PORTABLE SOLAR PANEL SYSTEM ELECTRICAL CONTROL

BACKGROUND

A solar panel is a packaged assembly of photovoltaic cells. Solar panels use light energy (e.g., photons) from the sun to generate an electric current via the photovoltaic effect. A solar panel is typically used to generate and supply electricity to a load device or system. Solar panels are an environmentally-friendly alternative to other sources of energy such as coal, oil, or gasoline. Portable solar panels may be used in place of traditional portable power supply devices (e.g., generators, batteries).

SUMMARY

One exemplary embodiment relates to a solar panel assembly. The solar panel assembly includes a solar panel and an output module. The solar panel includes a plurality of solar cells configured to absorb light energy from a light source to generate electrical power. The output module has an input interface electrically coupled to the plurality of solar cells and an output interface configured to at least one of power and charge a load device. The output module is configured to provide an output power having an output current and an output voltage at the output interface. The output module includes a processing circuit configured to control the output voltage based on a maximum available power associated with the plurality of solar cells.

Another exemplary embodiment relates to an output module for a portable solar panel. The output module includes an input interface, an output interface, and a processing circuit. The input interface is configured to engage with an output of the portable solar panel to receive an input electrical power having an input voltage and an input current. The output interface is configured to engage an input of a load device and provide an output electrical power having an output voltage and an output current. The processing circuit is configured to (i) monitor at least one of the input electrical power, the input voltage, the input current, the output electrical power, the output voltage, and the output current, (ii) determine whether the load device has stopped charging based on a change in the at least one of the input electrical power, the input voltage, the input current, the output electrical power, the output voltage, and the output current, and (iii) stop providing and thereafter again provide the output electrical power to the load device in response to determining that the load device stopped charging.

The invention is capable of other embodiments and of being carried out in various ways. Alternative exemplary embodiments relate to other features and combinations of features as may be recited herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

FIG. 1 is a front perspective view of a solar panel assembly, according to an exemplary embodiment;

FIG. 2 is a cross-sectional view of the solar panel assembly of FIG. 1, according to an exemplary embodiment;

FIG. 3 is another front perspective view of the solar panel assembly of FIG. 1, according to an exemplary embodiment;

FIG. 4 is a perspective view of the solar panel assembly of FIG. 1 in a folded configuration, according to an exemplary embodiment;

FIG. 5 is a rear perspective view of the solar panel assembly of FIG. 1, according to another exemplary embodiment;

FIG. 6 is a rear plan view of the solar panel assembly of FIG. 1 with an output module, according to an exemplary embodiment; and

FIG. 7 is a schematic diagram of the output module of the solar panel assembly of FIG. 1, according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Conventional solar panels may operate as a static source of power without a system that (i) balances load power to available power (ii) restarts the flow of energy in response to a load device stopping an acceptance of power due to a temporary voltage drop, and/or (iii) communicates available power and output power to an end-user. Some large, commercial scale solar panel systems employ Maximum Power Point Tracking (“MPPT”) algorithms to optimize available solar energy, but these implementations typically exist as a stand-alone charge controller designed for a specific battery chemistry. Some portable solar panels implement a feature which attempts to restart the flow of energy to a device that has stopped charging due to a temporary low voltage condition by periodically disabling and enabling the output, irrespective of whether power is actually being transferred to the load, resulting in an unnecessary interruption in the power supply. While dedicated solar meters are available for measuring available power, these devices typically require a dedicated solar cell and display to communicate this information. The data from such devices is not precisely representative of the power at a panel, and traditional devices therefore provide at best an approximation of the solar power available at the desired panel.

In one embodiment, the method and the system of the present disclosure optimize the relationship between incoming solar energy and an end-user device through several methods. The method and system may employ an algorithm to balance outgoing power with available power by (i) measuring environmental conditions and (b) maximizing available energy (e.g., by attempting control of the load device, etc.). The method and system may monitor and control the outgoing power in order to ensure a load device continues to accept energy after a condition occurs which temporarily interrupts the power. The method and system may improve the user experience with a photovoltaic power source by measuring incident solar energy as well as outgoing power and providing the information to an end-user. The user may use employ this information to orient the panel for increased (e.g., maximum, etc.) energy reception.

According to the exemplary embodiment shown in FIGS. 1-5, a solar panel assembly, shown as solar panel assembly 10, is configured to generate electrical power from incident light. The generated electrical power may be provided to at least one of charge and power a load device (e.g., a phone, a tablet, a computer, a portable and rechargeable battery pack, etc.). In one embodiment, the solar panel assembly 10 is configured (e.g., arranged, sized, etc.) to provide an output power of up to 7 watts (“W”). In another embodiment, the solar panel assembly 10 is configured to provide an output power of up to 14 W. In other embodiments, the solar panel assembly 10 is configured to provide still another output power (e.g., 10 W, 20 W, etc.). The power output of the solar panel assembly 10 may be related to a surface area thereof and/or a relative orientation between the solar panel assembly and a light source (e.g., the sun, etc.). According to an exemplary embodiment, the solar panel assembly 10 is lightweight and portable.

