Self-built solar lamp suite

Abstract

Disclosed herein is a solar light kit and a method of assembling the same, the kit comprising: a printed circuit board (PCB) housing configured to surround a first PCB and a second PCB, where the first PCB comprises an array of light sources and the second PCB comprises a plurality of electrical ports, the first PCB and the second PCB being configured to be connected and fitted in the PCB housing in an orientation; a battery case configured to surround the at least one rechargeable battery, where the battery case is configured to be connected to the PCB case; a housing configured to surround the connected PCB case and battery case; and a solar panel configured to be connected to the second PCB using a connector cable that can be removably connected to the solar panel and the second PCB.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Application No. 18 / 053,954, filed November 9, 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, which limits the scope 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 of the lack of energy resources that their peers in developing countries face. Energy poverty has left billions of people in darkness, poor health, an unattainable future, and a repeating cycle of poverty. Specifically, energy poverty causes more child deaths each year than AIDS and malaria combined. In developing countries, many families do not have the resources to charge electronic devices at home. Therefore, people (usually children) need to go to charging stations to charge their devices. These charging stations are usually powered by fossil fuel-driven generators and are not cost-friendly. Summary of the Invention

[0005] As mentioned above, classrooms have shifted to an educational style that relies heavily on virtual resources. Furthermore, many communities in developing countries face energy poverty, with limited access to lights and energy to charge personal devices. Consequently, there's a gap in educating children through hands-on, STEM (science, technology, engineering, and math)-based activities, such as building functional devices, while also creating a lasting impact by donating the constructed devices to children and families in need in developing countries.

[0006] The disclosed solar lantern kit connects two groups—those facing energy poverty and those in need of improved educational tools—by providing a system where children have the opportunity to learn about solar lanterns and energy poverty in developing countries, build a solar lantern device from the kit using instructions, and donate the solar lantern to a child in need. The learning experience can also include the opportunity to write a letter to the child receiving the device, along with the donated solar lantern. Children and families facing energy poverty can intuitively operate the lantern to complete schoolwork, work, play, and travel in otherwise dark environments, thereby improving their lives. Not only is the knowledge gained from learning how to build the solar lantern and spreading awareness about energy poverty, but the knowledge gained also contributes to the education of children in developed countries. Furthermore, when receiving the solar lantern, children in developing countries can learn about the solar lantern system and how to maintain their own devices, thereby also improving the education of children in developing countries.

[0007] The disclosed solar lantern kit can include various custom-shaped, modular, removably connectable components for building solar panels and flashlight-style solar lanterns that can be used in various situations. Once constructed, the solar panel device and the solar lantern device can be electrically connected (e.g., via a cable) to transfer energy generated by the solar panel to the solar lantern device to power the light source on the solar lantern device. In some embodiments, the flashlight-style solar lantern can include one or more charging ports for charging other devices (e.g., mobile devices such as phones, tablets, etc.). The solar panel and solar lantern can be portable and constructed of environmentally sustainable, lightweight, and weather-resistant materials to withstand adverse environmental conditions such as rain and UV sun exposure.

[0008] In some embodiments, a method of assembling a solar lamp kit is provided, the method comprising: connecting a first printed circuit board (PCB) comprising a light source array and a set of leads and a second PCB comprising a plurality of electrical ports, wherein connecting the first PCB and the second PCB comprises aligning a set of leads on the first PCB with a first electrical port among a plurality of electrical ports on the second PCB, and applying pressure between the first PCB and the second PCB; inserting the connected first PCB and the second PCB into a PCB housing, wherein the connected first PCB and the second PCB are assembled in the PCB housing in one orientation; connecting the PCB housing and the battery housing by aligning one end of the PCB housing with one end of a battery housing surrounding a rechargeable battery and applying pressure between the PCB housing and the battery housing; inserting the connected PCB housing and the battery housing into a casing; and connecting a solar panel to a second electrical port among the plurality of electrical ports on the second PCB using a connector cable, wherein the connector cable is removably connectable to the solar panel and the second electrical port.

[0009] In some embodiments, the method includes attaching a lens to a first printed circuit board (PCB), wherein the lens is configured to disperse light from an array of light sources on the first PCB.

[0010] In some embodiments, the first printed circuit board includes a switch configured to activate and deactivate the array of light sources.

[0011] In some embodiments, a third electrical port of the plurality of electrical ports on the second printed circuit board is configured to charge a mobile device.

[0012] In some embodiments, a first printed circuit board (PCB) includes one or more through-holes, and a through-hole of the one or more through-holes is configured to receive a second electrical port on a second PCB.

[0013] In some embodiments, the method includes attaching an end cap to one end of the connected first and second printed circuit boards (PCBs) before inserting the connected first and second PCBs into a PCB housing.

[0014] In some embodiments, inserting the connected first and second printed circuit boards (PCBs) into the PCB housing includes inserting ends of the connected first and second PCBs opposite the end caps into the PCB housing.

[0015] In some embodiments, the method includes, before inserting the connected printed circuit board (PCB) housing and battery housing into the housing, attaching the electrical port plate to the PCB housing by aligning the electrical port plate with corresponding portions of the PCB housing and applying pressure between the electrical port plate and the PCB housing.

[0016] In some embodiments, the electrical port plate includes one or more through-holes configured to align with one or more of the plurality of electrical ports on the second printed circuit board.

[0017] In some embodiments, the electrical port plate includes a button configured to align with and engage a switch on the first printed circuit board.

[0018] In some embodiments, the method includes attaching the electrical port cover to the connected printed circuit board (PCB) housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing before inserting the connected printed circuit board (PCB) housing and the battery housing into the housing.

[0019] In some embodiments, the electrical port cover includes one or more electrical port caps configured to removably cover one or more electrical ports of the plurality of electrical ports on the second printed circuit board.

[0020] In some embodiments, the method includes, prior to coupling the printed circuit board housing and the battery housing, inserting a rechargeable battery into an end of the battery housing.

[0021] In some embodiments, the method includes, after inserting the rechargeable battery into one end of the battery housing, enclosing the rechargeable battery in the battery housing with one or more end caps.

[0022] In some embodiments, enclosing the rechargeable battery in the battery casing includes inserting a portion of one or more end caps into an end of the battery casing by aligning the end cap with the end of the battery casing and applying pressure between the end cap and the battery casing.

[0023] In some embodiments, connecting a printed circuit board (PCB) housing and a battery housing includes aligning an end of the battery housing including one or more end caps with an open end of the PCB housing.

[0024] In some embodiments, connecting a printed circuit board (PCB) housing and a battery housing includes connecting leads extending from the rechargeable battery to the connected first and second PCBs.

[0025] In some embodiments, the method includes, prior to inserting the connected printed circuit board housing and battery housing into the housing, connecting a first end cap of the plurality of end caps to the first end of the housing.

[0026] In some embodiments, inserting the connected printed circuit board (PCB) housing and battery housing into the housing includes inserting the connected PCB housing and battery housing into the housing at a second end of the housing after connecting the first end cap to the first end of the housing.

[0027] In some embodiments, the method includes, after inserting the connected printed circuit board housing and battery housing into the housing, connecting a second end cap of the plurality of end caps to the second end of the housing.

[0028] In some embodiments, connecting the first and second end caps of the plurality of end caps to the housing includes using at least one hand tool and a plurality of removable fasteners.

[0029] In some embodiments, assembling the solar light kit includes assembling a solar panel stand and a solar panel frame.

[0030] In some embodiments, assembling the solar panel frame includes connecting a plurality of corner members and a plurality of edge members around an outer edge of the solar panel.

[0031] In some embodiments, connecting the plurality of corner members and the plurality of edge members includes using a plurality of removable fasteners and at least one hand tool.

[0032] In some embodiments, assembling the solar panel stand includes connecting an arm connecting member to a pair of stand arms.

[0033] In some embodiments, connecting the stand connection member to the pair of stand arms includes using a plurality of removable fasteners and at least one hand tool.

[0034] In some embodiments, assembling the solar panel includes connecting the assembled solar panel stand and the solar panel frame.

[0035] In some embodiments, connecting the assembled solar panel stand and the assembled solar panel frame includes using one or more stand connectors, a plurality of removable fasteners, and at least one hand tool.

[0036] In some embodiments, the solar light kit is provided in a kit package that includes instructions and a plurality of hand tools for assembling the solar light kit.

[0037] In some embodiments, a solar lamp kit is provided, comprising: a printed circuit board (PCB) housing configured to enclose a first PCB and a second PCB, wherein the first PCB includes a light source array and a set of leads, the second PCB includes a plurality of electrical ports, the first PCB and the second PCB are configured to be connected by aligning a set of leads on the first PCB with a first electrical port of the plurality of electrical ports on the second PCB and applying pressure between the first PCB and the second PCB, and the connected first and second PCBs are configured to be assembled in the PCB housing in one orientation; a battery housing configured to enclose at least one rechargeable battery, wherein the battery housing is configured to be connected to the PCB housing by aligning one end of the PCB housing with one end of the battery housing and applying pressure between the PCB housing and the battery housing; a housing configured to enclose the connected PCB housing and the battery housing; and a solar panel configured to be connected to the second PCB using a connector cable, wherein the connector cable is removably connectable to the second electrical port on the solar panel and the second PCB, and the PCB housing, the first PCB, the second PCB, the battery housing, the rechargeable battery, the housing, the solar panel and the connector cable are bundled together unassembled in the kit package.

