Self-built solar lamp suite

Abstract

Disclosed herein is a solar light kit, the solar light kit comprising: a housing comprising a removably attached solar panel and a removably attached battery; a PCB including one or more light sources, the PCB configured to be connected to the solar panel and the battery; a lens for diffusing light from the one or more light sources of the PCB, where the lens is configured to be connected to the housing and the PCB; a plurality of removable fasteners, wherein the plurality of removable fasteners are used for connecting the lens to one or more of the PCB and the shell; and a tool for fastening the plurality of removable fasteners wherein the housing, the PCB, the lens, the plurality of removable fasteners, and the tool are bundled together in a kit package without assembly.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Application No. 17 / 838,972, filed on June 13, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to solar powered lights and, more particularly, to solar powered light kits designed to be constructed by children. Background Art

[0004] Students, especially young children, are more frequently educated using virtual resources, leaving limited room for hands-on activities. More specifically, many young students are not provided with opportunities to participate in basic, practical engineering projects. In addition, children in the education system are often unaware that children their age in developing countries lack energy resources. Energy poverty traps billions of people in a repeating cycle of darkness, poor health, uncertainty and poverty. Specifically, energy poverty causes more child deaths each year than AIDS and malaria combined. Solutions exist for reducing energy poverty in developing countries, such as solar lanterns that provide lighting in resource-limited areas. However, these lanterns are often not available to those in need.

[0005] Currently, there are no programs that enable students to learn and build functional devices and donate the devices to children in need. Therefore, there is a need for hands-on educational programs that improve STEM (science, technology, engineering and mathematics) based education, educate communities about energy poverty in developing countries, and allow students to make a lasting impact on communities in need of energy. Summary of the invention

[0006] The disclosed solar lantern kit connects two communities - communities living in energy poverty and communities in need of improved educational tools - by providing a system in which children have the opportunity to learn, build and donate solar lantern devices to communities with limited energy resources. The process includes learning about energy poverty and solar lanterns in developing countries, building solar lantern devices from kits with instructions, and donating solar lanterns to children in need. In addition, the learning experience can include the opportunity to write letters to the children who receive the devices to attach to the donated solar lanterns. Children and families living in energy poverty can intuitively operate the lights to complete schoolwork, work, play and walk in an otherwise dark environment, thereby improving their living standards. The knowledge gained not only from learning how to construct solar lanterns, but also from spreading awareness of energy poverty also contributes to the education of children in developed countries. In addition, when obtaining solar lanterns, children in developing countries can learn about solar lantern systems and how to maintain their personal devices, thereby also improving the education of children in developing countries.

[0007] In some embodiments, a method of assembling a solar light kit is provided, the method comprising: placing the solar light kit in a kit packaging, the kit packaging comprising a lens, a printed circuit board (PCB), a housing, a plurality of removable fasteners, and a hand tool, wherein the housing comprises a removably attached solar panel and a removably attached battery; connecting the PCB to the lens using one or more of the plurality of removable fasteners and the hand tool, electrically connecting wires from the battery in the housing to a first socket on the PCB, and electrically connecting wires from the solar panel in the housing to a second socket on the PCB, wherein the connection is secured by applying pressure between the wires from the battery inserted into the first socket and between the wires from the solar panel inserted into the second socket; and connecting the housing to the lens using one or more of the plurality of removable fasteners and the hand tool, wherein each of the solar panel, the battery, and the PCB is assembled within the housing in one orientation.

[0008] In some embodiments, connecting the PCB to the lens includes orienting switches on the PCB using one or more illustrative facial features on the lens.

[0009] In some embodiments, prior to connecting wires from the battery and solar panel to the first and second sockets on the PCB, the method includes inserting a seal into a lip of the lens, wherein the lip extends the perimeter of the lens.

[0010] In some embodiments, before coupling the housing to the lens, the method includes inserting a switch button into a hole in the housing, the hole being configured to receive at least a portion of the switch button.

[0011] In some embodiments, connecting the housing to the lens includes orienting a switch button inserted into the housing using a switch on a PCB connected to the lens.

[0012] In some embodiments, after connecting the housing to the lens, the method includes placing a buffer around the connected lens and at least a portion of the housing, wherein the orientation of the buffer around the connected lens and a portion of the housing is based at least in part on a position of a button indicator on the buffer, the button indicator being configured to align with a position of a switch button inserted into the housing.

[0013] In some embodiments, the method includes attaching the handle to the housing by connecting at least two pegs on the housing to at least two slots on the removable handle.

[0014] In some embodiments, the angle of the assembled solar-powered light is configured to be adjustable by rotating the handle about at least two pegs on the housing.

[0015] In some embodiments, the height of the assembled solar-powered light is configured to be adjustable by modifying the positions of the at least two pegs within the at least two slots of the handle.

[0016] In some embodiments, the at least two slots provide at least two height settings for the assembled solar-powered light.

[0017] In some embodiments, the first socket is labeled "Battery" and the second socket is labeled "Solar Panel".

[0018] In some embodiments, the handheld tool is a screwdriver sized for use by a child and the removable fastener is a screw configured for use with the screwdriver.

[0019] In some embodiments, the handheld tool is a wrench sized for use by a child, and the removable fasteners include one or more of bolts, nuts, and screws configured for use with the wrench.

[0020] In some embodiments, each of the connections between the PCB and the lens, the housing and the lens, the wires from the battery and the first socket, and the wires from the solar panel and the second socket do not require the use of solder, glue, or adhesive.

[0021] In some embodiments, wires from the battery are removably inserted into the first socket and wires from the solar panel are removably inserted into the second socket.

