Photovoltaic device and method for charging electric vehicle (EV) or battery thereof

Abstract

A charging station includes a structure or cabinet for charging a battery of an EV vehicle whether the battery is taken out of the EV for a charging cycle or the EV is directly connected to a charging point. The present invention provides for accommodating or storing a battery for an electric vehicle (EV) or its use in order to facilitate charging thereof by means for charging a battery cell of the electric vehicle (EV), utilizing power from primarily solar radiation through a PV panel or PV array. Embodiments include charging stations for electric vehicles (EVs), particularly bicycles and scooters. Further described are methods of forming a charging station having a plurality of access gates through which a battery of an EV or an EV can be connected to a charging port. In a preferred configuration, an independent charging station for an EV scooter provides means for mounting and storing the scooter during a charging cycle. The invention further discloses a municipal scooter renting system.

Description

TECHNICAL FIELD

[0001] The present invention relates to the design and installation of a charging station for charging the batteries of electric vehicles (EVs), primarily or exclusively using energy accumulated by photovoltaic (PV) panels, which are installed as a major part of a structure or enclosure.

[0002] The present invention relates, inter alia, to providing a structure or enclosure for charging the batteries of EV vehicles, whether the batteries are removed from the EV for a charging cycle or the EV is directly connected to a charging point within the structure or enclosure, and inter alia, to the containment, securing or storage of electric vehicles (EVs) or batteries used therein, to facilitate charging using electricity from PV panels or arrays thereof, primarily from solar radiation.

[0003] The present invention relates, inter alia, to a self-powered, self-supporting charging station for the batteries of electric vehicles (EVs), in particular single-person EVs such as electric motorcycles, bicycles and scooters.

[0004] The present invention also relates to methods for charging and storing batteries for EVs, and to methods for the containment, securing and / or storage of EVs, in particular single-person EVs.

[0005] The present invention also relates to an optimized PV generator on which PV panels are operatively formed as its major vertical face, to optimize the collection of solar radiation under sub-optimal conditions, with respect to the diurnal and seasonal variations of direct and indirect incidence of solar radiation, the generator being particularly suitable for remote and / or culturally sensitive areas which lack a mains electricity supply or where solar power is unreliable or highly variable.

[0006] The present invention teaches an off-grid solar generator which provides a constant rated power in all seasons in areas of large seasonal variation in solar power, such as all latitudes in the United Kingdom (UK), without the need for a supplemental power source; in a second aspect, the present invention relates to a hybrid grid generator which can be connected to other generators of the present invention, supplemental power sources and / or the mains electricity supply of regional or national grid infrastructure. The UK mainland is located between 50° and 59° North and there is a large difference in the average angle of incidence of solar radiation between summer and winter. Many other countries are also located in similar latitudes of the Northern Hemisphere (including most of Canada, Northern Europe and most of the Russian Federation), however, only the southern end of Chile and Argentina have significant population centres in corresponding latitudes of the Southern Hemisphere.

[0007] The present invention also proposes an enclosure or monolithic structure which is weatherproof, robust, easy to maintain and deployable or transportable to remote and off-grid areas to provide a useful daily power output under sub-optimal conditions, in particular during months of lowest average harvestable solar radiation.

[0008] The present invention also relates to a charging station for electric vehicles (EV) suitable for locations where connection to the mains is inconvenient, expensive or causes disturbances in traffic-intensive areas and places of cultural or natural significance.

[0009] The terms "generator unit" and "monolithic structure" as used herein refer primarily to a cabinet or enclosed housing within which control circuitry is fixed and protected from weather and curious onlookers. The terms also extend to structures suitable for supporting solar / PV panels and suitable for connection to auxiliary energy sources (such as batteries, motor-generators, wind turbines, etc. and of course the mains grid). However, the scope of the invention is not limited to this, but should be understood to include any reinforced cabinet suitable for deployment to remote locations and hoisted or otherwise elevated during its positioning on site or retrieval from site. This is particularly important when the weight of the deployed or retrieved unit can be much greater than the weight of the unit when unladen, and equally applies to cabinets housing battery packs.

[0010] The terms "cabinet" and "housing" as used herein are intended to mean a unit or construct formed as a monolithic generator and suitable for connection to auxiliary energy sources and other units (which can form a group or array). Although the term "useful amount" is used to refer to the expected daily power output from the generator unit during the seasonally lowest values of solar radiation (November, December and January in the northern hemisphere), this is not to limit the overall power rating of the device, which can be connected to other generator units or external power sources (including the mains) and have its power output augmented by these. Furthermore, the term "useful amount" has a specific meaning in different contexts, which will be described below with reference to the various uses to which the generator device can be applied. BACKGROUND

[0011] There are many methods and technologies for harnessing energy from the sun, each with their respective advantages and disadvantages depending on their application scenario and factors ranging from environmental impact to capital and maintenance costs.