[0038] In some embodiments, a solar light kit includes a lens configured to be attached to a first printed circuit board (PCB) to disperse light generated from an array of light sources on the first PCB.

[0039] In some embodiments, the first printed circuit board includes a switch configured to activate and deactivate the array of light sources.

[0040] In some embodiments, a third electrical port of the plurality of electrical ports on the second printed circuit board is configured to charge a mobile device.

[0041] In some embodiments, a first printed circuit board (PCB) includes one or more through-holes, and a through-hole of the one or more through-holes is configured to receive a second electrical port on a second PCB.

[0042] In some embodiments, a solar light kit includes an end cap configured to attach to one end of a connected first printed circuit board (PCB) and a second PCB.

[0043] In some embodiments, the connected first and second printed circuit boards (PCBs) are configured to be inserted into a PCB housing at an end of the connected first and second PCBs opposite the end caps.

[0044] In some embodiments, a solar-powered light kit includes an electrical port plate configured to be attached to a printed circuit board (PCB) housing by aligning the electrical port plate with corresponding portions of the PCB housing and applying pressure between the electrical port plate and the PCB housing.

[0045] In some embodiments, the electrical port plate includes one or more through-holes configured to align with one or more of the plurality of electrical ports on the second printed circuit board.

[0046] In some embodiments, the electrical port plate includes a button configured to align with and engage a switch on the first printed circuit board.

[0047] In some embodiments, a solar light kit includes an electrical port cover configured to be attached to a printed circuit board (PCB) housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing.

[0048] In some embodiments, the electrical port cover includes one or more electrical port caps configured to removably cover one or more electrical ports of the plurality of electrical ports on the second printed circuit board.

[0049] In some embodiments, the solar light kit includes one or more end caps configured to be inserted into an end of the battery housing to enclose the rechargeable battery in the battery housing.

[0050] In some embodiments, enclosing the rechargeable battery in the battery casing includes inserting a portion of one or more end caps into an end of the battery casing by aligning the portion of the end cap with the end of the battery casing and applying pressure between the end cap and the battery casing.

[0051] In some embodiments, connecting the printed circuit board (PCB) housing and the battery housing includes aligning an end of the battery housing including one or more end caps with an open end of the (PCB) housing.

[0052] In some embodiments, a rechargeable battery includes leads extending from the battery, the leads configured to connect to connected first and second printed circuit boards (PCBs).

[0053] In some embodiments, the solar-powered light kit includes a first end cap of the plurality of end caps configured to be connected to the first end of the housing.

[0054] In some embodiments, the connected printed circuit board (PCB) housing and battery housing are configured to be inserted into the housing at the second end of the housing.

[0055] In some embodiments, the solar-powered light kit includes a second end cap of the plurality of end caps configured to be connected to the second end of the housing.

[0056] In some embodiments, a solar-powered light kit includes at least one handheld tool and a plurality of removable fasteners configured to connect a first end cap and a second end cap of the plurality of end caps to the housing.

[0057] In some embodiments, the solar panel includes a solar panel frame and a solar panel stand configured to be assembled.

[0058] In some embodiments, the solar panel frame includes a plurality of corner members and a plurality of edge members configured to surround an outer edge of the solar panel.

[0059] In some embodiments, the plurality of corner members and the plurality of edge members are configured to be connected around the periphery of the solar panel using a plurality of removable fasteners and at least one hand tool.

[0060] In some embodiments, a solar panel stand includes a pair of stand arms and an arm connecting member configured to connect the pair of stand arms.

[0061] In some embodiments, the arm connecting member and the pair of arms are configured to connect using a plurality of removable fasteners and at least one hand tool.

[0062] In some embodiments, the assembled solar panel stand and the assembled solar panel frame are configured to connect using one or more stand connectors, a plurality of removable fasteners, and at least one hand tool.

[0063] In some embodiments, the kit packaging includes a plurality of hand tools and instructions for assembling the solar light kit.

[0064] In some embodiments, a solar lamp kit is provided, comprising: a solar lamp device, comprising a first printed circuit board (PCB), a second PCB and a rechargeable battery, wherein the first PCB comprises a light source array and a lens, and the second PCB comprises a plurality of electrical ports, wherein a first electrical port of the plurality of electrical ports is configured to receive a connector cable, and a second electrical port of the plurality of electrical ports is configured to receive a charging cable for charging a mobile device; and a solar panel device, comprising a frame and a stand, wherein the solar panel device is configured to be removably connected to the solar lamp device using the connector cable.

[0065] In some embodiments, the solar-powered light device comprises a rectangular prism shape configured to be hand-held by a human.

[0066] In some embodiments, an array of light sources on a first printed circuit board (PCB) and a plurality of electrical ports on a second PCB are disposed on a face of the solar-powered lamp device.

[0067] In some embodiments, the light source array includes a plurality of light emitting diodes (LEDs).

[0068] In some embodiments, the solar-powered light device includes a third electrical port configured to receive a charging cable for charging a mobile device.

[0069] In some embodiments, the second electrical port and the third electrical port comprise universal serial bus (USB) ports.

[0070] In some embodiments, the first electrical port comprises a direct current (DC) barrel jack.

[0071] In some embodiments, the solar-powered lamp apparatus includes an electrical port cover comprising a plurality of caps configured to removably cover a plurality of electrical ports on the second printed circuit board.

[0072] In some embodiments, the first printed circuit board includes a button configured to activate and deactivate the light source array.

[0073] In some embodiments, engagement of the button toggles between a plurality of light illumination settings of the light source array.

[0074] In some embodiments, the connector cable is at least 2 meters in length.

[0075] In some embodiments, the solar panel device is a polycrystalline panel comprising a plurality of solar cell units. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] The present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0077] Figure 1 A perspective view of a solar panel and solar lamp constructed in accordance with some embodiments is shown.

[0078] Figures 2A-2D Components of a solar light kit package are shown according to some embodiments.

[0079] Figure 3A-Figure 3P The steps for assembling a solar lamp of a solar lamp kit according to some embodiments are shown.

[0080] Figures 4A-4H Steps for assembling a solar panel of a solar light kit are shown, according to some embodiments.

[0081] Figure 5A method for assembling a solar-powered light from a solar-powered light kit is shown, according to some embodiments. DETAILED DESCRIPTION

[0082] Reference will now be made in detail to embodiments and examples of various aspects of the systems and methods described herein and variations thereof. 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, having all or some combinations of the described aspects.

[0083] The disclosed solar lantern kit may include a modular solar panel device and a flashlight-style solar lantern device that are removably connected (e.g., via a cable) to transfer energy generated by the solar panel to the solar lantern. The solar lantern may include a rechargeable battery configured to receive energy generated by the solar panel and provide power to the light source of the solar lantern device. The solar lantern may include one or more charging ports for providing power stored by the solar panel to one or more personal devices (e.g., mobile devices, phones, tablets, etc.). One or more components of the solar lantern kit may be specifically designed to be assembled by children using a limited number of handheld tools and without the use of solder, glue, or other adhesives. In addition, the components used to construct the solar panel and solar lantern may be manufactured so that each piece must be assembled in a specific order and orientation. The flashlight-style solar lantern may be sized so that it is handheld and portable for a child when disconnected from the solar panel. The solar panel of the solar lantern kit may include a stand that allows the device to be stood / hung in any preferred orientation.

[0084] In the description of the following multiple embodiments, it should be understood that, unless the context clearly indicates otherwise, the singular forms "a", "an" and "the" used in the following description are also intended to include the plural forms. It should also be understood that the term "and / or" as used herein refers to and covers any and all possible combinations of one or more of the associated listed items. It should further be understood that the terms "includes", "including", "comprises" and / or "comprising" when used herein specify the presence of the features, integers, steps, operations, elements, parts and / or units, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts, units and / or groups thereof.

[0085] Features of the solar light kit

[0086] Figure 1The solar panel and solar lantern are shown assembled and connected according to some embodiments. The solar lantern 100 can include one or more features, including a button 102 configured to switch between states of the solar lantern; one or more charging ports 104; and an electrical port 106 configured to receive an electrical connector (e.g., a cable 180) for transmitting energy (e.g., electricity) generated by the solar panel to components within the solar lantern 100.

[0087] In some embodiments, button 102 can be configured to activate and deactivate the solar-powered lamp (e.g., the light source of the solar-powered lamp). For example, a user can interact with button 102 by pressing the button a first time to turn the lamp on, and a second time to turn the lamp off. In some embodiments, solar-powered lamp 100 can include multiple light settings. For example, the solar-powered lamp can be configured to emit light in multiple colors (e.g., red, green, blue, white, yellow, etc.) and / or at multiple intensities (e.g., low, medium, and high). In some embodiments, a user can interact with button 102 to switch between these light settings. For example, a user can press button 102 a first time to turn the lamp on, and by pressing and holding the button for a predefined amount of time (e.g., 1 second, 2 seconds, 3 seconds, or longer), the color and / or brightness of the lamp can be changed. In some embodiments, a user can switch between light settings by repeatedly pressing button 102.