As shown in FIGS. 1-3, the solar panel assembly includes a first surface, shown as front surface 12, and an opposing second surface, shown as rear surface 14. The front surface 12 is separated from the rear surface 14 by a thickness of the solar panel assembly 10, according to an exemplary embodiment. The solar panel assembly 10 has a first edge, shown as bottom edge 16, an opposing second edge, shown as top edge 18. The bottom edge 16 is separated from the top edge 18 by a height of the solar panel assembly 10, according to an exemplary embodiment. As shown in FIGS. 1 and 3, the solar panel assembly 10 has a first end, shown as left end 22, and an opposing second end, shown as right end 24. The left end 22 is separated from the right end 24 by a width of the solar panel assembly 10, according to an exemplary embodiment. As shown in FIGS. 1 and 3, the bottom edge 16, the top edge 18, the left end 22, and the right end 24 define a generally-rectangular shape of the solar panel assembly 10. In alternative embodiments, the solar panel assembly 10 is otherwise shaped (e.g., square, circular, hexagonal, etc.). As shown in FIGS. 1 and 3, the solar panel assembly 10 defines an axis, shown as axis 20. The axis 20 is vertical and equidistantly positioned between the left end 22 and the right end 24, according to an exemplary embodiment. According to an exemplary embodiment, the axis 20 divides the solar panel assembly 10 into a first side, shown as left side 26, and a second side, shown as right side 28.

According to the exemplary embodiment shown in FIGS. 1-3 and 5, the solar panel assembly 10 is constructed of multiple layers. As shown in FIGS. 1-3, the solar panel assembly 10 includes a first layer, shown as cover layer 30. As shown in FIG. 2, the solar panel assembly 10 includes a second layer, shown as solar cell layer 40. As shown in FIGS. 1 and 3, the solar cell layer 40 includes a plurality of solar cells 46 arranged into a first solar panel, shown as left solar panel 42, and a second solar panel, shown as right solar panel 44. According to an exemplary embodiment, the solar cells 46 are configured to receive and convert solar power (e.g., light energy, etc.) from a light source (e.g., the sun, etc.) to generate electrical power. A third layer, shown as structural layer 50, is provided as part of the solar panel assembly 10, according to an exemplary embodiment. According an exemplary embodiment, the structural layer 50 includes a printed circuit board (“PCB”). The PCB may include a substrate (e.g., a non-conductive substrate, etc.) configured to mechanically support the solar cells 46. The PCB may also electrically couple the solar cells 46 (e.g., using conductive tracks, pads, and/or other features etched or otherwise formed into sheets that include copper or another material laminated onto the substrate, etc.). As shown in FIG. 2, the solar panel assembly 10 includes a fourth layer, shown as cover layer 60. As shown in FIGS. 2 and 5, the cover layer 60 is disposed along the structural layer 50.

As shown in FIG. 2, an adhesive layer, shown as adhesive layer 32, is disposed between the cover layer 30 and the solar cell layer 40. The adhesive layer 32 couples the cover layer 30 and the solar cell layer 40. As shown in FIG. 2, an adhesive layer, shown as adhesive layer 34, is disposed between the solar cell layer 40 and the structural layer 50. The adhesive layer 34 couples the solar cell layer 40 and the structural layer 50. As shown in FIG. 2, an adhesive layer, shown as adhesive layer 36, is disposed between the structural layer 50 and the cover layer 60. The adhesive layer 36 couples the structural layer 50 and the cover layer 60.

As shown in FIGS. 1 and 3-5, the solar panel assembly 10 defines a plurality of apertures, shown as through holes 98. Solar panel assembly 10 may be supported using (e.g., hung by, etc.) and/or support other devices (e.g., provide a hanging point for, etc.) using the through holes 98. By way of example, the through holes 98 may facilitate coupling the solar panel assembly 10 to a backpack, belt, or other structure (e.g., using a clasp, rope, a zip-tie, etc.).

As shown in FIG. 4, the solar panel assembly 10 is selectively reconfigurable (e.g., foldable, etc.) about the axis 20 into a folded orientation. In one embodiment, the left end 22 of the left side 26 and the right end 24 of the right side 28 of the solar panel assembly 10 meet when the solar panel assembly 10 is arranged into the folded orientation. The foldable solar panel assembly 10 may be stored in smaller areas and/or more easily transported by a user (e.g., carried, etc.) relative to traditional solar panel assemblies.

According to the exemplary embodiment shown in FIGS. 3 and 5, the solar panel assembly 10 includes a module, shown as module 70. The module 70 may be configured to support the solar panel assembly 10. As shown in FIG. 5, the module 70 includes a support, shown as kickstand 80. In one embodiment, the kickstand 80 includes a storage compartment, shown as storage pocket 90. The kickstand 80 is rotatably coupled to a base portion of the module 70, according to an exemplary embodiment. The kickstand 80 may thereby pivot away from the rear surface 14 to adjust an angle at which the solar panel assembly 10 is oriented. According to an exemplary embodiment, changing the orientation angle of the solar panel assembly changes (e.g., increases, decreases, etc.) the intensity of the solar energy incident upon the solar panel assembly 10. In some embodiments, the kickstand 80 is vented. Such venting may facilitate heat transfer (e.g., convective heat transfer, etc.) from a device (e.g., a load device, etc.) disposed within the storage pocket 90. As shown in FIG. 5, the storage pocket 90 is partially defined by a mesh layer 92 coupled to a backing plate of the kickstand 80. The mesh layer 92 and the backing plate of the kickstand 80 define a cavity therebetween. According to an exemplary embodiment, a load device (e.g., a phone, a battery pack, etc.) may be disposed within the cavity of the storage pocket 90. The mesh layer 92 provides ventilation through the cavity and thereby reduces the risk of overheating the load device. The storage pocket 90 is closable using a fastener, shown as zipper 94. The zipper 94 is configured to facilitate accessing the cavity defined between the kickstand 80 and the mesh layer 92. In other embodiments, another type of fastener is provided (e.g., hook and loop fasteners, magnets, etc.) to facilitate selectively closing the storage pocket 90.