[0022] In some embodiments, the assembled solar powered lamp can be repaired by removing one or more removable fasteners from the attached housing and lens to disconnect the lens from the housing, and replacing one or more of the battery, solar panel, and PCB.

[0023] In some embodiments, a solar lamp kit is provided, comprising: a housing comprising a removably attached solar panel and a removably attached battery; a PCB comprising one or more light sources, the PCB being configured to be connected to the solar panel and the battery; a lens for diffusing light from the one or more light sources of the PCB, wherein the lens is configured to be connected to the housing and the PCB; a plurality of removable fasteners for connecting the lens to one or more of the PCB and the housing; and a tool for fastening the plurality of removable fasteners, wherein the housing, PCB, lens, plurality of removable fasteners and tool are bundled together in a kit packaging when unassembled.

[0024] In some embodiments, the solar light kit includes a seal configured to fit around a perimeter of the lens.

[0025] In some embodiments, the housing is configured to receive a switch button configured to connect to a switch on the PCB.

[0026] In some embodiments, the PCB includes at least two sockets, a first socket configured to connect to wires from a battery and a second socket configured to connect to wires from a solar panel.

[0027] In some embodiments, the solar light kit includes a bumper configured to surround at least a portion of the attached housing and lens.

[0028] In some embodiments, the bumper includes a button indicator whose position is configured to align with the position of a switch button inserted into the housing.

[0029] In some embodiments, the solar light kit includes a handle configured to be removably attached to at least two pegs on the housing, the handle including at least two slots configured to receive the at least two pegs.

[0030] In some embodiments, the assembled solar powered light is configured to hang from a handle or to stand using the handle.

[0031] In some embodiments, at least one of the height of the assembled solar-powered light and the angle of the assembled solar-powered light about the handle is adjustable.

[0032] In some embodiments, the at least two slots provide at least two height settings for the assembled solar-powered light.

[0033] In some embodiments, this tool is the only tool required to assemble the solar light kit.

[0034] In some embodiments, the handheld tool is a screwdriver sized for use by a child and the removable fastener is a screw configured for use with the screwdriver.

[0035] In some embodiments, the handheld tool is a wrench sized for use by a child, and the removable fasteners include one or more of bolts, nuts, and screws configured for use with the wrench.

[0036] In some embodiments, the PCB includes at least 18 light sources, and the light sources are light emitting diodes (LEDs).

[0037] In some embodiments, the first portion of the light sources are white LEDs and the second portion of the light sources are colored LEDs.

[0038] In some embodiments, at least one light source in the second portion of light sources is a battery indicator for indicating a charge status of a battery.

[0039] In some embodiments, the battery is a rechargeable lithium-ion battery.

[0040] In some embodiments, the solar panel is a polycrystalline silicon solar panel comprising at least 10 photovoltaic (PV) cells.

[0041] In some embodiments, the solar light kit includes a set of instructions for guiding a user in assembling a solar light from the solar light kit. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0043] Figures 1A to 1D Various perspective views of a solar powered lamp according to some embodiments are illustrated.

[0044] FIG. 2A to FIG. 2B Components of a solar light kit package are illustrated according to some embodiments.

[0045] Figures 3A to 3G The assembly of components of a solar light kit according to some embodiments is illustrated.

[0046] Figure 4 A method for assembling a solar-powered light from a kit is illustrated according to some embodiments. DETAILED DESCRIPTION

[0047] Reference will now be made in detail to implementations and embodiments of various aspects and variations of the systems and methods described herein. Although several exemplary variations of the systems and methods are described herein, other variations of the systems and methods may include various aspects of the systems and methods described herein combined in any suitable manner, with combinations of all or some of the described aspects.

[0048] The disclosed solar lantern kit includes a built-in solar panel for charging a battery, which powers a plurality of LED lights. One or more components of the solar lantern kit can be specifically designed to be assembled by a child using at most one hand-held tool, and without the use of solder, glue or other adhesives. In addition, the components of the solar lantern can be manufactured so that each workpiece must be assembled in a specific order and orientation. The device can be sized so that it is handheld and portable for children, and can include a removably attachable handle that allows the device to stand, hang or transport easily. The solar lantern can include additional features such as a pair of legs and an illustrated face, which makes the device humane for the intended end user (i.e., a child who is previously unfamiliar with solar lantern technology).

[0049] In the following description of various embodiments, it is to be understood that the singular forms "a", "an", and "the" used in the following description are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is also to be understood that the term "and / or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It is to be further understood that when used herein, the terms "includes", "including", "comprises", and / or "comprising" specify the presence of stated features, integers, steps, operations, elements, parts, and / or units, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, units, and / or groups thereof.

[0050] Figures 1A to 1D Various perspective views of a solar powered lamp 100 according to some embodiments are shown. Figure 1A As shown in FIG. 1 , the solar light 100 may include a lens 102, a bumper 104, and a handle 106. The bumper 104 may at least partially surround a housing that is removably attachable to the lens 102 and protects the electrical components of the solar light 100. In some embodiments, the lens 102 may include one or more design features such as a logo and an illustrated face, such as Figure 1A to Figure 1B and Figure 1D. The illustrated face may include eyes and a mouth, thereby humanizing the solar light 100 for builders and intended end users (i.e., children) and making it easier for children who may be unfamiliar with solar technology to use the device. In some embodiments, the illustrated face may be etched, engraved, or adhered to the lens 102.