[0088] In some embodiments, the duration that the solar lantern 100 can illuminate when fully charged with solar energy from a solar panel (e.g., solar panel 140) can depend on the intensity of the light provided. For example, at low brightness (e.g., at or about 50 lumens), the solar lantern 100 can be configured to provide at least 30, 35, 40, 45, 50 hours, or more, of light via the light source array. In some embodiments, at high brightness (e.g., at or about 240 lumens), the solar lantern 100 can be configured to provide at least 3, 3.5, 4, 4.5, 5, 5.5, 6 hours, or more, of light via the light source array. In some embodiments, the light source array can include at least 5, 6, 7, 8, 9, 10, or more light emitting diodes (LEDs). In some embodiments, the solar lantern 100 can include a third light setting (e.g., a "flashlight" setting) configured to provide high-power light (e.g., approximately 150 lumens) via one light source (e.g., an LED). In some embodiments, the solar-powered lamp 100 can be configured to provide at least 3, 3.5, 4, 4.5, 5, 5.5, 6, or more hours of light from a single high-powered LED.

[0089] In some embodiments, the solar lantern 100 may include one or more electrical ports, such as a charging port 104, configured to provide power to (e.g., charge) a user's personal device. For example, a user can plug a charging cable (e.g., a Universal Serial Bus (USB) cable, such as USB-A, USB-B, USB-C, etc.) into a charging port (e.g., a USB port) on the solar lantern 100 to charge the user's personal device (e.g., a mobile device, smartwatch, tablet, etc.) using energy stored in the solar lantern device (e.g., via a rechargeable battery within the solar lantern). In some embodiments, the solar lantern 100 may include one, two, three, or more charging ports 104. In some embodiments, the charging port 104 may provide less than or equal to 5V, 9V, 15V, or 20V of power to the mobile device being charged. In some embodiments, the charging port 104 may provide greater than or equal to 5V, 9V, 15V, or 20V of power to the mobile device being charged.

[0090] In some embodiments, the one or more electrical ports of the solar lantern 100 may include an electrical port 106 configured to transmit electricity generated from the solar panel 140 to the solar lantern 100 via an electrical connector 180. In some embodiments, the electrical port 106 may be a direct current (DC) port (e.g., a 5.5V DC barrel jack). The electrical port 106 may be configured to removably connect to one end of a corresponding electrical connector 180, wherein the opposite end of the electrical connector 180 may be configured to connect to the solar panel 140. In some embodiments, the port on the solar panel 140 for receiving the electrical connector 180 may be a DC port (e.g., a 5.5V DC barrel jack). In some embodiments, one or more ports on the solar panel 140 and / or the solar lantern 100 configured to correspond to the electrical connector 180 may be a USB port. In some embodiments, one or more of the electrical ports may be capped when not in use. For example, the solar-powered lantern 100 can include an electrical port cover comprising one or more caps configured to be inserted into the electrical ports 104 and / or 106 when the ports are not connected to cables.

[0091] In some embodiments, the solar-powered lantern 100 may include a rechargeable battery configured to store energy (e.g., electricity) transmitted from the solar panel 140 (e.g., via the electrical connector cable 180) to the solar-powered lantern 100. In some embodiments, the rechargeable battery may be a lithium-ion battery, a lead-acid battery, a nickel-cadmium battery, or a nickel-metal hydride battery. For example, the rechargeable battery may be a 3000 mAh, 3.7 V lithium-ion battery. In some embodiments, the solar-powered lantern 100 may include more than one battery. In some embodiments, the battery may be electrically coupled to circuitry configured to provide additional features associated with the battery. For example, the solar-powered lantern 100 may be configured to provide an indication when the battery is charging, when the battery is sufficiently charged (e.g., more than 50%, 75%, 90%, etc.), and / or when the battery is low. For example, an indicator may be included in one or more light sources (e.g., LEDs) of the solar-powered lantern 100, such that the indicator illuminates and / or flashes in different colors (e.g., red, green, etc.) to provide battery status. In some embodiments, the circuitry coupled to the battery of the solar-powered lamp 100 can be configured to automatically shut down the device if a threshold battery level (e.g., 1%, 2%, 5%, 10%, etc.) is breached. In some embodiments, the circuitry can provide overcharge and / or over-discharge protection. In some embodiments, the rechargeable battery can be configured to store at least six months of backup battery charge.

[0092] The solar lantern kit described herein may additionally include a solar panel 140. The solar panel 140 may be a thin film (e.g., amorphous silicon), polycrystalline silicon, or monocrystalline silicon solar panel. For example, the solar panel 140 may be a polycrystalline silicon panel including a plurality of solar (e.g., photovoltaic (PV)) cell units. In some embodiments, the solar panel 140 may be rated at a wattage of at least 5W (e.g., 5.5W). In some embodiments, the solar panel 140 may be configured to provide a full solar charge to the solar lantern 100 in less than 8 hours. For example, the solar panel 140 may provide a full solar charge in 3, 4, 5, 6, 7, or 8 hours. The cable configured to removably connect the solar panel 140 and the solar lantern 100 may be selected so that the solar panel can be placed a certain distance from the lantern when charging the solar lantern (e.g., the solar panel can be deployed outdoors, on a roof, etc.). For example, cable 180 can be at least 1 meter, 1.5 meters, 2 meters, 2.5 meters, 3 meters, or longer in length to allow the panel and lights to be stored in different environments (e.g., the panel can be placed outdoors where the lights can be stored indoors).

[0093] In some embodiments, the solar panel 140 may include a solar panel stand 142. In some embodiments, the solar panel stand 142 may be lockable, such that the solar panel 140 may be positioned and operably locked at a variety of angles customized by the user. For example, as will be described below with respect to at least Figures 4A-4H In more detail, the solar panel assembly can include a stand connector configured to removably lock the solar panel stand 142 to the solar panel 140. In some embodiments, the stand 142 can be folded so that it lies flat against the panel 140. In some embodiments, the solar panel 140 can be hung from the solar panel stand 142 (e.g., from a window, door frame, etc.).

[0094] In some embodiments, the solar panel 140 and / or solar lantern 100 may include one or more hanging features. For example, one or more corners and / or sides of the solar panel 140 may include hooks configured to hang the solar panel 140, as described above with respect to the stand 142. In some embodiments, one or more corners and / or sides of the solar panel 140 may include through-holes configured to receive the hooks, allowing the device to be hung by inserting the hooks through the hole(s). Similarly, the solar lantern 100 may include one or more hooks and / or through-holes configured to receive the hooks. For example, one or more ends of the solar lantern 100 may include hanging features. Thus, each solar lantern 100 can be hung from, for example, a door frame, a pillar, a ceiling, etc., to illuminate an area, such as a room in a home. In some embodiments, the solar panel 140 can be removably attached to a roof, pillar, or other object, for example, using removable fasteners and / or hooks inserted into one or more through-holes on the solar panel 140.

[0095] In some embodiments, the solar panel 140 and / or solar lantern 100 may include one or more features configured to organize / maintain at least a portion of the electrical connector 180 when connected to one or more components. For example, the solar panel 140 may include one or more slots (e.g., at one or more corners and / or sides of the solar panel 140) configured to receive the cable of the electrical connector 180 for cable management. In some embodiments, the slots may be disposed on one or more arms of the solar panel stand (e.g., at least one of the arms of the solar panel stand). Figure 2A ).

[0096] In some embodiments, each of the solar lantern 100 and the solar panel 140 can be lightweight so that the device is portable for the intended user (e.g., a child). For example, the weight of each of the solar lantern panel 140 and / or the solar lantern 100 can be less than or equal to 1.5 kg, such as 1.4 kg, 1.3 kg, 1.2 kg, 1.1 kg, or less than 1.0 kg. In some embodiments, the weight of each of the solar lantern panel 140 and / or the solar lantern 100 can be greater than 1.5 kg, such as 1.6 kg, 1.7 kg, 1.8 kg, 1.9 kg, or greater than 2.0 kg.

[0097] In some embodiments, the length of solar panel 140 can be less than or equal to 30 cm, 32 cm, 34 cm, 36 cm, 38 cm, or 40 cm. In some embodiments, the length of solar panel 140 can be greater than or equal to 30 cm, 32 cm, 34 cm, 36 cm, 38 cm, or 40 cm.

[0098] In some embodiments, the width of solar panel 140 can be less than or equal to 14 cm, 16 cm, 18 cm, 20 cm, 22 cm, or 24 cm. In some embodiments, the width of solar panel 140 can be greater than or equal to 14 cm, 16 cm, 18 cm, 20 cm, 22 cm, or 24 cm.

[0099] In some embodiments, the thickness (e.g., depth) of solar panel 140 can be less than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm. In some embodiments, the thickness (e.g., depth) of solar panel 140 can be greater than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm.

[0100] In some embodiments, the length of the solar lamp 100 can be less than or equal to 32 cm, 34 cm, 36 cm, 38 cm, 40 cm, 42 cm, or 44 cm. In some embodiments, the length of the solar lamp 100 can be greater than or equal to 32 cm, 34 cm, 36 cm, 38 cm, 40 cm, 42 cm, or 44 cm.