According to the exemplary embodiment shown in FIGS. 6-7, the solar panel assembly 10 includes an output, shown as output 100, coupled to an output module, shown as output module 110. The output 100 is configured to couple the output module 110 to the solar cells 46 of the solar panel assembly 10, according to an exemplary embodiment. The output module 110 may couple a load device 160 (e.g., a smartphone, a cell phone, a rechargeable battery pack, a tablet, a personal computer, a laptop, a smartwatch, etc.), to the solar panel assembly 10. In an alternative embodiment, the output 100 is configured to directly couple the load device 160 to the solar panel assembly 10 (e.g., bypassing the output module 110, in embodiments where the solar panel assembly 10 does not include the output module 110, etc.). In some embodiments, the output 100 and/or the output module 110 are disposed within the cavity of the storage pocket 90.

As show in FIG. 6, the output 100 includes a module, shown as panel module 102, that is coupled to the output module 110 with a cable, shown as cable 104. The panel module 102 is configured to couple the output module 110 to the solar cells 46 of the solar panel assembly 10, according to an exemplary embodiment. In one embodiment, the cable 104 is hard wired into the panel module 102. In other embodiments, the cable 104 is removably coupled to the panel module 102 (e.g., with corresponding male and female connectors, etc.). As shown in FIG. 6, the cable 104 is coupled to the output module 110 with a connector, shown as output connector 106. In one embodiment, the cable 104 is configured to couple the panel module 102 with the output connector 106. The output connector 106 may be configured to couple the panel module 102 to at least one of the output module 110 and the load device 160.

As shown in FIGS. 6-7, the output module 110 includes an input, shown as input interface 112, and an output, shown as output interface 114. According to an exemplary embodiment, the output connector 106 includes a male connector (e.g., a barrel plug, etc.), and the input interface 112 includes a female connector configured to interface with and receive the output connector 106. In an alternative embodiment, the output connector 106 includes a female connector and the input interface 112 includes a male connector. According to an exemplary embodiment, the output interface 114 includes a female connector. In one embodiment, the female connector of the output interface 114 is a female USB interface configured to receive a male USB connector (e.g., of a charging and/or power cable for the load device 160, etc.). In an alternative embodiment, the output interface 114 is a male connector (e.g., a lightning connector, a 30-pin connector, a micro USB, a mini USB, etc.).

The output module 110 may thereby be detachably coupled to the solar cells 46. The output module 110 may receive power from the solar cells 46 and at least one of power and charge the load device 160 (e.g., coupled to output interface 114, etc.). Solar panel assembly 10 having an output module 110 that is releasably coupled to the panel module 102 may be upgraded (e.g., with new and/or redesigned output modules 110, etc.) by unplugging the existing output module 110 and replacing it with a different output module 110. In an alternative embodiment, the cable 104 is hard wired to the output module 110. In another alternative embodiment, the output module 110 is coupled to and/or integral with the module 70 (e.g., disposed within a cavity positioned behind the kickstand 80, etc.).

As shown in FIGS. 6-7, the output module 110 includes a display, shown as display 116. According to an exemplary embodiment, the display 116 is configured to indicate the intensity of the solar energy incident upon the front surface 12 of to the solar panel assembly 10 (e.g., providing a power flow indicator, etc.). According to another embodiment, the display 116 is configured to indicate the available input power associated with the solar cells 46. According to still another embodiment, the display 116 is configured to indicate the current draw associated with the load device 160. According to an exemplary embodiment, the display 116 includes a plurality of LEDs. By way of example, as the solar intensity increases, the number of LEDs of the display 116 that illuminate may increase, providing an indication as to the intensity of solar energy incident upon the solar panel assembly 10. In an alternative embodiment, the display 116 is or includes a digital display or any other type of display that provides an indication of the solar intensity and/or other information (e.g., current draw, input power, etc.). According to an exemplary embodiment, the display 116 is positioned such that a user of the solar panel assembly 10 may see the intensity of the incident solar energy and reorient the solar panel assembly 10 (e.g., rotate the solar panel assembly 10, adjust the angle of the kickstand 80, change the panel-to-sun placement, etc.) to achieve a maximum power output from the solar panel assembly 10.