[0012] One of the most technologically advanced areas is in the collection, storage and distribution of solar energy, which is collected by photovoltaic (PV) cells, most commonly arranged in interconnected groups of cells to form modules, with multiple modules making up a "solar panel".

[0013] Each PV cell is capable of producing approximately 0.6V when exposed to nominal sunlight, and when combined in a panel of 72 cells is capable of producing 300W. Modular panels can therefore transmit a useful amount of electrical energy in direct sunlight. This has become the de facto implementation for domestic rooftop installation systems as well as commercial and large "solar farms", including ground-mounted panel arrays for generating electricity for commercial enterprises ranging from farms to data centres and for connection to national or regional grid power systems.

[0014] Commercialization and large scale applications differ from home and remote (or "off-grid") applications in terms of factors relating to the collection of solar photovoltaic electricity which will be mentioned in more detail below, the latter being the particular focus of the present invention.

[0015] In recent years, the capital cost of PV modules and panels has decreased significantly with the industrialization of printing PV cell technology and the popularization of modules with integrated DC-DC converters and micro-inverters. With the decrease in the cost of solar collection and the need for near-constant energy supply for off-grid and home applications, even at low or nominal levels, the focus must now be placed on the storage of the energy produced, especially in cases where the cost of the energy supplied can be prohibitive.

[0016] Insolation refers to the amount of radiation or exposure in a particular region, however, many factors come into play in terms of solar collection. The most important is the seasonal variation in the region of a particular latitude, where the intensity of solar radiation, even at the highest amounts of the season, is not sufficient to provide a usable level of power and additional sources must be used.

[0017] For any given latitude, the average or optimal panel angle can be calculated, however, for any selected angle towards the perpendicular, factors such as structural strength to resist incident wind forces must be taken into account. Likewise, for angles towards the horizontal, in this case snow load is very important and must also be taken into account. Obviously, accumulated snow can seriously affect the collection of solar radiation. In less severe conditions, the dust or debris deposited on the panels means that they need to be cleaned periodically to maintain optimal collection.

[0018] Aligning the solar panels with the azimuth corresponding to the particular latitude or selecting different azimuths in the selected panels of a solar array to adapt to seasonal variations is a well-established practice.

[0019] The prior art is full of structures and arrangements for tracking the path of the sun to optimize the incidence of solar radiation on the receiving surface of the PV cells, however, whether single-axis tracking (for example, diurnal tracking) or dual-axis tracking with diurnal and seasonal variations is used, significant additional costs are incurred and the inherent complexity is increased. For PV generators that are remotely transportable or at least movable, robustness and service life are of paramount importance.

[0020] From the patent literature it is not difficult to see that many different approaches have been adopted to address some of the technical deficiencies. Specific concerns exist in each field, however, many aspects are common and will be illustrated below.

[0021] CN107733067 describes a solar charging shed including a structure with support columns for top mounted solar panels and side wall solar panels (can be used as a vehicle parking garage / shed). The panels are connected to a battery pack including a current stabilizing device, on which a charging interface is arranged. The shed facilitates storing solar energy in the battery pack for charging a vehicle.

[0022] GB2574373 describes a solar charging assembly (whether arrayed or a standalone structure) including at least one tree-like structure in which a plurality of solar cells are connected to branches, which are connected to a trunk portion. A battery can be placed within the trunk or underground below the structure. A charging station (outlet port) is connected to the or each battery for charging an electric vehicle (EV).

[0023] It is an object of the present invention to overcome the drawbacks of the prior art arrangements and to provide a charging station including a structure or cabinet for charging a battery of an EV vehicle, whether the battery is removed from the EV for a charging cycle or the EV is directly connected to a charging point.

[0024] It is a main object of the present invention to provide a device for charging a battery unit of an electric vehicle (EV) with electricity mainly from solar radiation by photovoltaic (PV) panels.

[0025] It is another object of the present invention to provide a structure or cabinet for housing, securing or storing an electric vehicle (EV) or a battery used thereby for facilitating charging with electricity mainly from solar radiation by photovoltaic panels or PV arrays.

[0026] It is another object of the present invention to provide a self-powered, self-supporting charging station for a battery of an electric vehicle (EV), particularly a single person EV such as an electric motorcycle, bicycle and scooter.