[0101] In some embodiments, the first width and / or second width of the solar-powered lamp 100 can be defined as a dimension perpendicular to the longitudinal axis of the solar-powered lamp 100. The solar-powered lamp 100 can be sized so that it can be handheld and portable by an intended user (e.g., a child). In some embodiments, the first width and / or second width of the solar-powered lamp 100 can be less than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm. In some embodiments, the width of the solar-powered lamp 100 can be greater than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm.

[0102] As mentioned above, the solar panel 140 can be configured to be mounted on a roof (e.g., the roof of a home) so that a removably attached cable 180 can be fed through a nearby window, rafter, or other opening to charge the solar lantern 100 (e.g., where the solar lantern is stored indoors). In some embodiments, the solar lantern 100 can be used for extended periods of time outdoors in adverse weather. Therefore, each of the solar panel 140 and / or the solar lantern 100 can be made of durable, weather-resistant materials.

[0103] For example, one or more components of the solar lantern 100 and / or solar panel 140 can be made from aluminum and / or an aluminum alloy. Aluminum can be selected, at least because it is lightweight, yet strong, recyclable, and durable. For example, the solar panel frame and / or solar lantern frame can comprise aluminum (and / or an aluminum alloy). In some embodiments, one or more additional components of the solar lantern 100 and / or solar panel 140 can be made from a durable, long-lasting polymer (e.g., an elastomer). For example, one or more components can include polycarbonate, acrylonitrile butadiene styrene (ABS), 30% glass fiber reinforced polyamide, and / or silicone. For example, one or more corner members configured to connect to the edge members of the solar panel 140 (where the corner members and edge members can be assembled to form the frame of the solar panel 140) can be made from a polymer (e.g., 30% glass fiber reinforced polyamide). In some embodiments, one or more components of the solar lantern kit can be manufactured using injection molding, at least because injection molding techniques can allow components to have unique, custom geometries.

[0104] Features of the solar light kit package

[0105] Figures 2A-2D Components of a solar light kit package according to some embodiments are shown. For example, Figure 2AThe unassembled parts of the solar lamp device (200a) and the solar panel device (240a) can be shown. Figure 3A-Figure 3P and Figures 4A-4H Each component used to construct the solar lantern 200a and the solar panel device 240a is described in more detail. In some embodiments, the components used to construct the solar lantern 200a may include one or more printed circuit boards (PCBs) (208, 210), a plurality of end caps (212, 224, 226, 230, 234), a PCB storage component 214, a housing 228, an electrical port plate 216, an electrical port cover 218, and one or more battery storage components (220, 222). In some embodiments, the PCB 208 may be configured to be attached to (and / or may include) a lens 209 for dispersing light from one or more light sources (e.g., LEDs). In some embodiments, the PCB 210 may include one or more electrical ports for charging additional devices (e.g., mobile devices) and / or transmitting electricity generated by the constructed solar panel to the constructed solar lantern device.

[0106] In some embodiments, components for constructing the solar panel apparatus 240a may include a solar panel 254, one or more edge members (244, 252), one or more corner members (246, 248), one or more stand members (256, 258), and one or more stand connectors 262. The solar light kit may include a plurality of removable fasteners (e.g., screws, nuts, bolts, etc.) for assembling the solar light panel and / or solar light apparatus (not shown). For example, as will be described in more detail below, the solar light kit may include a plurality of screws of different sizes that are configured to be tightened with a limited number of wrenches (e.g., Allen keys).

[0107] Figure 2B The diagram illustrates the packaged components of a solar lantern kit including a solar lantern component 200b and a solar lantern panel component 240b. As shown, each component used to assemble the solar lantern can be packaged together in a manner such that each component has a defined storage space (e.g., a bag, an envelope) in a packaging pallet 290. The bags in the packaging pallet 290 can be configured to contain each of the components in a specific orientation, thereby allowing the builder to see each component. For example, the bags in the packaging pallet 290 can be configured to contain each of the arms of a stand for assembling the solar panel 240b, so that the arms can be stacked in a shared bag in the packaging pallet 290. Similarly, edge members of the same size can be stacked in a shared bag on the packaging pallet 290.

[0108] In some embodiments, the packaging tray 290 can be constructed from recycled materials, such as recycled paper pulp, and additionally can be compostable after use. In some embodiments, the packaging tray 290 can be configured to store unassembled solar light kits (e.g., Figure 2B ) and the assembled solar light kit (as shown in Figure 2D ). In some embodiments, the packaging pallet 290 can be stackable so that multiple pallets can be stacked to transport the kit. For example, the packaging pallet 290 can include tapered sidewalls, wherein one or more of the sidewalls of the packaging pallet can include built-in handles. The tapered sidewalls and / or handles can not only facilitate stacking of the pallets, but also allow one or more pallets to be separated from the stack of pallets. Thus, the unassembled kit can be easily shipped to the builder (e.g., children in a school), and once built, the assembled solar lantern can be placed back on the packaging pallet for ultimate shipment to the intended end user (e.g., children and / or families in developing groups). The packaging pallet can be reused, or as mentioned above, can be recycled and / or composted.

[0109] Figure 2C A tool kit for assembling a solar lantern kit according to some embodiments is illustrated. For example, the tool kit 270 may include one or more hand-held tools for tightening and / or loosening one or more fasteners in the solar lantern kit. In some embodiments, the size of the one or more hand-held tools may be designed for use by an intended builder (e.g., a child). In some embodiments, the tool kit 270 may include one or more wrenches, such as hex keys (e.g., Allen keys), open-end wrenches, and / or ratchet wrenches. In some embodiments, the tool kit 270 may include one or more screwdrivers, such as a flat-head screwdriver, a Phillips screwdriver, and / or a hex screwdriver. In some embodiments, as Figure 2C As shown in FIG, tool kit 270 may include various hand tools (e.g., wrenches), wherein each wrench in the tool kit is configured to correspond to a fastener (e.g., a screw) of a different size. Each of the hand tools may be bundled, for example, using a tool holder 272. In some embodiments, tool holder 272 may be manufactured from a biodegradable material (such as polylactic acid (PLA)) using, for example, 3D printing manufacturing technology.

[0110] In some embodiments, a sticker containing a scannable barcode (e.g., a QR code) can be attached to the tool holder 272, allowing the builder to scan the barcode to receive building instructions for the solar lantern kit, instructional materials regarding the procedures associated with the solar lantern kit, and the like. In some embodiments, the tool holder 272 can include one or more markings for distinguishing between each of the tools in the tool kit 270. For example, the position of a handheld tool, as bundled by the tool holder 272, can correspond to one or more markings on the tool holder 272, and the one or more markings can be referenced throughout the building instructions. By using the tool kit and removable fasteners, the solar lantern kit (e.g., the solar panel device and the solar lantern device) can be assembled using a limited number of handheld tools and fasteners and can be easily disassembled in the event that one or more components of the device need to be replaced and / or repaired. Furthermore, the solar lantern kit may not require any adhesives (e.g., glue, tape, etc.), power tools, or welding to successfully assemble the solar lantern kit.

[0111] In some embodiments, one or more tool kits 270 and fasteners for assembling a solar lantern kit can be provided in a bag so that a group of users (e.g., a class of students) can be provided with multiple tool kits and sets of fasteners in a single bag. In some embodiments, the bag can be made from recycled materials.

[0112] Solar light equipment assembly

[0113] Figure 3A-Figure 3P The steps for assembling a solar lantern device of a solar lantern kit according to some embodiments are shown. In some embodiments, each of the components used to assemble a solar lantern from the solar lantern kit can be assembled in a specific manner so that each part can be assembled together in a limited number (one or more, for example, one) of orientations. In some embodiments, assembling the solar lantern may require sequentially following the steps described in the following sections. Figure 3A-Figure 3P At least a portion of the steps described below can be completed without having to complete the steps described previously. In some embodiments, each component of the kit can be removably attached so that each of the steps described below can be completed in the reverse order of disassembling the solar light device.

[0114] like Figure 3AAs shown in FIG, a user (e.g., a builder) can begin assembling a solar lantern by first connecting a first printed circuit board (PCB) 308 and a second PCB 310. For example, PCBs 308 and 310 can be attached by aligning corresponding portions of the PCBs and applying pressure between the components. In some embodiments, PCBs 308 and / or PCB 310 can include one or more receiving portions and one or more inserting portions. For example, PCB 308 can include a set of leads (e.g., inserting portions) configured to insert into ports (e.g., receiving portions) on PCB 310. For example, the ports can be communication ports configured to receive leads on PCB 308 in a press-fit manner. In some embodiments, PCB 308 can include one or more through-holes configured to receive (e.g., in a slip-fit manner) one or more elevated portions (e.g., ports) on PCB 310. Therefore, when attaching PCBs 308 and 310, the user may need to align each of the components on the PCBs that are configured to mate in order to successfully attach the PCBs. In some embodiments, the solar lantern kit may include a single PCB that includes all electrical modules, rather than multiple PCBs (each of which includes a portion of the modules required to operate the solar lantern), thereby eliminating the need for a connection step. In some embodiments, the solar lantern kit may include multiple PCBs, and the modules used to operate the device may be arranged in a manner different from that described above.