[0051] Due to the texture on the inner surface of the lens 102, the lens 102 can diffuse the light from the multiple light emitting diodes (LEDs). The texture on the inner surface of the lens 102 can be, for example, a polygonal (e.g., hexagonal) pattern that covers the inner surface of the lens 102, except for the facial features. The solar light 100 may include multiple white LEDs and / or multiple colored (e.g., red, green, and blue or "RGB") LEDs. In some embodiments, the solar light 100 includes up to 18 white LEDs and up to 4 RGB LEDs electrically connected in parallel on a printed circuit board (PCB). In some embodiments, the light includes only a single RGB LED and multiple white LEDs, and the RGB is used as a power / charging indicator, as described in more detail below. In some embodiments, the device includes a total of less than or equal to 14, 16, 18, 20, 22, or 24 LEDs. In some embodiments, the device includes a total of more than or equal to 14, 16, 18, 20, 22, or 24 LEDs. In some embodiments, the device may include any combination of white lights / colored lights (such as red, green, blue, pink, purple, yellow, orange, etc.).

[0052] In some embodiments, the intensity of the white light and / or the colored light can be changed according to one or more light settings. For example, the light can be set to three different modes, such as low mode, medium mode, and bright mode. In some embodiments, the light can be set to two different modes. For example, the colored light can be set to a red light mode (i.e., learning mode) and a light-emitting mode (i.e., party mode). In some embodiments, the light includes only a single brightness setting. In some embodiments, the solar light 100 includes more than three light settings, such as 4, 5, or 6 light settings. The LED used in the solar light 100 can be a surface-mounted LED such as SMD 2835. The LED of the solar light 100 can be any type of LED suitable for powering via a solar panel, such as a through-hole LED, an SMD LED, a bicolor, and / or an RGB LED. In an embodiment with three light settings, the brightness associated with each of the three white light settings can be approximately 4 lm, 34 lm, and 145 lm, respectively.

[0053] Figure 1BA perspective view of a solar lantern 100 according to some embodiments is illustrated. The buffer 104 can be made of a synthetic rubber such as an elastomer to provide ergonomics to the user and can surround at least a portion of the attached lens 102 and the device housing. For example, the buffer 104 can be made of natural rubber, polyurethane, silicone, or neoprene materials. In some embodiments, the buffer 104 can be made of fabric, foam, or other flexible materials. In some embodiments, the buffer 104 can include a texture / pattern to enhance the user's grip and feel. The buffer 104 can be manufactured to withstand the wear and tear that accompanies daily use of the solar lantern, such as drops, abrasion, water, temperature, and humidity.

[0054] In addition, the buffer 104 may include one or more features 112 on the bottom side of the device that are similar to feet. Like the facial features on the lens 102 described above, the foot features 112 can assist in making the solar light 100 humanized for the target user, children. The foot features may be simple oval / circular shapes in some embodiments, or may be shaped to resemble a human foot, as shown. The foot features 112 may be made of the same material as the buffer 104, and may include one or more texture patterns, such as texture patterns found on the buffer 104, logo patterns, or patterns modeled after actual foot creases (i.e., further humanizing the solar light 100). In the event that the handle 106 is removed from the device, the solar light 100 may stand using the foot features 112.

[0055] like Figure 1A and Figure 1B As shown therein, the solar light 100 can be rotatable about one or more pegs 108 on the housing to direct the light as desired by the user. The solar light 100 can include, for example, two or more pegs 108 on opposite side surfaces of the device. In some embodiments, the pegs 108 can be located anywhere along the side surface of the light, such as at a middle portion, an upper portion, or a lower portion. The pegs 108 can be configured to be received via one or more slots 110 on the handle 106, such as Figure 1A . The slot 110 can have a vertical length along a portion of the handle 106 so that the peg 108 can translate along the length of the slot 110 to raise and / or lower the solar light 100. The slot 110 can provide, for example, three lockable height positions for the device. In some embodiments, less than three height positions can be provided on the device, such as 1 or 2 height positions. In some embodiments, 4, 5, or more height positions can be provided by the slot 110. Figure 1DAs shown in , the lamp 100 can be adjusted to the lowest position on the slot 110 and aligned so that the face of the lens 102 is flush with the handle 106. With this alignment, the solar lamp 100 can be easily portable and compact for the user.

[0056] Figure 1C A rear view of a solar lantern 100 is illustrated. As shown, the face of the solar lantern 100 opposite the lens 102 includes a solar panel 114. The solar panel 114 may be removably attachable to the housing of the solar lantern 100. The solar panel 114 may generate energy to charge a battery, and the rechargeable battery provides power to a plurality of LEDs within the solar lantern 100. The solar panel 114 may be polycrystalline silicon and may include 12 photovoltaic (PV) cells electrically connected in series. In some embodiments, the solar panel 114 may include less than 12 PV cells, such as 6, 8, or 10 cells. In some embodiments, the solar panel 114 may include more than 12 PV cells, such as 14, 16, or 18 cells. In some embodiments, the solar lantern 100 may include one or more other types of solar panels, such as monocrystalline and thin film panels.

[0057] In some embodiments, the solar powered light 100 may include a rechargeable battery (in Figure 3A ), such as one or more lithium-ion batteries. The battery can be removably attachable to the housing of the solar lamp 100. The battery 100 can be, for example, a lithium battery, an alkaline battery, or a nickel-metal hydride (NiMH) battery. In some embodiments, the solar lamp 100 can include a 1000mAh 3.6 V lithium polymer battery. Due to the characteristics of including a single-cell construction, the lithium-ion battery can be suitable for use in the solar lamp 100, which can provide users with less complicated assembly. In addition, the battery can be lightweight and have a high energy density. The integration of lithium-ion batteries in the solar lamp 100 can provide a low self-discharge rate of approximately 3% per month and low maintenance because lithium does not require the battery to be cycled at regular intervals to maintain its maximum capacity. In some embodiments, the integrated battery in the solar lamp can be a nickel-metal hydride (NiMH) battery, such as a 750 mAh 3.6 V NiMH battery. The NiMH battery can include 3 cylindrical cells in series. In some embodiments, each of the solar panel 114 and the battery can be wired using silicone rubber and a 26 AWG gauge.