[0027] It is another object of the present invention to provide a device and method for battery charging and storage of an EV and for housing, securing and / or storing an EV, particularly a single person EV. SUMMARY

[0028] The present invention provides a photovoltaic (PV) charging station for charging a battery of an electric vehicle (EV), the charging station comprising: a cabinet having structural frame elements and grounding elements attached thereto; a plurality of PV panels secured to the frame elements; a control circuit and an energy accumulator connected to the control circuit, sealingly disposed within the cabinet for regulating electrical energy generated by the PV panels; and a charging coupler, wherein at least two PV panels are arranged in a vertical plane and comprise the outer face of the cabinet.

[0029] Preferably, the PV panels are integrally formed with the frame elements.

[0030] Advantageously, the cabinet comprises wall portions and a top portion, the PV panels being fixed to the wall portions and the top portion.

[0031] Preferably, wherein the cabinet has a box-like form, wherein the structural frame members provide its peripheral corners and the PV panels are fixed between the structural frame members.

[0032] Conveniently, each wall portion comprises frame-like PV panels arranged in a vertical direction, to present the outward face of the cabinet.

[0033] The total surface area of the PV panels is optimized to produce a daily average power generation of at least 200 Wh.

[0034] In one configuration, the cabinet comprises a plurality of receptacles for detachable EV batteries, each receptacle having a charging coupler for connection to terminals of the EV battery.

[0035] In an alternative configuration, the charging station is adapted to provide means for directly charging an electric vehicle (EV).

[0036] Advantageously, the power generator means comprise a structural or cabinet with a housing, fixing or storage space for at least one EV.

[0037] In another alternative configuration, the structure or cabinet is a building with a plurality of receiving bays for EVs.

[0038] Preferably, the charging station comprises mounting means for at least one EV.

[0039] In a configuration designated for municipal use, the charging station comprises a communication module.

[0040] Conveniently, the charging station comprises a payment verification tool.

[0041] In another configuration, the structural frame elements define an octagonal cabinet, between which PV panels are arranged to present eight solar collection faces, at least one of which is hingedly fixed to a respective frame element to facilitate access to the interior of the cabinet.

[0042] Advantageously, the energy accumulator comprises a set of batteries with deep cycling characteristics and a set of batteries with high power delivery characteristics, and wherein the combination of battery technology with a charge controller and voltage monitoring circuit optimizes charging and power delivery under sub-optimal conditions.

[0043] In a preferred arrangement, the first battery bank comprises a working bank of frequently and deeply cycled batteries, with superior weight / kWh ratio, the second battery bank comprises a reserve bank, providing additional charge capacity and lower charge temperature capability than the working bank batteries, each bank having a charge balancer to compensate for state of charge differences during charge and discharge cycles.

[0044] Advantageously, the first battery bank comprises lithium ion or lithium iron phosphate batteries, the second battery bank comprises absorbent glass mat (AGM) batteries, each arranged in a configuration associated with a required system voltage.

[0045] The present invention also relates to a method of charging a battery of an electric vehicle (EV), the method comprising: accessing a mounting point for an EV battery within a cabinet of a charging station of the type described above; mounting the EV battery within the charging mount and aligning the battery terminals of the battery with the charge couplings of the mounting point; connecting the charge couplings to the EV battery terminals to the charging device; conducting a charging cycle; and; verifying that the EV is ready for reuse.

[0046] The present invention also relates to a method of charging a battery of an electric vehicle (EV), the method comprising: accessing a mounting point for an EV within a cabinet of a charging station of the type described above; mounting the EV to the mounting point; connecting the EV to the charging device; conducting a charging cycle; and; verifying that the EV is ready for reuse.

[0047] Advantageously, the mounting point is elevated.

[0048] Preferably, the charging cycle comprises a payment verification step.

[0049] Conveniently, the method comprises storing the EV. BRIEF DESCRIPTION OF DRAWINGS