As shown in FIG. 7, the output module 110 includes a regulator, shown as switching regulator 118. The output module 110 includes a communication device 120, according to the embodiment shown in FIG. 7. As shown in FIG. 7, the output module includes a processing circuit 130. An input current sensor 150 (e.g., positioned to monitor a current of the electrical power provided to the output module 110 from the solar cells 46, etc.), an input voltage sensor 152 (e.g., positioned to monitor a voltage of the electrical power provided to the output module 110 from the solar cells 46, etc.), an output current sensor 154, and an output voltage sensor 156 are provided as part of the output module 110, according to the embodiment shown in FIG. 7. In other embodiments, the output module 110 includes a different combination of sensors and/or still other types of sensors. In still other embodiments, the output module 110 includes a combination of electrical components (e.g., diodes, resistors, capacitors, etc.) that replace and/or supplement at least one of the switching regulator 118, the communication device 120, the processing circuit 130, the input current sensor 150, the input voltage sensor 152, the output current sensor 154, and the output voltage sensor 156.

According to an exemplary embodiment, the switching regulator 118 is configured to regulate (e.g., change, increase, reduce, decrease, throttle, etc.) at least one of an output voltage and an output current provided by the output module 110. By way of example, the output module 110 may provide an output power (e.g., having the output voltage and/or the output current, etc.) to the load device 160. According to an exemplary embodiment, the switching regulator 118 is configured to buck (e.g., reduce, decrease, throttle, etc.) the output voltage (e.g., via pulse width modulation (“PWM”), etc.) of the output power provided by output module 110 to a target voltage (e.g., 5 Volts, etc.). In one embodiment, the output module 110 is configured to buck the output voltage (e.g., with the switching regulator 118, etc.) an amount that varies as a function of the input power (e.g., the electrical power provided to the output module 110 from the solar cells 46, etc.). By way of example, the processing circuit 130 may monitor an available input power and regulate the output voltage as a function of the available input power.

According to an exemplary embodiment, the solar cells 46 of the solar panel assembly 10 are at least one of configured and arranged to produce an input voltage of up to approximately 12 Volts. In one embodiment, the output module 110 is configured to provide an output of 5 Volts, corresponding with the standard voltage of USB connections. According to an exemplary embodiment, the switching regulator 118 is configured to receive the 12 Volt input from the solar cells 46 and reduce, decrease, throttle, etc. the 12 Volts to 5 Volts such that the 5 Volts may be provided to the load device 160 (e.g., via the output interface 114, etc.). In other embodiments, the output module 110 does not include the switching regulator 118 and/or the switching regulator 118 is configured to not buck the input voltage (e.g., in all instances, etc.). Such an output module 110 may provide an output voltage that is substantially the same as the input voltage (e.g., 12 Volts, etc.).

In one embodiment, the switching regulator 118 of the output module 110 is configured to regulate the output voltage to a target voltage level. In one embodiment, the processing circuit 130 is configured to determine the target voltage level based on the available input power. The available input power may vary with the electrical current and voltage provided to the input interface 112.

According to an exemplary embodiment, the input current sensor 150 is configured to acquire input current data relating to the electrical current provided to the input interface 112 of the output module 110 by the solar cells 46 (e.g., monitor an input current of an electrical power provided to the output module 110 from the solar cells 46, etc.). According to an exemplary embodiment, the input voltage sensor 152 is configured to acquire input voltage data relating to a voltage provided to the input interface 112 of the output module 110 by the solar cells 46. The processing circuit 130 may calculate the amount of electrical power generated by the solar cells 46 (i.e., from solar energy) using the input current data and the input voltage data. According to an exemplary embodiment, the output current sensor 154 is configured to acquire output current data relating to a current provided by the output interface 114 of the output module 110 to the load device 160. According to an exemplary embodiment, the output voltage sensor 156 is configured to acquire output voltage data relating to a voltage provided by the output interface 114 of the output module 110 to the load device 160. The processing circuit 130 may calculate the amount of electrical power provided by the output interface 114 (e.g., to the load device 160, etc.) using the output current data and the output voltage data.

As shown in FIG. 7, the processing circuit 130 includes a processor 132 and a memory 134. The processor 132 may be implemented as a general-purpose processor, an application specific integrated circuit (ASIC), one or more field programmable gate arrays (FPGAs), a digital signal processor (DSP), a group of processing components, or other suitable electronic processing components. The memory 134 (e.g., RAM, ROM, Flash Memory, hard disk storage, etc.) may store data and/or computer code for facilitating the various processes described herein. Thus, the memory devices may be communicably connected to the processor 132 and provide computer code or instructions to the processor 132 for executing the processes described in regard to the output module 110 herein. Moreover, the memory 134 may be or include tangible, non-transient volatile memory or non-volatile memory. Accordingly, the memory 134 may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described herein.

The memory 134 includes various modules for completing the activities described herein. As shown in FIG. 7, the processing circuit 130 includes a display module 136, a comparison module 138, and a restart module 140. In other embodiments, the processing circuit 130 includes additional, fewer, and/or different modules. The display module 136, the comparison module 138, and the restart module 140 may be configured to receive inputs relating to various data and/or information (e.g., current data, voltage data, electrical power data, etc.) and provide signals. In one embodiment, the processing circuit 130 analyzes the output signals (e.g., with the processor 132, etc.) and controls one or more components of the solar panel assembly 10. By way of example, the processing circuit 130 may control the operation of the display 116, the switching regulator 118, and/or the communication device 120, among other components, based on the various data. While various modules with particular functionality are shown in FIG. 7, it should be understood that the output module 110 and the memory 134 may include any number of modules for completing the functions described herein. By way of example, the activities of multiple modules may be combined as a single module, as additional modules with additional functionality may be included, etc. Further, it should be understood that the output module 110 may further control other activity (e.g., other aspects of the solar panel assembly 10, functionality associated with the load device 160, etc.).