[0058] Depending on the battery type, battery size, solar panel characteristics, and estimated light output, the rechargeable battery can provide up to 140 hours of light. For example, before solar charging is required, the solar light 100 can provide a total of about 140 hours of white light in low mode, about 14.5 hours of white light in medium mode, and about 3.5 hours of white light in high mode. In some embodiments, the solar light 100 can provide up to 26.3 hours of RGB light in party mode and up to 10.5 hours of RGB light in learning mode. For a fully discharged battery, the solar light 100 may take about 9 hours to 17 hours for a full solar charge, depending on the exposure of the light to sunlight. For example, the solar light 100 may take 9 to 12 hours, 12 to 15 hours, or up to 17 hours for a full solar charge. In some embodiments, the battery life after the device is stored may decrease over time. For example, after 1 day, the battery life of the device may decrease by about 5%. Similarly, the battery life may decrease by about 6% after 30 days, by about 8% after 60 days, and by about 12% after 150 days.

[0059] The solar light 100 may include a battery charge indicator and / or a battery level indicator (not shown), which may be implemented, for example, via one or more colored LEDs. Additionally, the solar light 100 may include circuitry that allows for overcharge and / or overdischarge protection, as well as an automatic shutoff feature when the device is low on power. The solar light 100 may be waterproof (e.g., having an IP54 waterproof rating) and be designed with one or more features that provide protection from sun exposure.

[0060] In some embodiments, the solar light 100 may additionally include a button indicator 116 on the buffer 104. The button indicator 116 may be located, for example, along the side or top of the solar light 100. The button indicator 116 may correspond to a button and switch mechanism on the interior of the light, as will be described in more detail below. By engaging the button indicator 116, the user can turn the light on and off, as well as switch between light settings, as described above. The button indicator 116 may include one or more design features, such as an outline with a logo.

[0061] The solar light 100 can be sized so that it is handheld, lightweight, and portable for the intended user (i.e., a child). For example, without the stand / handle 106, the device can weigh between 325 g and 375 g (e.g., 350 g), and can be approximately 100 mm wide and 98 mm high. In some embodiments, the solar light 100 can be greater than or less than 100 mm wide by 98 mm high. For example, the width and / or height of the solar light 100 can be less than or equal to 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, 110 mm, 115 mm, or 120 mm. In some embodiments, the width and / or height of the solar light 100 can be greater than or equal to 80 mm, 85 mm, 90 mm, 95 mm, 100 mm, 105 mm, 110 mm, 115 mm, or 120 mm. With the handle 106, the device can be greater than 100 mm high, for example, approximately 106 mm high. However, the height of the device can vary based on the height setting of the handle 106. The thickness of the solar lamp can be about 30 mm, thus allowing children to easily hold and grip the solar lamp. In some embodiments, the thickness of the device can be less than or equal to 20 mm, 25 mm, 30 mm, 35 mm, or 40 mm. In some embodiments, the thickness of the device can be greater than or equal to 20 mm, 25 mm, 30 mm, 35 mm, or 40 mm.

[0062] Unless otherwise specified, one or more components of the solar light kit 100 can be made of plastics such as polyethylene and / or polypropylene. For example, the housing, lens 102 and / or handle 106 can be made of plastics such as those mentioned above or other types of plastics. In some embodiments, the solar light 100 can be manufactured in a variety of colors. The different color options of the device can be related to the intended use of the device. For example, a solar light intended for an educational situation can be yellow or black. In some embodiments, a solar light intended for a corporate situation can be light blue or dark blue. Finally, a solar light intended for a festival / party situation can be light purple or dark purple. However, any color can be selected for any intended use of the device. Providing color options can increase user satisfaction and allow users to customize their solar lights.

[0063] FIG. 2A to FIG. 2B Components of a solar light kit according to some embodiments are illustrated. The solar light kit may include Figures 1A to 1D Any of the features of the solar powered lamp 100 described above. Figure 2AAs shown in , the solar light kit packaging can include an unassembled solar light 200 and a hand tool 218 for construction. The solar light can be constructed using a single tool, which can be a screwdriver or a wrench. For example, the hand tool 218 can be a flat head, cross (Phillips) or hexagonal screwdriver; or a hexagonal (i.e., Allen), open or ratchet wrench. The hand tool 218 can be sized to be easily used for the intended user group (i.e., children). Additional components of the solar light kit can be stored inside the unassembled solar light 200. By storing the individual components of the kit inside the solar light 200, the packaging is self-contained, reducing the need for additional waste, and can help simplify the transportation of large quantities of kits.

[0064] A builder, such as a young student, child, or other intended user, can open the solar light 200 to reveal modular components that need to be assembled in a specific manner (i.e., in a specific orientation) and following an ordered set of steps. Figure 2B As shown in , a builder can detach the housing 220 from the bumper 204, handle 206, and lens 202 to reveal additional components of the kit. For example, the housing 220 and lens 202 may include one or more features that are configured to mate with each other and be removably attachable to each other. Additional components stored within the unassembled solar lantern 200 include a printed circuit board (PCB) 222 and a package 224 of removable fasteners. The PCB 222 and housing 220 may each include additional modular features that are already connected and do not require additional assembly by the builder (i.e., no solder, wiring, etc.), as will be described with respect to FIG. Figures 3A to 3G Described in more detail.