[0050] The present invention will now be described in more detail with reference to the accompanying drawings, which show by way of example only an exemplary embodiment of a charging station for charging a battery of an electric vehicle (EV), and the construction of a self-supporting and anchored electric vehicle (EV) charging station in accordance with the present invention. In the drawings: Figure 1a is a schematic diagram of the sun path for the UK winter and summer solstices and the optimal angle for the position of the corresponding solar panels; Figure 1bis a bar chart showing the average level of direct and indirect solar radiation available per month of the year for a solar panel corresponding to the latitude of London, UK (51.5° N); Figure 2 is a perspective view of a first embodiment of a charging station according to the present application, with PV panels on each outer face of the cabinet; Figure 3 is a schematic view of the components of the control circuit housed within the cabinet or housing; Figure 4a and 4b are an oblique view and a perspective view, respectively, of an enhanced configuration of the first embodiment of the charging station, with PV panels on each outer face of the cabinet; Figure 4c is a similar exploded perspective view, with the battery and control circuit in an alternative configuration; Figure 4b Figure 4d and 4e are perspective views of another configuration of the first embodiment of the charging station, with substantially equal areas of PV panels present on each outer face of the cabinet (each face provided with an MPPT); Figure 5a and 5b are similar to Figure 4d and 4e are detailed side and perspective views of a configuration of the charging station similar to that shown in Figures 6a to 6c are perspective views of various configurations of framed PV panels; Figure 7a and 7b are perspective views of a second embodiment of the charging station according to the present application; Figure 8a and 8b are perspective views of a third embodiment of the charging station according to the present application, with PV panels on each exposed face of the mechanism; Figure 9 is a perspective view of a variant of the first embodiment of the charging station, with multiple securable receiving bays for detachable EV batteries; Figure 10a is a perspective view of a fourth embodiment of the charging station, comprising a structural frame, with PV panels secured to the structural frame and battery packs and control electronics sealed within the structural frame; Figure 10b and 10c are perspective views of the hinging details of at least one frame panel, adapted to facilitate access to Figure 10a the interior of the embodiment shown in Figures 11a to 11c ​is a perspective view of a specific configuration of a fourth embodiment of a charging station adapted as a storage cabinet for a foldable electric kick scooter. DETAILED DESCRIPTION

[0051] Referring to the drawings and first to Figure 1, as an example of the prior art, Figure 1 shows a power generation assembly for powering a small farm or self-contained dwelling, comprising an array of solar panels (a) arranged in three groups connected in a daisy chain configuration through cable connectors (b). The panels are fixed at an angle of inclination corresponding to the latitude of the site, and for a site in the northern hemisphere facing south. To increase the input from the solar panels (and to provide additional power at night), a wind turbine (c) is provided. For large power plants, turbines operating at medium-high voltage provide a less expensive solution per kilowatt of installed cost, whereas small wind turbines (SWT) are typically two to four times more expensive per kilowatt of installed cost, as the SWT market is relatively immature. Many "micro-wind" devices, i.e. those with a rotor swept area of less than 40 cm 2 have a rated power between 1 kW and 7 kW. A 6 kW turbine can generate up to 9000 kWh per year.

[0052] A typical household consumes about 11000 kWh of electricity per year, equivalent to about 30 kWh per day.

[0053] The direct current (DC) output of the PV panels (a) and the wind turbine (b) can be sent through a fixed power output junction box (d) to a battery bank housed in a cabinet (e) in which voltage regulators, monitoring and control electronics are also housed in a weatherproof cabinet. A power inverter can also be found in the cabinet (e) or, alternatively, in the junction box (d), where the power supply feeders (f) couple the power generation assembly to the demand. Supplementary PV panels (g) are provided for the control electronics, installed on poles attached to the cabinet.

[0054] As previously mentioned, the configuration of the prior art PV array and equipment for charging electric vehicles is not easily used for small domestic or off-grid applications, nor is it suitable in most cases for a power hub for charging electric vehicles.

[0055] As mentioned above, the angle of incidence of direct solar radiation on a surface varies significantly during the day and season. The main diurnal effect is the arc formed by the sun (relative to the incident surface, i.e. a static PV panel) during the day between sunrise and sunset. Other diurnal variations include cloud cover and shading from adjacent vegetation or structures (e.g. buildings, but can also include other PV panels in the array). Tracking the arc of the sun using an automated tracking mechanism to keep the plane of the PV panel perpendicular to the sun overcomes most but not all diurnal variations, but significantly increases the cost of power collection. For static PV panels, to maximise the collection of incident radiation, they should be directly south in northern latitudes and directly north in southern latitudes, i.e. lie in an east-west plane.

[0056] To account for seasonal variations, the angle at which the PV panel is inclined depends on the latitude of the site. In Figure 1a the centre of the cabinet 1 representing the charging station of the present invention is centrally located within a circle on which the four cardinal directions N, S, E, W are marked. A first line ES represents a plan view of the daily path of the sun at the summer solstice and represents the optimum slope or inclination angle TS of the PV panel to collect the maximum available solar radiation at that time of the year. Likewise, a second line EW represents a plan view of the sun path significantly lower at the winter solstice, but still represents the optimum inclination angle TW of the PV panel to collect solar radiation at that time of the year. For static PV panels, the optimum inclination angle can be represented by the mid-point of the two extremes (represented by the lines ES, EW and their corresponding inclination angles TE, TW), which remains close to the equinoxes.