According to an exemplary embodiment, the display module 136 is configured to interpret the input current data (e.g., acquired and/or calculated based on data provided by the input current sensor 150, etc.) to determine the intensity of the solar energy incident upon the solar cells 46 of the solar panel assembly 10. The display module 136 may be configured to calculate the electrical power provided by the solar cells 46 of the solar panel assembly 10. In one embodiment, the display module 136 is configured to calculate the electrical power provided by the solar cells 46 by multiplying the input current with the input voltage (e.g., acquired and/or calculated based on data provided by the input current sensor 150, the input voltage sensor 152, preset and stored in memory, etc.).

The display module 136 may be configured to provide a signal such that the processing circuit 130 produces a command to the display 116. The display 116 may receive the command and provide an indication of the solar intensity to the user of the solar panel assembly 10. According to another embodiment, the display 116 is configured to indicate the available input power associated with the solar cells 46 (e.g., as determined by the comparison module 138, etc.). According to still another embodiment, the display 116 is configured to indicate the current draw associated with the load device 160 (e.g., as measured by one or more output current sensors 154, etc.). The command may include a series of commands (e.g., voltages, etc.) applied to the one or more LEDs of the display 116 (e.g., to illuminate certain LEDs based on the displayed information value, etc.).

In one embodiment, the display module 136 is configured to provide levels of user indication that vary based on the available input power of the solar cells 46 (e.g., as determined by the comparison module 138, etc.). By way of example, the display module 136 may be configured to provide commands such that: no LEDs are illuminated in response to a determination that the available input power is less than 1 Watt, one LED is illuminated in response to a determination that the available input power is greater than or equal to 1 Watt, two LEDs are illuminated in response to a determination that the available input power is greater than or equal to 2 Watts, three LEDs are illuminated in response to a determination that the available input power is greater than or equal to 3 Watts, and four LEDs are illuminated in response to a determination that the available input power is greater than or equal to 4 Watts (e.g., for a 7 W set of solar cells 46, etc.).

The display module 136 may be configured to provide a command such that the illuminated LEDs blink at a rate that is related to the output current or the current being drawn by the load device 160. By way of example, the display module 136 may be configured to provide a command such that the illuminated LEDs blink at a rate of 1 blink per second when the current draw of the load device 160 is approximately 0.1 Amps and the illuminated LEDs blink at a rate of 8 blinks per second when the current draw of the load device 160 is approximately 1 Amp. The blink rate may be related to the current draw linearly, according to a step function, or still otherwise related.

In another embodiment, the display module 136 is configured to provide a first level of user indication (e.g., illuminate one of the LEDs of the display 116, etc.) in response to a determination that the intensity of the solar energy incident upon the solar cells 46 of the solar panel assembly 10 is less than 25% of a maximum level. In another embodiment, the display module 136 is configured to provide a first level of user indication (e.g., illuminate one of the LEDs of the display 116, etc.) in response to a determination that the electrical power produced (e.g., current, voltage, etc.) by the solar cells 46 is less than 25% of a maximum level. In still another embodiment, the display module 136 is configured to provide a first level of user indication (e.g., illuminate one of the LEDs of the display 116, etc.) in response to a determination that the input current produced by the solar cells 46 and/or the output current provided by the output module 110 is less than 25% of a maximum level.

The display module 136 may be configured to provide a second level of user indication (e.g., illuminate two LEDs of the display 116, etc.) in response to a determination that at least one of (i) the intensity of the solar energy incident upon the solar cells 46, (ii) the electrical power produced by the solar cells 46, and (iii) the input current produced by the solar cells 46 and/or the output current provided by the output module 110 is greater than 25% but less than 50% of a maximum level. The display module 136 may be configured to provide a third level of user indication (e.g., illuminate three LEDs of the display 116, etc.) in response to a determination that at least one of (i) the intensity of the solar energy incident upon the solar cells 46, (ii) the electrical power produced by the solar cells 46, and (iii) the input current produced by the solar cells 46 and/or the output current provided by the output module 110 is greater than 50% but less than 75% of a maximum level. The display module 136 may be configured to provide a fourth level of user indication (e.g., illuminate four LEDs of the display 116, etc.) in response to a determination that at least one of (i) the intensity of the solar energy incident upon the solar cells 46, (ii) the electrical power produced by the solar cells 46, and (iii) the input current produced by the solar cells 46 and/or the output current provided by the output module 110 is greater 75% of a maximum level. In other embodiments, the display module 136 is configured to initiate control of the LEDs according to step thresholds other than the combination of 25%, 50%, and 75%. In other embodiments, the display module 136 is configured to still otherwise initiate control of the display 116 to facilitate user control of the solar panel assembly 10 (e.g., facilitating a user's efforts to maximize or otherwise increase the performance of the solar panel assembly 10, etc.).