[0065] Figures 3A to 3G The assembly of a solar light from components of a solar light kit according to some embodiments is illustrated. The unassembled solar light 300 may include components related to Figures 1A to 1D and FIG. 2A to FIG. 2B Any one or more of the features of solar powered lamps 100 and 200 described herein. Figure 3AAs shown in , the solar light kit may include a buffer 304, a lens 302, a housing 320, a PCB 322, and a handle 306. The solar light kit may additionally include a seal 332 and a switch button 330. The PCB 322 may include additional modular features such as a switch 328, and the housing 320 may include additional modular features such as a rechargeable battery 326 and wires 334. In addition, the housing 320 may include a modular solar panel (not shown) on the opposite side of the battery 326, such that the wires 334 are electrically connected to the solar panel through an opening in the housing 320. The solar panel and battery 326 may be configured to fit into the housing 320 in a specific orientation, and may be removably locked in place in one or more dedicated features within the housing 320.

[0066] Now, about Figures 3B to 3G The assembly of a solar lamp from a solar lamp kit 300 is described. Students can assemble the solar lamp 300 from the packaging in a classroom context as a form of social STEM learning. By providing the solar lamp kit as an activity in an educational system, students can not only learn about solar technology and how to assemble a solar lamp, but also learn about energy poverty in other countries, because once the lamp is constructed, the students will donate the lamp to children in need. In some embodiments, the solar lamp 300 can be assembled in a context other than an educational system. The solar lamp kit can be designed so that each individual component within the kit needs to be assembled in a specific order and / or manner to achieve a functional solar lamp, as will be described in more detail below. In addition, each component of the device can be assembled into the solar lamp in a single orientation. In addition, the solar lamp kit can be constructed using at most one handheld tool, without the need to use techniques such as welding wire connections. The kit can be accompanied by an instruction manual that provides step-by-step instructions with diagrams / images for successfully assembling the solar lamp. The instructions can be intended for children, including diagrams and simple instructions for the intended user to understand. For example, the instructions can be included in the form of a paper manual or electronically via a QR code.

[0067] In the user as above FIG. 2A to FIG. 2B After opening the solar powered light 300 as described, the builder can begin assembly according to the instructions. Figure 3BAs shown in the figure, the user can first insert the seal 332 into the narrow groove on the lens 302, which extends the periphery of the lens 302. The seal 332 can be made of an elastomer such as those described above, and can be configured to protect the internal components of the solar lamp from water damage. Therefore, when assembling the lamp before closing the lamp (i.e., reattaching the lens 302 to the housing 320), it is important to insert the seal into the narrow groove on the lens 302. Before or after installing the seal 332, the builder can install the PCB 322 to the lens 302, such as by using a plurality of removable fasteners 324. The fastener 324 can include any combination of screws, nuts, bolts, or other removable fasteners. For example, the fasteners can include a set of short screws and a set of long screws intended for different uses when assembling the solar lamp. In some embodiments, removable fasteners such as short screws can be installed to the PCB 322 and the lens 302 at each of the 4 corners of the rectangular PCB 322 and the lens 302. For example, screwdriver 218 may be used to tighten screw 324. In some embodiments, one or more of lens 302 and / or PCB 322 may be configured to receive a bolt in addition to or in place of screw 324 and configured to be tightened using a wrench. For example, lens 302 and / or PCB 322 may be configured to receive a screw with a hexagonal cap that is configured to be tightened using an Allen wrench.

[0068] In some embodiments, the lens 302 can be configured to be attached to the PCB 322 without the use of fasteners 324. For example, the lens 302 can include one or more connection features (e.g., snap fasteners, adhesive fabric, pins, tabs) that are configured to be removably attached to corresponding connection features on the PCB 322. The PCB 322 must be installed to secure the board before enclosing the housing 320 with the lens 302, thereby stabilizing the plurality of LEDs and minimizing any chance of damage to individual features (such as LEDs) on the PCB 322. The PCB 322 can be packaged with most of the electronic components (such as LEDs, switches, and various connections between different components) permanently attached (e.g., soldered), thereby minimizing any confusion, safety issues, and complexity for the intended builder (e.g., children).

[0069] The lens 302 may include a plurality of connection features (e.g., ports) intended to receive fasteners 324 and / or connection features on the PCB 322. For example, the lens 302 may include 2 ports positioned relative to each corner of the rectangular lens 302. In some embodiments, of the 2 ports in a given corner of the lens 302, the port positioned closer to the center of the lens 302 is configured to receive a short screw. In some embodiments, in the case where the PCB 322 includes a tab, the lens 302 may include a slot configured to receive the tab during attachment. The PCB 322 should be mounted so that the position of the switch 328 on the PCB 322 is oriented in the direction of the facial features 336 on the lens 302, as shown. In some embodiments, because the lens 302 is textured to diffuse light in all areas except the area of ​​the facial features 336, the user observes the facial features 336 when the light is turned on. In some embodiments, the facial features 336 are printed onto the outer surface of the lens 302. The switch 328 must be oriented in the same direction as the facial feature 336 (ie, at the upper / top portion of the lens 302) so that this position correlates with the position of the button indicator on the bumper 304, as will be described in more detail below.