[0115] As mentioned above, one or more ports on PCB 310 can be charging ports for external devices. In some embodiments, a port in the one or more electrical ports on PCB 310 can be configured to receive an electrical connector (e.g., a cable) for connecting the assembled solar light to the assembled solar panel (e.g., to transfer the charge generated from the solar panel to the light). In some embodiments, PCB 308 can include an array of light sources (e.g., light emitting diodes, LEDs). In some embodiments, PCB 308 can include a lens that is configured to disperse light from the LED array. In some embodiments, the user may need to attach a lens 309 that is packaged separately from PCB 308 to the PCB (e.g., as shown in FIG. 1 ). Figure 3B ), so that the lens 309 can cover the array. In some embodiments, the lens 309 can click (e.g., snap into) onto a portion of the PCB 308 so that the lens can be attached to the PCB 308 only on a specific side of the PCB and in a specific orientation on the PCB.

[0116] PCBs 308 and 310 are shaped so that they can be inserted into the housing of the flashlight-type solar-powered lamp and extend along the housing. For example, the PCB can be an elongated strip-shaped member that includes a substantially flat top and bottom surface, wherein one or more modules (e.g., ports, leads, etc.) are configured thereon. For example, each of the aforementioned receiving portion and inserting portion can be disposed on the top and / or bottom surface of PCBs 308 and 310. In some embodiments, the first end of PCB 308 can include an LED array, and the second end of PCB 308 can include one or more through-holes configured to receive protruding ports on PCB 310. In some embodiments, the length of PCB 310 can be approximately half the length of PCB 308, such that PCB 310 extends the length of PCB 308 including the one or more through-holes and ends approximately where the LED array begins on PCB 308.

[0117] After connecting PCBs 308 and 310, the builder can attach end caps (e.g., brackets) 312 to one end of the connected PCBs. Figure 3B As shown in , the bracket 312 may include one or more openings configured to receive a portion of the PCB 308 and the PCB 310, and may be configured to surround at least a portion of the connected PCBs. Due at least to the custom geometry of one or more of the PCBs and / or one or more modules on the PCBs, the bracket 312 may include a custom configuration that may be attachable to the PCBs in a single orientation. In some embodiments, the bracket 312 may be attached to the connected PCBs by applying pressure between the bracket 312 and the connected PCBs 308, 310. In some embodiments, the bracket 312 may snap into place over a portion of the connected PCBs.

[0118] Figure 3C The following steps of the method of assembling a solar lamp are shown. As mentioned above, the solar lamp may include one or more housings, such as a PCB housing 314. In some embodiments, after inserting the connected PCB into the PCB housing 314 (e.g., Figure 3DBefore the electrical port plate 216 is attached to the PCB housing 314 (as shown in FIG. 2 ), the electrical port plate 216 can be attached to the PCB housing 314. In some embodiments, the electrical port plate 216 can be attached after the connected PCBs 308, 310 are inserted into the PCB housing 314. In determining the orientation for attaching the electrical port plate 316 to the PCB housing 314, the plate can include one or more through-holes configured to align with one or more through-holes on the PCB housing 314. Each of the sets of through-holes on the PCB housing 314 and the electrical port plate 316 can be configured to align with and receive one or more raised (e.g., protruding) electrical ports on the connected PCB (e.g., PCB 310). In some embodiments, the PCB housing 314 can include a recessed portion configured to correspond with and receive the electrical port plate 316. In some embodiments, the electrical port plate 316 can snap into place with one or more features on the PCB housing 314 (e.g., by applying pressure between the electrical port plate 316 and the PCB housing 314). In some embodiments, the electrical port plate 316 may include clickable buttons (e.g., Figure 1 102), the clickable button is configured to align with a switch on a connected PCB and activate / deactivate the switch. Thus, the electrical port plate 316 can be configured to connect to the PCB housing 314 in a specific orientation so that each of the buttons and / or through-holes / ports can be in the correct alignment.

[0119] As mentioned above, the connected PCBs can be inserted into the PCB housing 314. In some embodiments, the PCB housing 314 can include an open end and a closed end. The connected PCBs 308 and 310 can be inserted into the PCB housing 314 so that the first end of the connected PCBs (e.g., the end opposite the bracket 312) is guided into the open end of the housing. In determining the correct orientation for inserting the connected PCBs into the PCB housing 314, the builder can orient the face of the connected PCBs including the receiving end of the electrical port in a direction facing the port opening (e.g., a through hole) on the PCB housing 314. In some embodiments, the bracket 312 can be designed so that the top portion of the bracket is larger than the bottom portion, and the bottom portion can correspond to the outer edge of the PCB housing 314. Therefore, the connected PCBs with the bracket 312 can only be assembled into the PCB housing 314 in a specific orientation.

[0120] Once the electrical port plate 316 is attached to the PCB housing 314 and the connected PCBs 308 and 310 are inserted into the housing, the builder can attach the electrical port cover 318 to the partially assembled device. The electrical port cover 318 can include a strip portion having one or more caps extending away from the strip and configured to cover the electrical ports on the PCB 310 (e.g., through one or more of the openings mentioned above). For example, the strip portion of the electrical port cover 318 can snap into corresponding recessed portions of the side of the PCB housing 314 (e.g., by applying pressure between the strip portion and the PCB housing 314). Each of the one or more caps on the electrical port cover 318 can be configured to be removably inserted into one or more ports when the ports are not in use. In some embodiments, at least a portion of the electrical port cover 318 (e.g., each cap) can include a deformable, bendable polymer (e.g., an elastomer) so that a user of the solar-powered lantern can easily switch the electrical port cover 318 between a state in which one or more of the caps are inserted into or removed from a port. In some embodiments, the electrical port cover 318 may include a first color (e.g., red, blue, yellow, green, black, white, etc.) and the electrical port plate 316 may include a second color different from the first color so that a user can easily determine the location of the ports on the device.

[0121] In some embodiments, each of the caps may include a mark indicating, for example, the purpose of the port. For example, one or more caps configured to cover a port for charging an external device may include a mark marked "out", where power from the solar lantern device is transferred out of the device to charge other devices. Similarly, one or more caps configured to cover an electrical port for transmitting electricity from a solar panel may include a mark marked "in", where power can be transferred into the solar lantern to charge the solar lantern (e.g., from a solar panel). In some embodiments, the type of electrical connector (e.g., cable) configured to be inserted into each of the above-mentioned ports may be different. For example, one or more ports for transmitting electricity to the solar lantern may be a first type of port (e.g., a DC barrel jack input as mentioned above), and one or more ports for charging other devices may be a second type of port (e.g., a USB port as mentioned above).

[0122] The solar-powered lamp device described herein may include at least one body, and in some embodiments, at least two bodies. For example, the first body may be the PCB housing 314 described above, wherein the PCB housing may enclose one or more PCBs and may include one or more removable components attached thereto (e.g., electrical port plate 316 and / or electrical port cover 318). The second body of the solar-powered lamp device may be a battery housing 320, as will be described below with respect to Figure 3F-3J In some embodiments, the PCB housing 314 and the battery housing 320 described herein can be enclosed in a single housing.

[0123] like Figure 3F , the battery 322 can be inserted into the battery housing 320. In some embodiments, the first end of the battery 322 can be attached to a wire (e.g., a lead) extending from the battery. In some embodiments, the battery housing 320 may include an open end and a closed end. Thus, the battery 322 can be inserted into the battery housing 320 by first introducing one end of the battery 322 into the housing so that the end without the wire is aligned with the closed end of the housing 320. In some embodiments, the battery housing 320 can be an elongated member that is configured to completely cover (e.g., accommodate) the battery 322. Thus, the user can ensure that the battery is fully inserted (e.g., completely covered by the housing 320) through the housing 320 when inserting the battery into the housing.

[0124] exist Figure 3G In the assembly steps shown in , the battery end cap 324 can be configured to be inserted into the battery housing 320, for example, by applying pressure to the end cap 324 as it is inserted into the housing to at least ensure that the battery 322 is secured within the housing. In some embodiments, the battery end cap 324 can be sized and designed so that the outer edge of the end cap corresponds to the outer edge of the housing 320. Therefore, the end cap 324 can only be inserted into the housing 320 in a specific orientation, such as Figure 3G In some embodiments, the end cap 324 may include a through hole configured to receive a wire extending from the battery 322. Thus, a user may feed the wire into the through hole when inserting the end cap 324 into the housing 320. Figure 3H As shown in , the end cap 324 can be fully inserted into the housing 320 so that a portion of the end of the housing extends beyond the thickness of the end cap 324.

[0125] After the end cap 324 is inserted, a second end cap 326 (e.g., a battery housing end cap) can be attached to (e.g., at least partially inserted into) the housing 320. Importantly, the end cap 324 must be fully inserted into the housing 320 to secure the battery 322 before the end cap 326 is inserted. In some embodiments, the outer edge of the end cap 326 can be designed and sized so that a first portion of the battery housing end cap 326 can be received by the housing 320 until a lip on the end cap 326 is reached. For example, a builder can apply pressure to snap the end cap 326 into the housing 320 until the lip on the end cap 324 is reached. In some embodiments, the size of the lip on the end cap 326 can be substantially the same as the size of the outer edge of the battery housing 320. In some embodiments, the end cap lip can extend only a portion of the thickness of the end cap 326 so that a first side of the end cap 326 can be inserted into the battery housing 320, as described above, and a second side of the end cap 326 can be configured to receive an end of a PCB housing, as will be described below with respect to Figure 3K-3M The battery housing end cap 326 may include at least one through hole (e.g., opening) so that a wire extending from the battery 322 and passing through the end cap 324 may also extend through the end cap 326 (e.g., Figure 3J ). In some embodiments, a first side of an end cap 326 configured to be inserted into a battery housing 320 may include a single opening surrounding a through-hole, wherein a second side of the end cap 326 facing outward from the battery housing 320 may include more than one opening, wherein at least one opening surrounds the through-hole.