According to an exemplary embodiment, the comparison module 138 is configured to increase performance of the solar panel assembly 10. As shown in FIG. 7, the output module 110 includes a circuit, shown as test circuit 180. The test circuit 180 is coupled to the input interface 112, according to an exemplary embodiment. In one embodiment, the test circuit 180 is configured to variably load the solar cells 46. The test circuit 180 may “load down” the solar cells 46 and/or the solar panel in an “on demand” manner. By way of example, the available input power of the solar cells 46 may be 10 Watts, and 8 Watts may be provided to the load device 160. The test circuit 180 may load down the solar cells 46 and/or the panel (e.g., at 2 Watts, with an increasing load starting with zero or another reduced load, etc.) until the test circuit 180 and/or the comparison module 138 notices a decrease in the power from the solar cells 46 and/or the panel (e.g., begins to decrease, decreases at more than a threshold rate, decreases to below a threshold level, etc.). The power from the solar cells 46 and/or the panel may be measured using the input current sensor 150 and/or the input voltage sensor 152.

In one embodiment, the voltage of the electrical power provided by the solar cells 46 is generally constant (e.g., 12 Volts, etc.). The comparison module 138 may interface with (e.g., provide a command signal to, communicate with by way of the processing circuit 130, etc.) the test circuit 180 to variably load the solar cells 46. In one embodiment, loading the solar cells 46 includes increasing the current draw using the dedicated test circuit 180. The comparison module 138 is configured to determine an available input power associated with the solar cells 46, according to an exemplary embodiment, by interfacing with the test circuit 180. In one embodiment, the comparison module 138 is configured to monitor the voltage and/or the current provided at the test circuit 180 and determine an instantaneous power level associated with the solar cells 46 (e.g., by multiplying the voltage and the current draw of the test circuit 180, etc.).

According to an exemplary embodiment, the comparison module 138 is configured to incrementally increase the load applied by the test circuit 180 while continuing to monitor the instantaneous power level associated with the solar cells 46. As the current draw applied by the test circuit 180 continues to increase, the input voltage applied by the solar cells 46 may at a threshold load level decrease (e.g., drop off, suddenly decrease, sharply decrease, etc.). The decrease in the input voltage applied by the solar cells 46 may decrease to a large degree, thereby decreasing the instantaneous power level associated with the solar cells 46. The comparison module 138 is configured to maximize the power level of the solar cells 46 (e.g., and thereby maximize electrical power provided to the load device, etc.). In one embodiment, the comparison module 138 is configured to determine that the solar cells 46 are providing an available input power (e.g., a potential input power, a maximum available input power, operating at a maximum power point, etc.) in response to a decrease in an instantaneous power level (e.g., below a threshold level, at a rate that is greater than a threshold rate, etc.). The decrease in the instantaneous power level may occur in response to the incremental increase in the load applied by the test circuit 180. The comparison module 138 may regularly or intermittently determine the available input power (e.g., multiple times per second, etc.).

The comparison module 138 is configured to manipulate the output voltage (e.g., the voltage applied at the output interface 114, the voltage provided to the load device 160, etc.), according to an exemplary embodiment, such that the output power corresponds with (e.g., matches, etc.) the available input power associated with the solar cells 46. By way of example, the comparison module 138 may be configured to monitor the available input power and interface with (e.g., command, provide signals such that the processing circuit 130 commands, etc.) the switching regulator 118 to manipulate the output voltage. The comparison module 138 may be configured to manipulate the output voltage regularly or intermittently in response to determining the available input power.

The current draw of the load device 160 may be related to the voltage applied thereto (e.g., the output voltage, etc.). The current draw of the load device 160 is non-linearly related to the applied voltage, according to an exemplary embodiment. The specific relationship between the current drawn and the applied voltage may vary based on one or more characteristics of the load device 160. By way of example, the load device 160 may draw 2.3 Amps with an applied voltage of 5.2 Volts, 2.0 Amps with an applied voltage of 5 Volts, 1.5 Amps with an applied voltage of 4.8 Volts, and 1.2 Amps with an applied voltage of 4.6 Volts. The comparison module 138 is configured to interface with the switching device 118 to produce small variations in the output voltage that yield larger variations in the current draw of the load device 160. The inventors of the present application discovered a non-liner relationship between a change in the applied voltage and the current draw of the load device 160.

By way of example, the comparison module 138 may be configured to interface with the switching regulator 118 to selectively increase the output voltage, thereby causing the load device 160 to increase the current draw and therefore increasing the output power being provided to the load device 160. By way of another example, the comparison module 138 may be configured to interface with the switching regulator 118 to selectively decrease the output voltage, thereby causing the load device 160 to decrease the current draw and therefore decreasing the output power being provided to the load device 160. The comparison module 138 may be configured to monitor the output power being provided to the load device 160 (e.g., using one or more of an output current sensor 154, an output voltage sensor 156, and the voltage at which the comparison module 138 instructed the switching regulator 118 to produce, etc.). In one embodiment, the comparison module 138 is configured to selectively vary (e.g., increase, decrease, etc.) the output voltage based on the available input power. By way of example, the comparison module 138 may be configured to monitor the output power, compare the output power with the available input power, and determine a target voltage to be applied by the switching regulator 118 at the output interface 114. By way of another example, the comparison module 138 may be configured to selectively vary the output voltage based only on the available input power (e.g., using a predetermined algorithm for determining the output power, etc.). In one embodiment, the switching regulator 118 is configured to regulate the output voltage to values between 4.7 Volts and 5.3 Volts.