[0070] After mounting PCB 322 to lens 302, refer to Figure 3C , the builder can insert a portion of the switch button 330 into a corresponding through-hole on the housing 320. For example, the hole can be located on the top surface of the housing 320 and sized so that the fit between the rubberized (i.e., pliable elastomer) switch button 330 and the through-hole is a transition fit. Therefore, at least in part due to the materials of the button and the housing and the type of fit, the user can insert a portion of the switch button 330 into the through-hole with minimal effort, thereby maintaining its position in the hole after insertion. At least a portion of the switch button 330 can have a larger diameter than the diameter of the through-hole on the housing 320 (i.e., the cover), so that the cover provides a mechanism that prevents the builder from pushing the entire switch button 330 into the through-hole. The switch button 330 must be inserted from the interior of the housing 320 so that the cover portion of the switch button 330 is located on the interior of the housing 320 and can engage with the switch 328, as will be described below. Once properly inserted, the switch button may have an end on the exterior of the housing 320 that is configured to engage a button indicator on the bumper during use.

[0071] After the switch button 330 is mounted to the housing 320, as shown in FIG. Figure 3D, the builder can connect the plug on the wire 334 to the corresponding socket on the PCB 322. The socket 338 can be pre-installed on the PCB 322 to minimize the damage that may accompany the connection welding. The PCB 322 can be marked to indicate which socket 338 is configured to receive the plug on the wire 334 from the solar panel and from the battery, thereby minimizing the risk of confusion when assembling the lamp. The wire 334 can be removably connected to the socket 338 via one or more wire board connectors. For example, when the user applies pressure to connect the plug on the wire 334, due to the friction between the socket and the plug, the plug snaps into place or remains in place until the desired removal. The wire 334 can be specially designed and / or selected to provide safe power from the solar panel 314 to the PCB 322.

[0072] Because the wires, once connected, may block a portion of the lip of the lens 302, the builder must ensure that the seal 332 is installed to the slot of the lens 302 before connecting the wires 334 to the PCB 322, thereby making it impossible to successfully install the seal without disconnecting the wires again. The seal 332 provides waterproof protection for the internal components of the device 300, so it is important to install the seal at the right time. It is important and urgent to correctly connect the wires 334 to their corresponding sockets 338 to achieve a functional final product.

[0073] After successfully installing the above FIG. 3B to FIG. 3D After describing the internal components, the user can close the solar lantern 300 by aligning the PCB 322 and the battery 326 within the housing 320 so that the side of the lens 302 with the one or more facial features 336 is facing outward. The builder can ensure the correct orientation of the lens 302 on the housing 320 by aligning the position of the switch button 330 on the housing 320 with the switch 328 on the PCB 322 (attached to the lens 302). Figure 3E As shown in , once the components are properly aligned, the user can secure the solar light 300 using removable fasteners 324 or via one or more tabs / slots configured to fit between the housing 320 and the lens 302. In embodiments utilizing fasteners 324, a set of large screws can be used compared to the screws that can be used to mount the PCB 322 to the lens 302. In some embodiments, the removable fasteners 324 can include a nut / bolt combination instead of a screw. In some embodiments, the lens 302 and / or the housing 320 can be configured to receive a screw with a hexagonal cap that is configured to be tightened using an Allen wrench.

[0074] The lens 302 may include ports in each corner of the lens (described above and in Figure 3B), the port is configured to receive a large screw. The builder can use a hand tool such as a screwdriver 318 to install the removable fastener 324. In an embodiment where the fastener 324 is a nut / bolt, the user can use a wrench to install the fastener, as described in more detail above. By installing the fastener 324 to the lamp, the solar lamp 300 is secure and the risk of damage to the internal components is minimized. In some embodiments, at any time during use, the intended user can uninstall one or more fasteners 324 from the housing 320 to access one or more internal components, such as to ensure adequate functionality, or replace one or more internal components. Similarly, in the case where the lens 302 and the housing 320 are removably connected via, for example, a set of tabs on the lens 302 configured to cooperate with a slot on the housing 320, the user can easily apply pressure to disengage and reengage the two components from each other. In some embodiments, the housing 320 may include a tab, and the lens 302 may include a slot configured to cooperate with the tab.

[0075] Once the housing 320 is secured to the lens 302, the builder can install the bumper 304 to the edge of the removably attached housing 320 and lens 302. The bumper 304 can also secure the connection between the lens 302 and the housing 320, such as in the case where the two components are connected via tabs / slots rather than removable fasteners. As mentioned above, the bumper 304 can include a button indicator (in the Figure 1D ). The builder can use the button indicator on the buffer 304 as a reminder of the correct vertical orientation of the buffer 304 on the housing 320. The buffer 304 may include one or more side holes configured to receive the pegs 308 on the housing 320. The user can identify the front surface of the buffer 304 from the rear surface because the cutout on the rear surface is sized so that the solar panel 314 is fully exposed to the external environment. On the other hand, the front surface of the buffer 304 can be open to fully expose the lens 302. As described above, the buffer 304 may include one or more features 312 designed to look like feet on the bottom surface to humanize the light. The solar light 300 may additionally stand upright from the foot features on the buffer 304. The buffer 304 may be designed to withstand exposure to water and sunlight, thereby providing additional protection for the rest of the solar light 300. In the event that a user needs to access one or more internal components of the solar powered light, such as to replace one or more components of the device, the buffer 304 can be easily removed from the rest of the light (ie, the attached housing 320 and lens 302) due to its flexibility.

[0076] The final step in assembling the solar light from the solar light kit 300 may be to mount the handle 306 to the rest of the light. As described above, the handle 306 may include one or more slots 310 configured to receive one or more pegs 308 on the housing 320. The slots 310 may include multiple settings for adjusting the height of the light during use and allowing the light to rotate around the handle 306. The handle 306 may be removably attachable to the solar light so that the solar light can be used with or without the handle 306. The handle 306 may be used for more than one purpose, such as hanging the device from a ceiling, focusing light during study, lighting a room as a lamp, or keeping for safe walking at night.