[0057] In calculating the available energy that can be collected from solar radiation, it is important to distinguish between "direct radiation" (the panel collects light from the sun) and "diffuse radiation" (the panel collects light energy scattered by clouds or reflected / ambient light). In Figure 1b the bar chart shows the monthly average values of direct and diffuse monthly radiation in a region of northern latitude 51° (London, UK) for each month of the year, measured in average daily kilowatt hours of energy incident per square metre (kWh / day.m2). From this example, the average daily direct light during November, December and January makes about 0.5 kWh to 0.75 kWh of energy per square metre of exposed PB panel available. Furthermore, at any period between October and February, the ambient or diffuse average does not exceed 1 kWh per square metre of available PV panel.

[0058] The daily average values of direct and indirect (ambient, diffuse or reflected) irradiation can be taken in combination and the minimum area of PV panels required to reach the nominal rating of the array or assembly of PV panels can be calculated. Reference is now made to Figure 2 , a first embodiment of a charging station 10 is shown, comprising a cabinet 12 defining a cabinet and having four planar faces 13 and a top portion 14.

[0059] In its most basic iteration, the charging station comprises a cabinet, PV panels 15 are fixed to the front, back and sides, vertically disposed to the cabinet, the front being the face that faces south in northern latitudes and which has the total area receiving PV panels to provide a rated output. For low output requirements, winter daily average output can be as low as 200 Wh, which can be sufficient to charge many electronic devices, or in one very specific application of the invention, to sustain a current to record, store and transmit collected data at a remote monitoring station. The energy collected can be enhanced by the placement of reflectors that will deflect direct incident light at an angle to the receiving panels. In the preferred configuration, the roof 14 comprises PV panels, which can be adjusted in pitch to optimize the collection of solar radiation and / or to prevent snow and leaves from accumulating on it.

[0060] In a modified orientation with a cabinet body having a rectangular cross section, the front faces east to the sun rise and the back is oriented to the sun set, so as to maximize the incident area during winter and allow the south side and roof panels to collect available light at the strongest time of the day.

[0061] The cabinet forms a cabinet body for the accumulation of energy through a battery bank and energy management or control circuitry. In the preferred configuration, the cabinet body is a rectangular prism with a roof 14, a base 13, a front 11, a back 12 and two sides 10, 10'. Figure 2 In the basic embodiment shown, seven PV panels 15 are disposed on five faces (two sides, front, back and roof).

[0062] The PV panels are designed and rated to withstand harsh environmental conditions. In the case of a cabinet formed from extruded or profiled aluminum frame parts, the final cabinet body will have good corrosion resistance properties and be able to withstand high temperature and UV extreme conditions. Anodized stainless steel is the preferred material for the production of the cabinet body, in which the panels are fixed to the existing surface by the attachment of the frame.

[0063] A variety of environmental management features are integrated to allow the cabinet to exist in potentially quite extreme outdoor environments.

[0064] Discrete ventilation holes, protected internally by a fine internal mesh (to prevent insect ingress), are built into the roof frame or below the roof panel to allow hot air and any gases produced by the battery charging to exit. Equivalent ventilation holes can also be provided in the base or supporting floor to allow cool air to enter the circulation. This feature can be complemented by automatic and temperature triggered waterproof cooling fans to improve the flow of air from the base to the roof. In the case where operating temperatures can exceed the thermal limits of the internal components, a series of fans can be triggered when a predetermined threshold is reached. An additional optional feature directs the air flow over the PV panels to reduce the surface temperature, thus minimizing the negative temperature coefficient, in which the power generation of the PV panels can be lower than the power utilized by the cooling fans.

[0065] A grounding rod (not shown) can be placed and connected to the frame components before the cabinet is installed to allow grounding of the cabinet and internal equipment, providing a connection from the cabinet and the internal frame. When grounding screws are used to secure the cabinet, the grounding screws can also be used as part of grounding the charging station.

[0066] In rack deployments in more extreme low-temperature environments, grooved corrugated plastic panels, used alone or in combination with commercially available insulation materials, can reduce extreme temperatures within the rack, thereby allowing equipment and batteries to operate over a wider range within their design parameters. Air gaps can also be incorporated between the external panels and frame components to prevent thermal bridging.

[0067] like Figure 3 As shown, seven 100W PV panels (five shown only) are connected to a charge controller 16 for each panel to regulate the charging current supplied to the battery cells. In the exemplary configuration, one of the charge controllers 16a (associated with one PV panel (hereinafter referred to as the “top panel”)) is connected to the spare group RB of the deep-cycle battery of the type described herein and is capable of charging at 5°C. The remaining four charge controllers 16 transfer harvested electrical energy from the remaining panels to charge a group of batteries (referred to as the “workgroup” WB), ideally comprising lithium-ion or lithium iron phosphate (LiFePO4) batteries, both with excellent power characteristics. The power is converted from DC to AC by a 2kW inverter INV, providing the main voltage through the circuit breaker RCD, or a selected voltage optimized for charging the EV battery or directly connected to the EV output of the inverter.