In one embodiment, the comparison module 138 is configured to monitor the input power (e.g., the electrical power generated by the solar cells 46, etc.) and the output power (e.g., based on the electrical current drawn by the load device 160, etc.). The comparison module 138 may be configured to vary (e.g., reduce, etc.) the output voltage based on the available input power. In one embodiment, the comparison module 138 is configured to vary the output voltage to increase (e.g., maximize, etc.) the power output provided by the solar cells 46 (e.g., to provide an MPPT controller, etc.).

The comparison module 138 may be configured to interpret the input current data and the input voltage data to determine the input power and interpret the output current data and the output voltage data to determine the output power. In one embodiment, the comparison module 138 reduces the output voltage (e.g., by controlling the switching regulator 118, etc.) to increase the power level of the solar cells 46. Comparison module 138 may thereby determine a current to provide to the load device 160 to prevent an adverse decrease in the voltage provided by the solar cells 46 (e.g., rather than increasing the output current and the input current to elevated or maximum values, which may decrease the input voltage provided by the solar cells 46 and thereby adversely decrease the power provided by the solar cells 46, etc.). The comparison module 138 may determine the current to provide to the load device 160 using an algorithm that relates the power generated by the solar cells 46, the power provided to the load device 160, the input current, the input voltage, the output current, and/or the output voltage (e.g., to prevent an adverse decrease in the voltage provided by the solar cells 46, etc.). According to an exemplary embodiment, the comparison module 138 is configured to control the switching regulator 118 to adjust the output voltage provided to the load device 160 to increase the electrical power generated by the solar cells 46 and/or the electrical power provided to the load device 160.

According to an exemplary embodiment, the restart module 140 is configured to “restart” the electrical power supply provided by solar panel assembly 10 in response to determining that the load device 160 may no longer be charging. By way of example, the restart module 140 may determine that the load device 160 is no longer charging in response to the current drawn by the load device 160 decreasing at a rate that is greater than a threshold rate. Restarting may include stopping a supply of output current from the output module 110 to the load device 160 for a period of time, and then thereafter providing the output current supply from the output module 110 to the load device 160. In one embodiment, the restart module 140 is configured to monitor the input voltage. The restart module 140 may disable the output (e.g., terminate the output current, continue terminating the output current, etc.) in response to a determination that the input voltage is below a threshold level.

The output module 110 may include a timer module (e.g., a countdown timer, etc.) configured to facilitate pausing the electrical power supply from the solar panel assembly 10. In one embodiment, the restart module 140 is configured to provide a signal to again provide electrical power in response to receiving a signal from the timer module (e.g., in response to the timer module counting down to zero and thereafter providing an alert signal, etc.).

By way of example, the load device 160 may reject the power output of the output module 110 if at least one of the output voltage and the output current fall below a voltage threshold and/or a current threshold, respectively, instantaneously and/or for a predetermined period of time. The load device 160 may determine that the charging device (e.g., the solar panel assembly 10, etc.) is not a compatible device and stops charging. By way of example, the load device 160 may be charging via the power output of the solar panel assembly 10. A cloud may pass overhead, decreasing at least one of the output current and the output voltage provided to the load device 160 below the threshold. The load device 160 may thereafter reject the power supply from the solar panel assembly 10 and stop charging. The cloud may then pass by, and the voltage output to the load device 160 may increase to a level above the threshold. Even during the period of decreased current and/or voltage, the load device 160 may draw a reduced current (e.g., 0.1 Amps, etc.). The restart module 140 may stop and reinstate the charging session, thereby reducing the risk that the load device 160 may not again receive charging current from the solar panel assembly 10 to reinstate the charging session until the power supply is disconnected and thereafter reconnected.

In one embodiment, the restart module 140 is configured to monitor the output current and determine whether the output current is decreasing and, if so, the rate at which the output current is decreasing. In response to a determination that the rate at which the output current is decreasing exceeds the threshold rate (e.g., a cloud comes overhead, etc.), the restart module 140 may initiate a restart. In another embodiment, the restart module 140 is configured to begin monitoring at least one of the input voltage, the input current, and the input power in response to a determination that the rate at which the output current is decreasing exceeds the threshold rate. In response to the input power increasing (e.g., a cloud or obstruction passes, etc.), the restart module 140 may restart the power supply provided by the solar panel assembly 10 (e.g., decrease the output current to 0 Amps, etc.). The solar panel assembly 10 thereby “tricks” the load device 160 into perceiving that a new charging cycle has been initiated with a compatible device (e.g., simulating unplugging and then plugging in the charging cable, etc.) such that the charging of the load device 160 may continue.

In some embodiments, the output module 110 is communicably coupled to the load device 160 (e.g., via the output interface 114, etc.) and/or an external device (e.g., a smartphone, a cell phone, a tablet, a personal computer, a laptop, a smartwatch, a remote server, etc.), shown as external device 170 (e.g., via the communication device 120, etc.). According to an exemplary embodiment, the communication device 120 is configured to transmit various information and data (e.g., current data, voltage data, power data, charging history, etc.) to at least one of the load device 160 and the external device 170. The communication device 120 may use one of various types of communication protocol to facilitate the exchange of information between and among the output module 110, the load device 160, and/or the external device 170. In this regard, the communication protocol may include any type and number of wired and wireless protocols. For example, a wired connection may include a serial cable, a fiber optic cable, a CAT5 cable, radio frequency (RF) or any other form of wired connection. The communication device 120 may facilitate a wireless connection (e.g., across the Internet, Wi-Fi, Bluetooth (BLE), Zigbee, cellular, radio, etc.). In one embodiment, a controller area network (CAN) bus including any number of wired and wireless connections provides the exchange of signals, information, and/or data. Further, the communication device 120 may include a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (e.g., through the Internet using an Internet Service Provider).

