of electrical energy without a physical connection. A transmitter device can be connected to the power bus to generate a time-varying electromagnetic field, which transmits power across space to a portable power unit. The portable power unit extracts power from the field and can eliminate the use of the wires. 
     Referring to  FIG. 5 , a solar array  10  can be connected to a distribution bus  78 , The distribution bus can include computer readable instructions for determining the input power and the amount of solar power to distribute to a base power storage system  80 . The base power storage can be a pennant power storage system such as batteries that is fixed in position. The base power storage is charged from the solar array  10  or can be charged with another external source such as AC power from a grid, generator, or other source. The base power storage can be connected to a power input controller  82  that can include computer readable instructions for delivering power to one or more storage units or portable power units  21  through a power bus  66 . The amount of power that is delivered to a storage unit can depend upon the charge of the storage unit. Storage units with less charge can be charged first so that the charge is balanced among the storage units in the set of storage units. The storage units can be connected to an output controller  84  which can be attached to a load  67 . The input controller can also provide power to one or more capacitors  86 . The capacitors can also be super capacitors, so that charging time is significantly reduced. A set of capacitors can be used that include AC capacitors, DC capacitors or a combination so that the load attached to the set of capacitors can receive AC or DC power. External AC or DC power  18  can be connected to the output controller to the distribution bus so that the base power storage, storage units, capacitors or output controller can receive power from the external power source. 
     Referring to  FIGS. 6A and 6B , the power system can be placed on a mobile platform  88  such as a trailer. The trailer can support storage units or portable power units  90 , base power source  92  and capacitors  94 . The storage units, base power source and capacitors can be placed in water resistant or waterproof containers carried on the trailer. The weight of the components on the trailer can be positioned so that approximately 60% of the weight is loaded on a front portion of the trailer and the remaining weight should be disposed on and behind one or more axles. 
     A solar panel support  96  can be carried by the trailer and support one or more solar panels of a solar array  10 . A port panel  98  can provide power output and input ports and be disposed under a cover  100  that can pivot upwards for access. 
     Referring to  FIGS. 7A and 7B , a solar array  10  can be carried by the trailer and include a set of solar panels. The solar array can have a retracted position where the solar panel array is lowered reducing the height of the system for transportation. The solar panel array can be raised upward above the trailer allowing sufficient clearance between the solar panel array and the trailer bed for access to the components carried by the trailer including the base power source, storage units, capacitors, and controllers. The solar panels of the solar panel array can be joined by hinges  102  allowing the solar panels to be deployed increasing the amount of light that can breach a solar panel. A first solar panel  104   a  can be support by standard allowing the first solar panel to be raised and lowered. A second solar panel  104   b  can be hinged to one side of the first solar panel and be retracted ( FIG. 7A ) or deployed ( FIG. 7B ). A third solar panel  104   c  can be hinged to one side of the first solar panel and be retracted ( FIG. 7A ) or deployed ( FIG. 7B ). When deployed the solar panel array can be raised to provide clearance under the solar panel array and increase the power available to the various components from solar power. Further, the weight distribution above and the lowered solar panel array improves the performance of the trailer when in motion. 
     The storage units, delivery units, base power source, capacitors, output controller can include outputs such as AC, DC, USC, batter connectors, USB-C and the like. 
     The portable power unit controller can include a computer readable medium having computer readable instructions. Various aspects described herein are directed to different methods, systems, and computer programs and instructions relating the utility and communications of the system. The portable power units can act as nodes to a network and communicate between the nodes. A microphone, speaker and display included in the portable power unit can allow users to communicate between the various portable power units. The reserve portable power units can be kept charged and in reserve conversion to a primary or secondary portable power unit or used remotely. The portable power unit controller can include a transmitter, receiver or transceiver and send information, such as status information, to another device. For example, a portable power unit can send a low power warning to a smart phone, or other receiving device notifying that the portable power unit should be charged, replaced, or otherwise attended. 
     It is understood that the above descriptions and illustrations are intended to be illustrative and not restrictive. It is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims. Other embodiments as well as many applications besides the examples provided will be apparent to those of skill in the art upon reading the above description. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventor did not consider such subject matter to be part of the disclosed inventive subject matter.