[0068] The backup battery RB is powered by the isolated DC-DC charger 17 to maintain the operating voltage of each battery in the work group WB. The DC-DC charger 17 is a 30A unit designed to charge the work group WB if the voltage of each battery drops below 12.5V when the backup battery voltage exceeds 11V.

[0069] Associated with the inverter is a startup sensor 18, which enables a low-power standby mode. A remote monitoring unit 19 measures the voltage of the operating and backup batteries, as well as the inverter load, and may include a communication module for issuing alerts to users or maintenance contractors.

[0070] It is worth noting that powering multiple charge controllers 16 via solar panels 15, with each PV panel operating differently on each face depending on day and season, provides an opportunity to combine multiple battery technologies to fully utilize their respective advantages and compensate for their respective weaknesses. By incorporating battery technologies into the generator circuit described in this invention, the lifespan of both battery technologies can be increased, which is particularly relevant to frequent cycling or frequent loads, especially in summer applications.

[0071] Advantageously, the work bank WB comprises lithium ion or lithium iron phosphate batteries connected together in series to produce the required circuit voltage (for example, two 12V batteries present a 24V circuit). Other batteries can be connected in parallel, if required, to provide additional capacity for the work bank. Charge balancers can be used to ensure that the state of charge differences between the batteries are compensated during the charging process.

[0072] In the preferred configuration detailed hereinafter, each face of the charging station is optimized to power 48V battery packs within the battery bank, such that the PV panels produce an open circuit voltage of 60V under maximum insolation intensity and a voltage of about 51V under load, i.e. the charging voltage of the corresponding battery pack.

[0073] Commercially available lithium ion and lithium iron phosphate batteries typically feature built-in protection circuits, cycle deeper and more frequently than alternative technologies, and have a more favorable weight / kWh ratio than alternative technologies.

[0074] However, it is important to note that these batteries decay over time between 80% and 100% state of charge, are more expensive per watt-hour than other battery technologies, and have poor charging characteristics below 5°C.

[0075] The Absorbed Glass Mat (AGM) batteries that make up the backup bank RB are connected together in series to produce up to 48V circuits. AGM batteries can also be connected in parallel to produce additional capacity, if required, but each bank is limited to 3 batteries in parallel. Charge balancers are always used to ensure that the state of charge differences between the batteries are compensated during the charging process. Overcurrent protection devices are installed on the circuit to compensate for the lack of built-in protection features.

[0076] It is worth noting that AGM batteries do not decay as much from being at 100% state of charge for long periods of time (compared to lithium-based batteries), are not expensive per kWh capacity compared to other technologies, can be charged at temperatures below 0°C, and have deep discharge characteristics, in that they are able to be discharged up to a maximum of 40% of their capacity every day, with more than 1000 cycles before they start to decay. However, in contrast, the battery cells decay more quickly if cycled frequently with a discharge rate of more than 40% for more than 2 hours.

[0077] Minimum temperatures can also be experienced during winter minima, so it is important to charge batteries with the lowest operating temperature range.

[0078] It will be appreciated by those skilled in the art that the above example graphs can change as battery technologies improve and operating and charging characteristics achieve better performance.

[0079] As Figure 3As shown, the lithium-based battery working group WB is directly charged by the charge controller 16, except for the charge controller 16a associated with the top plate, which is connected to the spare group RB. The plates selected to charge the working group WB are those that receive the maximum solar radiation during the winter minimum, thus favoring keeping them at a full charge state as much as possible.

[0080] In cases of frequent daily cycling of the AGM standby group RB, it is advantageous to add a lithium-based or alternative frequently cycled or sacrificial battery for charging by the top-plate charge controller 16a, directing most of the cycles to this battery, thereby reducing the depth of discharge experienced by the AGM battery and reducing the time the lithium battery is at full charge. An isolated DC-DC converter (or charger) 17 is used to transfer energy from the lithium battery of the working group WB to the AGM battery of the standby group RB, and must be sized to charge at a rate as close as possible to the AGM battery discharge rate. When a load is connected via the inverter INV, the voltage drop experienced by the working group WB triggers the charging process of the standby group RB, which continues until the working group battery is fully charged or the standby group is depleted.

[0081] This approach reduces the cycle depth of the working group's batteries, thereby increasing their lifespan, while also reducing the time the standby group spends at 100% charge, further increasing its lifespan. This arrangement also directs stronger summer solar output from the top panels to the standby group batteries, allowing them to cycle more frequently and recover faster when solar energy is more abundant, thus again reducing the working group's cycle depth. Advantageously, the solar panels that generate maximum output in winter to charge the group actually powering the load do not need to consume energy to keep the working group's battery temperature within operating range during periods of minimum solar energy. Therefore, the energy overhead of heating the lithium batteries to absorb charge or converting energy via DC-DC charging processes is avoided when energy is least abundant.