According to an exemplary embodiment, the communication device 120 is configured to transmit (e.g., on a mobile application, using a website, etc.) present power data, charging history, and other performance characteristics to the external device 170 and/or the load device 160. Therefore, a user may be provided with increased visibility into the performance of the solar panel assembly 10 and/or the load device 160 (e.g., as compared to the indications provided only as part of the display 116, etc.). In other embodiments, the display 116 includes a screen (e.g., and LCD screen, etc.) upon which the processing circuit 130 provides (e.g., displays, etc.) such information.

According to an exemplary embodiment, the solar panel assembly 10 establishes three distinct functions to maximize the available PV panel power. First is a method for testing the panel for available input power. Second is a method for adjusting the power drawn from the panel output. Third is a controller to interpret sensor data and facilitate control of input and output activity.

According to an exemplary embodiment, panel testing is accomplished by pulsing a test load onto the panel output while continuously monitoring voltage and current. The test load may include a transistor configured to switch power through a fixed value resistor. The transistor may be driven from an off state through its linear region to provide an increasingly strong load on the panel. Voltage and current information may be used to calculate the panel power. As the load is increased, the power may be monitored and its maximum value may be recorded. The system may employ this series of steps periodically at a frequency that may appear continuous to an end-user.

According to an exemplary embodiment, adjusting output power is accomplished by varying the voltage at the output of the panel. The voltage may be varied by manipulating the feedback voltage of an adjustable output regulator. The feedback voltage may be a scaled version of the output voltage that keeps the regulator providing a fixed voltage. This feedback signal may be adjusted by the controller to force the output voltage to vary in accordance with a control scheme employed by the controller.

According to an exemplary embodiment, with the input power information it has gathered, the controller manipulates the output voltage available to a device to balance the available energy with the demands of the output. With this scheme, the system operates the panel at its maximum power point under varying environmental conditions.

According to an exemplary embodiment, a unique control scheme is utilized to address a common problem encountered during the use of active load devices (e.g., smartphones) with photovoltaic panels under varying lighting conditions. This problem results when the source of power (e.g., the sun, etc.) is temporarily interrupted. This interruption may result in a momentary drop in output voltage to which the device may respond by disabling its input charging circuit in order to protect itself (e.g., the device may interpret this interruption as a failing power source, etc.). The result of this process is a device that refuses to accept power despite a now valid source (e.g., when a cloud obstructing the sun passes, etc.). One approach to solving this issue is to periodically disable then re-enable the source on the chance that the energy source has become unavailable during the preceding period. This approach is problematic in that power is regularly interrupted unnecessarily. The system pf the present application provides a reactive scheme to reset the connection. This has the advantage of avoiding unnecessary interruptions while practically eliminating the time between a device ceasing to accept power and restarting the flow of energy. The restart may be facilitated by an algorithm in firmware that monitors the average output current and voltage. The processor may be configured to interpret a decrease in output current as a need to restart the flow of energy, which it does by briefly disabling the output. This same action may be performed if the output voltage becomes invalid due to insufficient input voltage.

According to an exemplary embodiment, an end-user is provided with unique information that facilitates more effective use of a connected photovoltaic panel. Several systems for communication may be provided. One such embodiment provides light emitting diodes. The LEDs may be manipulated to communicate information in several ways including being arranged into a bar graph, varying intensity, varying frequencies, multiple colors, etc. Another embodiment provides a digital data link such as USB or Bluetooth to an application on a user's device with an integrated display. By communicating the incident power in near real-time, the panel is orientable to receive the maximum available solar energy. Similarly, communicating output power to the user facilitates observation that the panel is working as intended, avoiding situations where energy is not being transferred due to other factors such as cable faults and/or incorrect charger profiles.

The present disclosure contemplates methods, systems, and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine-readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or a combination of hardwired or wireless) to a machine, the machine properly views the connection as a machine-readable medium. Thus, any such connection is properly termed a machine-readable medium. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

Although the figures may show a specific order of method steps, the order of the steps may differ from what is depicted. Also two or more steps may be performed concurrently or with partial concurrence. Such variation will depend on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations could be accomplished with standard programming techniques with rule-based logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

As utilized herein, the terms “approximately”, “about”, “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as may be recited in appended claims.

It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments is intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such term is not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

The terms “coupled,” “connected,” and the like, as used herein, mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent, etc.) or moveable (e.g., removable, releasable, etc.). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another.

References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” “between,” etc.) are merely used to describe the orientation of various elements in the figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

It is important to note that the construction and arrangement of the solar panel assembly as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. It should be noted that the elements and/or assemblies of the components described herein may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from scope of the present disclosure or from the spirit of the appended claim.

Number	Date	Country
62201062	Aug 2015	US
62201100	Aug 2015	US
62275000	Jan 2016	US

PORTABLE SOLAR PANEL SYSTEM ELECTRICAL CONTROL

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Provisional Applications (3)