[0126] After the battery 322, end cap 324, and end cap 326 are sequentially inserted into the battery housing 320, the partially assembled components of the solar light device (e.g., Figure 3K Before connecting the battery housing 320 and the PCB housing 314, the builder can connect the battery wires (e.g., leads) extending from the battery housing 320 to one or more PCBs (e.g., PCB 310). For example, a portion of the PCB 310 configured to receive the battery wires can be positioned proximate to the open end of the PCB housing 314 so that the user can easily connect the wires to the PCB, as shown in FIG. Figure 3L In some embodiments, the housing (e.g., battery housing 320 and / or PCB housing 314) may include receiving portions configured to connect to battery leads. Once the battery is connected to the PCB, the builder can connect the PCB housing 314 (and all components attached thereto and / or inserted therein) to the battery housing 320 (and all components attached thereto and / or inserted therein). For example, the builder can apply pressure to removably connect the PCB housing 314 and the battery housing 320, wherein the attached components such as Figure 3M As shown in .

[0127] In some embodiments, one end of the battery housing 320 including the end cap 326 can be configured to connect to the open end of the PCB housing 314 (e.g., the end including the bracket 312). In some embodiments, as mentioned above, the battery housing end cap 326 can be sized and designed so that it can be inserted into the PCB housing 314. For example, the battery housing end cap 326 can include at least one opening on the side of the end cap facing outward from the battery housing 320. The at least one opening can be configured to receive one or more components 314 (e.g., the ends of one or more PCBs) extending toward the open end of the PCB housing. Thus, when the end cap 326 attached to the battery housing 320 is connected to the PCB housing 314, the components housed within the PCB housing 314 can be secured in place.

[0128] The solar light kits described herein may include one or more housings configured to protect one or more components of the kit. Figure 3N As shown in FIG, the solar light kit may include an elongated housing 328 including an opening extending along the housing, wherein the housing is configured to extend along at least two sides of the connected PCB housing 314 and battery housing 320. Before inserting the connected components into the housing 328, the builder may need to attach end caps to the housing 328. For example, as shown in FIG. Figure 3N As shown in FIG, one or more fasteners 332 and a handheld tool (the handheld tool is not shown for simplicity) can be used to attach the housing end cap 330 to the housing 328. In some embodiments, the end cap 330 can include at least one through-hole configured to receive the one or more fasteners 332. In some embodiments, one end of the housing 328 can additionally include one or more sockets configured to align with the through-holes on the end cap 330 and receive the one or more fasteners 332. In some embodiments, a first (e.g., upper) portion of the end cap 330 can be configured to align with a longitudinal opening in the housing 328 (e.g., where three of the four sides of the housing can be closed), and a second (lower) portion of the end cap 330 can be configured to align with the opposite side of the opening in the housing 328. Thus, a user can align the end cap 330 with the appropriate side of the housing at the end of the housing 328 and can attach (e.g., fasten) one or more fasteners (e.g., screws) into corresponding receiving portions (e.g., sockets) to secure the end cap to the housing.

[0129] In some embodiments, as mentioned above, the solar lantern kit kit may include a plurality of fasteners and / or hand tools. User instructions (e.g., accessed by scanning a QR code on a tool holder) may indicate to the builder the correct hand tools, fasteners (e.g., screw sizes), and the number of fasteners required to successfully complete the assembly steps. For example, fastening the end cap 330 to the housing 328 may require one or more fasteners (e.g., screws) of a first size / type that may be different from the remaining assembly steps of the solar lantern kit.

[0130] Once the housing end caps are attached to the housing 328, the builder can insert the connected housing into the housing, as shown in FIG. Figure 3O As shown in . For example, the portion of the connected component that includes the PCB housing (e.g., the end) can be inserted into the housing 328 so that the end of the housing 328 attached to the end cap 326 can be positioned adjacent to the PCB housing 314 and the remaining open end of the housing 328 can be positioned adjacent to the battery housing 320. In some embodiments, the connected housing can be inserted so that the opening extending the length of the housing 328 can be aligned with a surface that includes one or more interactive components (e.g., buttons and electrical ports) contained within the housing, thereby allowing a user to access the interactive components. In some embodiments, the housing 328 and the housings 314, 320 can be sized so that the connected housing can be easily inserted into the housing for securement (e.g., a sliding fit without the user applying pressure to insert the attached component into the housing). In some embodiments, the housing 328 can include one or more grooves along the length of the inner surface of the housing, which can be configured to receive one or more corresponding (e.g., recessed) portions on the connected housings 314, 320.

[0131] After inserting the connected PCB housing 314 and battery housing 320 into the housing 328, the user can secure the housing within the housing to complete the assembly of the solar light device. For example, as described above with respect to the end cap 332, the builder can use a handheld tool and one or more removable fasteners 332 to attach the end cap 334 to the housing 328. In some embodiments, the housing end cap 334 can be different from the end cap 332, at least because the end cap 334 can include one or more openings (e.g., recessed portions) on the inner surface of the end cap that are configured to receive a protrusion on the battery housing 320 extending from the open end of the housing 328. In some embodiments, similar to the end of the housing 328 that is configured to receive the end cap 332, Figure 3PThe open end of the housing 328 shown in FIG3 may include one or more sockets configured to receive one or more fasteners. Similarly, the housing end cap 334 may include one or more through-holes that are configured to align with the sockets on the housing 332 and receive one or more fasteners to attach the end cap 334 to the housing 328 and secure the solar-powered light components within the housing. As mentioned above, in some embodiments, the instructions for building a solar-powered light from a kit may inform the user which hand tool and / or fastener to use to secure the end cap 334 to the housing 328. In some embodiments, the hand tool and / or fastener used to install the end cap 334 may be the same as the hand tool and / or fastener used to install the end cap 332 to the housing 328. Thus, in some embodiments, assembling a solar-powered light device from a solar-powered light kit may include using a single hand tool and a single type / size of fastener.

[0132] In some embodiments, one or more of the end caps 332, 334 may include hooks and / or receiving portions (e.g., holes) for hooks, such that the constructed solar-powered lantern may be hung by one or more hooks on the end of the device. As mentioned above, each of the assembled components described herein may be disassembled, for example, to replace and / or repair one or more components in the device. For example, the above description of the solar-powered lantern may be reversed. Figure 3A-Figure 3P One or more steps in a process are described to disassemble a solar light device.

[0133] Solar panel equipment assembly

[0134] Figures 4A-4H The steps for assembling a solar panel device from a solar lantern kit according to some embodiments are shown. In some embodiments, each of the components used to assemble a solar panel from a solar lantern kit can be assembled in a specific manner so that each part can fit together in a limited number (one or more, for example, one) of orientations. In some embodiments, assembling the solar panel may require following the steps described in the following order: Figures 4A-4H At least a portion of the steps described below enables the steps described later to be completed without having to be completed before the steps described earlier. In some embodiments, each component in the kit can be removably attached so that each of the steps described below can be completed in the reverse order of disassembling the solar light panel.

[0135] like Figures 4A-4D As shown in , a solar panel can be assembled from solar light kit components by assembling the frame of the solar panel. In some embodiments, the frame of the solar panel can include a plurality of edge members and corner members. Figure 4AAs shown in FIG, at least one hand tool and one or more removable fasteners 450 can be used to connect corner members 446, 448 to edge member 444. In some embodiments, the frame of the solar panel can include different types of corner members and edge members of different sizes to accommodate the size of the solar panel. For example, corner member 446 can include two connecting portions configured to connect to the edge member of the solar panel, while corner member 448 can include two connecting portions configured to connect to the edge member and an additional connecting portion configured to connect to the stand of the solar panel, as will be described below at least with respect to FIG. Figure 4F-4H Described in more detail.

[0136] In some embodiments, a builder can determine the correct orientation of each of the corner members and edge members that are configured to be along the edge of the solar panel by positioning each of the components prior to assembly so that the inward bends (e.g., right angles) on corner members 446 and 448 can be configured to contact the solar panel when the solar panel is inserted into the frame assembly. In some embodiments, the edge members and / or corner members can include grooves (e.g., slots) that are configured to receive the solar panel. For example, the edge member can include a slot along the longitudinal axis of the member. Thus, the builder can determine the orientation of the edge member relative to the corner member by aligning the grooves to face inward (e.g., toward the solar panel that will be inserted into the assembly).