[0077] Once assembled, the solar lantern can be donated to children / families living in energy poverty to help improve their quality of life. In some embodiments, the constructed lantern comes with a handwritten letter from the builder (i.e., a child / student in a developed country). Once with the intended end user (i.e., a child), the device can be disassembled at any time to replace one or more components of the device in the event of a lamp failure. For example, a user can disassemble one or more of the bumper 304, the removable fastener 324, and the handle 306 to disengage the lens 302 from the housing 320 and expose the modular internal components.

[0078] Figure 4 A method 400 for assembling a solar light from a kit is illustrated according to some embodiments. At step 402, a solar light kit may be provided in a kit packaging, wherein the solar light kit includes a lens, a PCB, a housing, a plurality of removable fasteners, and a hand tool. In some embodiments, the housing includes a removably attached solar panel and a removably attached battery. In some embodiments, each component in the solar light kit packaging may be stored within the removably attached housing and lens, such that the packaging is compact and can be easily transported.

[0079] At step 404, the user may connect the PCB to the lens. In some embodiments, the PCB may be connected to the lens using one or more of the removable fasteners and a hand tool. In some embodiments, the PCB may be configured to attach to the lens in a unique orientation such that the switches on the PCB are oriented in the same direction as the illustrated facial features on the lens. In some embodiments, the hand tool may be a screwdriver or a wrench, and the removable fastener may be one or more of a screw, bolt, and nut configured to be installed using the screwdriver or the wrench. In some embodiments, the hand tool may be intentionally sized for an intended user (i.e., a child).

[0080] At step 406, the user can connect one or more wires extending from the battery in the housing to a first socket on the PCB, and can connect one or more wires extending from the solar panel in the housing to a second socket on the PCB. In some embodiments, the PCB can be marked so that the first socket corresponds to the battery and the second socket corresponds to the solar panel. In some embodiments, the wires from the battery and the solar panel can be inserted into the first socket and the second socket on the PCB by the user applying pressure between the wires and the sockets. In some embodiments, for example, if one or more components of the device need to be replaced, the connection between the PCB and the battery and the solar panel can be disconnected.

[0081] At step 408, the user can connect the housing to the lens, for example, using one or more fasteners and a hand tool. In some embodiments, the user can align the switch button inserted into the housing with the switch on the PCB (attached to the lens) to achieve the correct orientation when connecting the housing to the lens. In some embodiments, the lens and the housing can be configured to be attached with one or more tabs and slots. For example, the lens can include one or more tabs that are configured to fit into one or more slots in the housing. In some embodiments, the housing and the lens can be disassembled to replace one or more internal components of the solar lamp. In some embodiments, each of the PCB, solar panel, battery, and PCB can be configured to fit within the housing in a specific orientation.

[0082] In some embodiments, the solar light kit may include a handle and a buffer. The handle may be removably attached to at least two pegs on the side surface of the solar light via two or more slots on the handle. In some embodiments, the solar light may be configured to hang from the handle or stand from the handle. The buffer may be configured to be molded around at least a portion of the connected lens and housing. The buffer may include one or more features such as a button indicator configured to correspond to the position of the switch button in the housing and one or more exemplary foot features. In some embodiments, facial features on the lens and foot features on the buffer can help make the solar light humanized for both the builder and the intended end user (i.e., a child), where the user may be unfamiliar with solar light technology.

[0083] For purposes of illustration, the above description has been described with reference to specific embodiments. However, the above illustrative discussion is not intended to be exclusive or to limit the invention to the precise form disclosed. In view of the above teachings, many modifications and variations are possible. The embodiments are selected and described in order to best illustrate the principles of the technology and its practical application. Thus, others skilled in the art are enabled to best utilize the technology and various embodiments with various modifications suitable for the specific use contemplated. For the purpose of clarity and concise description, features are described herein as part of the same or separate embodiments; however, it should be understood that the scope of the present disclosure includes embodiments having a combination of all or some of the described features.

[0084] Although the present disclosure and examples have been fully described with reference to the accompanying drawings, it is to be noted that various changes and modifications will become apparent to those skilled in the art. Such changes and modifications are to be understood to be included within the scope of the present disclosure and examples as defined by the claims. Finally, the entire disclosures of the patents and publications mentioned in this application are hereby incorporated herein by reference.

Claims

1. A method of assembling a solar light kit, comprising: providing the solar light kit in a kit package, the kit package comprising a lens, a printed circuit board PCB, a housing, a plurality of removable fasteners, and a hand tool, wherein the housing comprises a removably attached solar panel and a removably attached battery; attaching the PCB to the lens using one or more of the plurality of removable fasteners and the hand tool, electrically connecting wires from the battery in the housing to a first socket on the PCB, and electrically connecting wires from the solar panel in the housing to a second socket on the PCB, wherein the connections are secured by applying pressure between the wires from the battery inserted into the first socket and between the wires from the solar panel inserted into the second socket; and The housing is connected to the lens using one or more of the plurality of removable fasteners and the hand tool, wherein each of the solar panel, the battery, and the PCB fits within the housing in one orientation.

2. The method according to claim 1, wherein: Connecting the PCB to the lens includes orienting switches on the PCB using one or more illustrated facial features on the lens.

3. The method according to claim 1 or 2, wherein: Prior to connecting wires from the battery and the solar panel to the first and second sockets on the PCB, the method includes inserting a seal into a lip of the lens, wherein the lip extends the perimeter of the lens.