[0082] Utilizing dual-cell technology to optimize solar energy collection at minimum levels provides additional capacity to a given system, economically reducing the total cost of the system without incurring any of the concessions that single-cell technology would offer.

[0083] Figure 4a and 4b It shows the relationship with Figure 2 A similar cabinet 10, but with greater capacity and an internal structural frame 11. As before, each wall 13 has a solar panel 15 attached thereto, ideally via a panel frame (such as...). Figures 6a to 6c As shown, the structural frame element 11 of the cabinet 12 is fixed to the plate frame. The top portion 14 is set at an angle relative to the front or back to optimize solar energy collection, thereby ensuring optimal conditions during the summer months.

[0084] The cabinet is sized and shaped to accommodate standard batteries to form the reserve bank RB and the working bank WB. Lithium-based batteries (such as lithium-ion or lithium-iron-phosphate batteries) are used as the working batteries and are provided in sufficient quantity to ensure that a discharge depth of less than 40% is achieved every day during periods of sub-optimal solar collection (especially during winter), thereby maximizing battery life (25 to 40 years per battery anywhere).

[0085] The batteries of the stacked working bank WB are connected in a 4S3P configuration (i.e. four batteries in series, three batteries in parallel) to deliver a maximum storage capacity of 33 kWh and a maximum power output of 15 kW (240V, 60A from 48V, 312A) through the wall-mounted inverter INV.

[0086] The embodiments described have multiple uses and can be used as hybrid grid charging cabinets with integrated solar power generation.

[0087] Figure 5c shows a minor but important improvement to the arrangement of the embodiments of the solar power cabinet body, in which the working bank is arranged as a linear stack. In the preferred construction, a standard 19-inch rack structure can be used, and selected components (such as lithium battery packs, inverters and charge controller circuitry) are packaged for simple detachable connection within the rack.

[0088] Figure 4d and 4e Another configuration of the first embodiment of the charging station cabinet body is shown, in which the internal frame 11 provides support for standard industrial rack-mounted components (such as the rack-mounted lithium battery packs described above). As production scales, the availability of reliable, inexpensive and possibly "plug-and-play" component modules becomes standardized, including power connections grounded to the frame elements will facilitate the rapid expansion of the capacity of the cabinet body of the present invention. As described below, the present invention can be provided in the form of a "kit of parts", allowing the purchaser to select the minimum of operational components and add capacity, join reserve bank batteries or access external energy sources as required.

[0089] In the embodiment shown, the charge controller 16 and inverter INV are mounted to the back panel (with a 10cm gap around the inverter), however these components can be provided in a rack-mounted alternative.

[0090] The cabinet body can comprise an aluminium or steel plate to which the PV panels are fixed. This facilitates the direct attachment of the PV panels to the cabinet body. Alternatively, the PV panels are mounted within a frame, which is then fixed to the face panels of the cabinet body. In the most preferred construction, the PV panels mounted within a rigid frame form the front, back and sides (and ideally also the top portion) of the cabinet body.

[0091] Figure 5a and 5bA charging station according to the present application is shown, at least one battery for charging is a battery of an autonomous aerial vehicle, such as a drone AD. The top portion 14 of the cabinet is adapted to pivot open about a motor drive shaft 17. The drone is magnetically latched to the inside of the top portion, which can be deployed from the top portion when a release force is applied to disable the magnetic latch. The drone battery is charged wirelessly by inductive coupling. During drone deployment, the top portion is closed to avoid obscuring the PV panels 13 and to allow further charging by the top portion PV panels, if any.

[0092] Figures 6a to 6c A panel frame component F is shown for holding a pair of PV panels. The first configuration of the panel frame includes a lip region L for mounting the panels to the existing face of the cabinet; and a fixing hole H through which a tamper-resistant bolt can be fixed. The PV panel cover portion C includes a folded box structure B to provide cable routing from the PV panels to the charge controller 16 within the cabinet.

[0093] In the preferred configuration of the first embodiment of the present application, the frame elements 11 comprise aluminium or steel extruded sections joined together at 90 degree corner joints to form the outer frame. As mentioned above, internal bracing can be used and form part of the structural integrity of the cabinet. The solar panels are located within the surrounding frame components and attached to the frame by means of a rest pin which locates the panel within a groove of the extrusion. This assembly method allows the panels to be installed vertically into a pre-assembled frame.