[0137] Corner members 446, 448 can be connected to the edge member by inserting an appropriate connecting portion on the corner member into a receiving portion on the edge member 444. For example, the first connecting portion of corner member 446 can be sized so that at least a portion of the corner member can be inserted into the first end of edge member 444. Similarly, the first connecting portion of corner member 448 can be sized so that at least a portion of the corner member can be inserted into the second end of edge member 444. The connection can be secured using at least one hand tool and one or more removable fasteners 450. For example, each corner member 446, 448 can require a single fastener (e.g., a screw) 450 to secure the corner member to the edge member. Corner members 446, 448 and / or edge member 444 can include a receiving portion for a screw, wherein the receiving portion includes one or more threads configured to correspond to threads on the screw. For example, the edge member 444 may include a socket and the corner member may include a through hole, wherein at least one of the socket and / or the through hole may include threads configured to correspond to threads on the fastener (e.g., where the fastener is a screw).

[0138] In some embodiments, the hand tools and / or fasteners used to assemble the frame of the solar panel may be different than the hand tools and fasteners described above for securing the end caps to the housing of the solar lantern. The instructions for assembling the solar lantern kit may include instructions for which hand tools and removable fasteners to use from the kit when assembling the frame of the solar panel.

[0139] In some embodiments, the builder may repeat the above described and Figure 4A , to assemble the other side of the frame for the solar panel, where the second side of the frame can be placed opposite the previously assembled portion of the frame assembly (e.g., as described above). The two assembled sides can be referred to as the long sides of the solar panel, at least because the edge members can be longer than the edge members of the unassembled sides relative to the remaining sides of the frame to be assembled. Figure 4B , the first assembled long side can be connected to two edge members 452. As mentioned above, in some embodiments, the length of edge member 452 can be shorter than the length of edge member 444, at least because the solar panel can be rectangular in shape (e.g., including a pair of long sides and a pair of shorter sides). In some embodiments, the solar panel can be square in shape, so the lengths of edge members 444 and 452 can be substantially the same.

[0140] Corner members 446, 448 can be connected to edge members 452 at each corner using at least one hand tool and one or more removable fasteners. For example, corner members 446, 448 and edge members 452 can include receiving portions configured to receive removable fasteners to secure the connection between edge members 452 and corner members 446, 448. For example, the receiving portion in edge member 452 can include a socket, while the receiving portion in corner members 446, 448 can include a through-hole, wherein at least one of the socket and / or through-hole can include threads configured to correspond to threads on the fastener. In some embodiments, at least a portion of corner members 446, 448 can be sized so that the corner member can be inserted into edge member 452. In some embodiments, edge member 452 can include grooves, as described above with respect to edge member 444, such that the grooves are configured to face inward toward the solar panel. Thus, when connecting the edge member 452 to the corner members 446, 448, the user can ensure that the grooves are oriented in the correct manner before connecting the edge member 452 to the corner members.

[0141] Before attaching the partial frame assembly comprising one side of the frame to the rest of the frame assembly, the user may insert the solar panel 454 into the partial frame assembly comprising three sides of the frame assembly, such as Figure 4CAs mentioned above, the edge members 444, 452 may include grooves (eg, slots) configured to receive the edges of the solar panels so that the solar panels may be slid into the grooves.

[0142] Once the solar panel is inserted into the three-sided partial frame assembly, the assembly step of connecting the edge members 452 to the corner members 446, 448 can be repeated additional times to enclose the solar panel in the frame (e.g., as shown in FIG. Figure 4D ). For example, a portion of the frame assembly comprising a single edge member 444 connected to corner members 446, 448 may be connected to the open end of edge member 452. In some embodiments, corner members 446, 448 may be connected in the same manner as described above with respect to Figure 4B The corner members 446, 448 may be connected to the edge member 452 in substantially the same manner as described above. For example, the second end of the edge member 452 and the corner members 446, 448 may include receiving portions (e.g., sockets and through holes, at least one of which may include corresponding threads) configured to receive removable fasteners. Thus, a user can connect the corner members 446, 448 to the edge member 452 and secure the connection using the removable fasteners 450 and a hand tool. In some embodiments, the removable fasteners and hand tool may be the same as described above with respect to Figure 4B The instructions for assembling the solar light panel from the solar light kit may direct the user to Figure 4D Which hand tools and fasteners to use in the steps shown in .

[0143] As mentioned above, the solar panel can include a stand for manipulating the angle at which the solar panel is oriented during use. In some embodiments, the stand can be assembled using a pair of stand arms 456 and an arm connecting member 458 for connecting the pair of arms. Each of the arms 456 can include one or more through holes configured to receive a removable fastener 460 to secure the arm to the connecting member 458. For example, the through holes on each arm can be located on a flat surface of the arm, at the end of the arm, and near an edge of the arm, such as Figure 4EAs shown in . In some embodiments, the connecting member 458 may include one or more receiving portions (e.g., sockets) configured to correspond to one or more removable fasteners 460. For example, a user can connect the first arm 456 to the arm connecting member 458 by inserting one or more removable fasteners 460 through a through hole in the arm and into a socket in the connecting member, and the fasteners can be secured using a handheld tool. In some embodiments, the removable fastener 460 can be a screw, and the socket in the connecting member 458 can include threads configured to correspond to the screw. In some embodiments, the edge of the connecting member 458 along the longitudinal axis of the connecting member can be raised so that the end of the connecting member can include a pair of sockets extending within the raised edge. Thus, each arm 456 can be connected to the arm connecting member 458 using removable fasteners 460 in two locations, such as Figure 4E As shown in .

[0144] In some embodiments, the one or more removable fasteners 460 and hand tools that can be used to assemble the solar panel stand can be different from the removable fasteners and hand tools described above with respect to assembling the solar lantern and solar panel frame. In some embodiments, the instruction manual provided with the solar lantern kit can indicate the hand tools and removable fasteners that can be used to assemble the stand. In some embodiments, it may be necessary to assemble the solar panel stand before attempting to connect the arms 456 to the corresponding portions of the solar panel assembly with the frame.

[0145] After assembling the solar panel stand, the assembled stand can be connected to the solar panel assembly with frame (such as Figure 4F ). As mentioned above, corner members 448 can include connecting portions for connecting the assembled stand to the solar panel assembly. For example, arm 456 can include one or more through-holes disposed at an end of the arm opposite the end of the connecting member that is attached to the stand. In some embodiments, the through-holes can be of different sizes; for example, a first through-hole can be larger than a second through-hole. One or more of the through-holes on each arm can be aligned with the connecting portion on each corner member 448 to connect the stand to the solar panel assembly, as shown. Figure 4G Once the through holes in the arms are aligned with the connecting portions on the corner members 448, the user can connect the stand to the solar panel assembly using one or more removable fasteners, one or more stand connectors 462, and a hand tool, as shown in FIG. Figure 4H As shown in .

[0146] In some embodiments, the stand connector 462 can include one or more protrusions configured to be received by one or more through-holes on the arm 456. In some embodiments, the stand connector 462 can include a through-hole, wherein the through-hole can extend through the protrusion of the stand connector. For example, the stand connector 462 can include a larger protrusion and a smaller protrusion, each of which is configured to correspond to the large through-hole and the small through-hole on the arm 456, respectively. The through-hole on the stand connector 462 can extend through the larger protrusion corresponding to the large through-hole on the arm 456. Thus, a user can insert the corresponding protrusion of the stand connector 462 into the through-hole in the arm (previously aligned with the connecting portion of the corner member 448) and secure the component using a hand tool and a removable fastener configured to be inserted through the through-hole in the stand connector, the through-hole in the arm, and the through-hole in the corner member 448 (in that order). In some embodiments, as indicated on the instructions received in the solar lantern kit, the hand tools and fasteners used to connect the stand to the rest of the solar panel assembly may be different than one or more of the hand tools and / or fasteners described above.

[0147] In some embodiments, when the stand is secured to the solar lantern using the stand connector 462 and the removable fastener 464, an additional fastener 466 configured to receive the end of the fastener 464 can be deployed on the side of the corner member 448 opposite the arm 456 to secure the components together. For example, the removable fastener 466 can be a nut configured to receive a screw so that when the screw is inserted through the stand connector 462, the arm 456, and the corner member 448, the screw can be secured using the nut 466 deployed on the side of the corner member 448 opposite the location where the screw is inserted. The above description regarding Figure 4H The steps described above are used to secure the remaining corners of the solar light panel to the solar light stand. As mentioned above, the stand can be configured to fold flat against the solar panel, such as Figure 4H 448 (e.g., about an axis through which a removable fastener 464 is inserted through the stand connector 462, the arm 456, and the corner member 448). Thus, a user can manipulate the angle at which the assembled stand positions the solar panel installation. In some embodiments, the angle can be set using the stand connector 462. For example, a protrusion on the stand connector 462 (e.g., the smaller protrusion described above) can be removably inserted into and removed from a corresponding portion in the corner member 448 to set the angle at which the solar panel is placed.

[0148] Method for assembling a solar light device

[0149] Figure 5 A method 500 for assembling a solar-powered light from a solar-powered light kit is shown, according to some embodiments.

[0150] At step 502, a first PCB including an array of light sources (e.g., an array of light-emitting diodes (LEDs)) and a set of leads and a second PCB including a plurality of electrical ports can be connected. In some embodiments, connecting the first and second PCBs can include aligning the set of leads on the first PCB with a first electrical port among the plurality of electrical ports on the second PCB and applying pressure between the first and second PCBs. In some embodiments, one or more electrical ports on the second PCB can be configured to charge a mobile device.