4. The method according to any one of claims 1 to 3, wherein: Prior to coupling the housing to the lens, the method includes inserting a switch button into a hole in the housing, the hole being configured to receive at least a portion of the switch button.

5. The method according to claim 4, wherein: Connecting the housing to the lens includes orienting the switch button inserted into the housing using a switch on the PCB connected to the lens.

6. The method according to any one of claims 1 to 5, wherein: After connecting the housing to the lens, the method includes placing a buffer around the connected lens and at least a portion of the housing, wherein the orientation of the buffer around the connected lens and a portion of the housing is based at least in part on a position of a button indicator on the buffer, the button indicator being configured to align with a position of a switch button inserted into the housing.

7. A method according to any one of claims 1 to 6, comprising attaching the handle to the housing by connecting at least two pegs on the housing to at least two slots on a removable handle.

8. The method according to claim 7, wherein: The angle of the assembled solar-powered light is configured to be adjustable by rotating the handle around the at least two pegs on the housing.

9. The method according to claim 7 or 8, wherein: The height of the assembled solar powered lantern is configured to be adjustable by modifying the positions of the at least two pegs within the at least two slots of the handle.

10. The method according to claim 9, wherein: The at least two slots provide at least two height settings for the assembled solar powered light.

11. The method according to any one of claims 1 to 10, wherein: The first socket is labeled "Battery" and the second socket is labeled "Solar Panel".

12. The method according to any one of claims 1 to 11, wherein: The handheld tool is a screwdriver sized for use by a child, and the removable fastener is a screw configured for use with the screwdriver.

13. The method according to any one of claims 1 to 12, wherein: The handheld tool is a wrench sized for use by a child, and the removable fastener includes one or more of a bolt, a nut, and a screw configured for use with the wrench.

14. The method according to any one of claims 1 to 13, wherein: Each of the connections between the PCB and the lens, the housing and the lens, the wires from the battery and the first socket, and the wires from the solar panel and the second socket do not require the use of solder, glue or adhesive.

15. The method according to any one of claims 1 to 14, wherein: Wires from the battery are removably inserted into the first socket, and wires from the solar panel are removably inserted into the second socket.

16. The method according to any one of claims 1 to 15, wherein: The assembled solar powered lamp can be repaired by removing the one or more removable fasteners from the attached housing and lens to disconnect the lens from the housing, and replacing one or more of the battery, the solar panel, and the PCB.

17. A solar light kit, comprising: a housing including a removably attached solar panel and a removably attached battery; a PCB including one or more light sources, the PCB being configured to be connected to the solar panel and the battery; a lens for diffusing light from the one or more light sources of the PCB, wherein the lens is configured to be connected to the housing and the PCB; a plurality of removable fasteners for connecting the lens to one or more of the PCB and the housing; and A tool is provided for fastening the plurality of removable fasteners, wherein the housing, the PCB, the lens, the plurality of removable fasteners and the tool are bundled together in a kit packaging in an unassembled state.

18. The solar powered light kit of claim 17, comprising a seal configured to be mounted to a perimeter of the lens.

19. The solar light kit according to claim 17 or 18, wherein: The housing is configured to receive a switch button, and the switch button is configured to connect with a switch on the PCB.

20. The solar powered light kit according to any one of claims 17 to 19, wherein: The PCB includes at least two sockets, a first socket configured to connect to wires from the battery and a second socket configured to connect to wires from the solar panel.

21. A solar powered light kit according to any one of claims 17 to 20, comprising a bumper configured to surround at least a portion of the connected housing and lens.

22. The solar powered light kit of claim 21, wherein: The bumper includes a button indicator whose position is configured to align with a position of a switch button inserted into the housing.

23. The solar powered light kit of any one of claims 17 to 22, comprising a handle configured to be removably attached to at least two pegs on the housing, the handle comprising at least two slots configured to receive the at least two pegs.

24. The solar powered light kit of claim 23, wherein: The assembled solar-powered lamp is configured to be hung from the handle or to stand using the handle.

25. The solar powered light kit according to claim 23 or 24, wherein: At least one of a height of the assembled solar-powered light and an angle of the assembled solar-powered light around the handle is adjustable.

26. The solar powered light kit of claim 25, wherein: The at least two slots provide at least two height settings for the assembled solar powered light.

27. The solar powered light kit according to any one of claims 17 to 26, wherein: The tools are the only tools needed to assemble the solar light kit.

28. The solar powered light kit according to any one of claims 17 to 27, wherein: The handheld tool is a screwdriver sized for use by a child, and the removable fastener is a screw configured for use with the screwdriver.

29. The solar powered light kit according to any one of claims 17 to 28, wherein: The handheld tool is a wrench sized for use by a child, and the removable fastener includes one or more of a bolt, a nut, and a screw configured for use with the wrench.

30. The solar powered light kit according to any one of claims 17 to 29, wherein: The PCB comprises at least 18 light sources, and wherein the light sources are light emitting diodes (LEDs).

31. The solar powered light kit of claim 30, wherein: A first portion of the light sources are white LEDs and a second portion of the light sources are colored LEDs.

32. The solar powered light kit of claim 31, wherein: At least one light source in the second portion of the light sources is a battery indicator for indicating a charging status of the battery.

33. A solar powered light kit according to any one of claims 17 to 32, wherein: The battery is a rechargeable lithium-ion battery.

34. A solar powered light kit according to any one of claims 17 to 33, wherein: The solar panel is a polycrystalline silicon solar panel comprising at least 10 photovoltaic PV cells.

35. The solar powered light kit of any one of claims 17 to 34, comprising a set of instructions for guiding a user to assemble the solar powered light from the solar powered light kit.

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