[0151] In some embodiments, method 500 may include attaching a lens configured to disperse light from the array of light sources to the first PCB. In some embodiments, the first PCB may include a switch configured to activate and deactivate one or more light sources. In some embodiments, the first PCB may include one or more through-holes configured to receive electrical ports on the second PCB when the first and second PCBs are connected.

[0152] In some embodiments, method 500 may include attaching an end cap to one end of the connected first and second PCBs, wherein, at step 504, the ends of the connected PCBs including the end caps may be inserted into a PCB housing. In some embodiments, the first and second PCBs may be assembled into the housing in a single orientation. For example, the connected PCBs may be inserted such that one or more electrical ports on the second PCB are oriented toward one or more corresponding openings on the PCB housing.

[0153] In some embodiments, method 500 may include attaching the electrical port plate to the PCB housing by aligning the electrical port plate with corresponding portions of the PCB housing and applying pressure between the electrical port plate and the PCB housing. In some embodiments, the electrical port plate may include a button configured to align with and engage a switch on the first PCB.

[0154] In some embodiments, method 500 may include attaching the electrical port cover to the PCB housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing. In some embodiments, the electrical port cover may include one or more electrical port caps configured to removably cover one or more electrical ports on the second PCB.

[0155] In some embodiments, the method may include inserting the rechargeable battery into one end of the battery housing. In some embodiments, the rechargeable battery may be enclosed in the housing using one or more end caps. In some embodiments, enclosing the rechargeable battery may include inserting a portion of the end cap into the one end of the battery housing by aligning the end cap with the one end of the battery housing and applying pressure between the end cap and the battery housing.

[0156] At step 506, the PCB housing, including the connected first and second PCBs, can be connected to the battery housing by aligning one end of the PCB housing with one end of the battery housing and applying pressure between the PCB housing and the battery housing. In some embodiments, connecting the PCB housing and the battery housing can include connecting wires (e.g., leads) extending from the rechargeable battery to the connected PCBs in the PCB housing. In some embodiments, one end of the battery housing, including one or more end caps, can be configured to connect to the open end of the PCB housing.

[0157] In some embodiments, method 500 may include attaching a first end cap to a first end of the housing so that the attached PCB housing and battery housing can be inserted into a second end of the housing at step 508. In some embodiments, the method may include attaching a second end cap to the second end of the housing. In some embodiments, the first and second end caps may be attached to the housing using a plurality of removable fasteners and at least one hand tool.

[0158] At step 510, the solar panel may be connected to the second PCB using a connector cable. In some embodiments, the connector cable may be removably connectable to the second PCB and the solar panel. In some embodiments, the solar panel may include a solar panel frame and a solar panel stand. In some embodiments, the solar panel frame may be assembled by connecting a plurality of corner members and a plurality of edge members that are configured to surround an outer edge of the solar panel. In some embodiments, the plurality of edge members and corner members may be connected using a plurality of removable fasteners and at least one hand tool.

[0159] In some embodiments, a solar panel stand can be assembled using a pair of stand arms and an arm connecting member, wherein the arm connecting member is configured to connect to each arm to connect the arms. In some embodiments, the arms and connecting members can be assembled using a plurality of removable fasteners and at least one hand tool. In some embodiments, the solar panel stand can be connected to the solar panel frame using one or more stand connectors, a plurality of removable fasteners and at least one hand tool. In some embodiments, each of the above components can be provided in an unassembled form in a solar lantern kit with instructions for assembling the solar lantern kit.

[0160] The foregoing description for purposes of explanation has been described with reference to specific embodiments. However, the foregoing illustrative discussions are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in light of the above teachings. Such modifications and variations are to be understood as being included within the scope of the present disclosure and the examples as defined in the claims. These embodiments were chosen and described in order to best explain the principles of these techniques and their practical applications. Thereby enabling others skilled in the art to best utilize these techniques and various embodiments with various modifications as are suitable for the particular use contemplated. For the sake of clarity and brevity of description, features are described herein as being part of the same or separate embodiments; however, it should be recognized that the scope of the present disclosure includes embodiments having all or some combination of the features described.

Claims

1. A method of assembling a solar light kit, comprising: connecting a first printed circuit board (PCB) including a light source array and a set of leads and a second PCB including a plurality of electrical ports, wherein connecting the first PCB and the second PCB includes aligning the set of leads on the first PCB with a first electrical port of the plurality of electrical ports on the second PCB and applying pressure between the first PCB and the second PCB; inserting the connected first PCB and the second PCB into a PCB housing, wherein the connected first PCB and the second PCB are assembled in the PCB housing in one orientation; connecting the PCB housing and the battery housing by aligning one end of the PCB housing with one end of a battery housing surrounding the rechargeable battery and applying pressure between the PCB housing and the battery housing; Insert the connected PCB housing and battery housing into the housing; as well as The solar panel is connected to a second electrical port of the plurality of electrical ports on the second PCB using a connector cable, wherein the connector cable is removably connectable to the solar panel and the second electrical port.

2. The method of claim 1, comprising attaching a lens to a first printed circuit board (PCB), wherein the lens is configured to disperse light from the array of light sources on the first PCB.

3. The method according to claim 1 or 2, comprising: Before inserting the connected first and second printed circuit boards (PCBs) into a PCB housing, end caps are attached to one ends of the connected first and second PCBs.

4. The method of claim 3, wherein inserting the connected first and second printed circuit boards (PCBs) into the PCB housing comprises inserting ends of the connected first and second PCBs opposite the end caps into the PCB housing.

5. The method according to any one of claims 1 to 4, comprising: Prior to inserting the connected printed circuit board (PCB) housing and battery housing into the enclosure, the electrical port plate is attached to the PCB housing by aligning the electrical port plate with corresponding portions of the PCB housing and applying pressure between the electrical port plate and the PCB housing.

6. A method as described in any one of claims 1-5, comprising, before inserting the connected printed circuit board (PCB) housing and battery housing into the housing, attaching the electrical port cover to the PCB housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing.

7. The method of any one of claims 1-6, wherein connecting a printed circuit board (PCB) housing and a battery housing comprises connecting leads extending from the rechargeable battery to the connected first and second PCBs.

8. The method of any one of claims 1-7, wherein assembling the solar light kit comprises assembling a solar panel stand and a solar panel frame.

9. The method of claim 8, wherein assembling the solar panel frame comprises connecting a plurality of corner members and a plurality of edge members around an outer edge of the solar panel.

10. The method of claim 8 or 9, wherein assembling the solar panel stand comprises connecting an arm connecting member to a pair of stand arms.

11. A solar light kit comprising: A printed circuit board (PCB) housing is configured to enclose a first PCB and a second PCB, wherein The first PCB includes a light source array and a set of leads, and the second PCB includes a plurality of electrical ports, The first PCB and the second PCB are configured to be connected by aligning the set of leads on the first PCB with a first electrical port of the plurality of electrical ports on the second PCB and applying pressure between the first PCB and the second PCB, and The connected first and second PCBs are configured to be assembled in the PCB housing in one orientation; a battery housing configured to enclose at least one rechargeable battery, wherein the battery housing is configured to connect to the PCB housing by aligning an end of the PCB housing with an end of the battery housing and applying pressure between the PCB housing and the battery housing; a housing configured to surround the connected PCB housing and battery housing; as well as A solar panel is configured to be connected to a second PCB using a connector cable, wherein The connector cable is removably connectable to the solar panel and the second electrical port on the second PCB, and The PCB housing, first PCB, second PCB, battery housing, rechargeable battery, outer casing, solar panel and connector cables are bundled together unassembled in a kit package.

12. The solar-powered light kit of claim 11, comprising a lens configured to be attached to a first printed circuit board (PCB) to disperse light generated from the array of light sources on the first PCB.

13. The solar-powered light kit of claim 11 or 12, wherein the first printed circuit board comprises a switch configured to activate and deactivate the array of light sources.

14. The solar-powered light kit of any one of claims 11-13, wherein a third electrical port of the plurality of electrical ports on the second printed circuit board is configured to charge a mobile device.

15. The solar-powered lamp of any one of claims 11-14, comprising an electrical port plate configured to be attached to a printed circuit board (PCB) housing by aligning the electrical port plate with corresponding portions of the PCB housing and applying pressure between the electrical port plate and the PCB housing.

16. The solar-powered light kit of claim 15, wherein the electrical port plate includes a button configured to align with and engage the switch on the first printed circuit board.

17. The solar-powered lamp kit of any one of claims 11-16, comprising an electrical port cover configured to be attached to a printed circuit board (PCB) housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing.

18. The solar-powered lantern kit of claim 17, wherein the electrical port cover comprises one or more electrical port caps configured to removably cover one or more electrical ports of the plurality of electrical ports on the second printed circuit board.

19. The solar lantern kit of any one of claims 11-18, wherein the solar panel comprises a solar panel frame and a solar panel stand configured to be assembled.

20. The solar-powered light kit of any one of claims 11-19, wherein the kit packaging includes a plurality of hand tools and instructions for assembling the solar-powered light kit.

Images