[0094] A bottom component, for example Figures 4a to 4e As shown, it can be made of thermoplastic polyurethane (TPU) with a hole formed in its interior to allow the internal frame to be fixed to it, thereby forming the core of the internal frame shape. In addition, there are ground fixing holes to allow the bottom to be fixed to the ground or a concrete slab by means of suitably rated bolts. As mentioned above, ground screws can be used to fix the charging station cabinet. Vent holes in the bottom component allow air to enter the cabinet from the bottom and are protected by a mesh cover to prevent insects from entering. Drain holes with mesh cover protection can also be provided for water ingress or condensation formed within the cabinet.

[0095] The top portion 14 or optional top PV panels 15 are connected to the internal frame by means of TPU forms which can be separately covered with an outer coloured composite aluminium panel to achieve the desired aesthetic effect.

[0096] The inverter INV can be mounted in the top left or top right corner of the cabinet with a 10cm or greater gap all around it. Batteries are stacked vertically in the internal area opposite the inverter to ensure that any escaping gases from the batteries do not affect the inverter.

[0097] To extract maximum energy from the respective PV panels 15, a maximum power point tracking (MPPT) controller is provided for each PV panel footprint of the cabinet. The controller 16 is located above the batteries on a fireproof backsheet. Circuitry to balance the rate of battery charging, such as a monitoring unit 19, can also be located on the backsheet.

[0098] A brushless motor driven DC fan is mounted within the top TPU formwork section of the cabinet. The fan, in combination with the vents in the base and the vents in the top of the cabinet, ensures that air can flow rapidly from the base of the cabinet to the top and atmosphere when required, thereby keeping the internal equipment cool. The fan is triggered by a temperature sensor with pre-set thresholds.

[0099] A central LED light strip can be used to visually indicate the current status of the batteries within the cabinet, the capacity level and the charge or discharge level, as well as to provide visual alerts to the user of any issues that can require investigation.

[0100] Reference is now made to Figure 7a and 7b which shows a garden shed or small garage structure 20, with structural frame elements 21, front, rear and side walls 23 and a sloping top section 24. Each wall is covered with PV panels 25, which are either fixed to the existing walls or mounted within the frame, which is fixed together and to the frame elements 21 of the cabinet along its perimeter edges. One wall can include a door (not shown) or form a complete hinged section.

[0101] The top section 24 is shown in a sloping tiled configuration, where the PV panels 25 replace the tiles, however, a single piece top can also be provided, to which the PV panels are fixed. As before, the angle of the slope of the top is determined by the individual or site requirements and can be in the direction of the summer sun at its peak during the day. In Figure 7b the exploded view, the front wall (or door) and side walls 13 have been removed to reveal the internal layout, with a bank of batteries WB, RB, connected in a similar configuration to that discussed in relation to Figure 5 or Figure 6b the rear wall, along with the associated inverter INV and control circuitry. Power outlets can be provided for internal and external lighting of the cabinet and for charging points for electric vehicles EV (from scooters and e-bikes to electric motorcycles (as shown) and cars). Wall-mounted spools (not shown) for EV cables can provide convenient connections near the garage.

[0102] The solar energy yield provided by the PV panels on the top section 24, as well as the front, side and back walls 23, provides a useful amount of energy to power the inverter INV, which can use the stored energy in the work bank WB to charge the EV at a power in excess of 2kW.

[0103] The panels are optionally joined together by 3D printed joints that are fixed inside each aluminum frame corner of each solar panel face and have a central hub that bolts them together to form a secure network of connections across the face. These joints can optionally be hinged to allow the panels on each face to open like an accordion, allowing full access to the internal equipment.

[0104] Thermal insulation can be installed within the panel apertures to provide improved temperature stability within the structure.

[0105] Apertures between the angled top panel and the side and front panels can be illuminated by LED light strips to indicate charge status and solar production by varying color and pattern.

[0106] Figure 8a And 8b A third embodiment of a charging station 30 is shown formed to present an open cabinet 32 including structural frame elements 31 and a series of PV panels 35 disposed therebetween. Since the cabinet is open, diffuse reflected light can be utilized by using bifacial PV panels. Conveniently, the panel frames are disposed to mount the PV panels back to back and can contain charge controllers / regulators to manage the mismatched voltage produced by the pairs of panels and facilitate securing the installed panels 35 to the structural frame elements 31.

[0107] In the shown configuration, there are two panels 35 (both bifacial) disposed one above the other on each side wall, and a pair of panels (which need not be bifacial) disposed one above the other on the rear wall, which is adapted to accommodate mounting hooks and charging posts for foldable electric scooters EVs, such as Figure 8b Batteries forming working bank WB and reserve bank RB can be housed at floor level within the cabinet. The application is for a charging station, no inverter is required. Additional communication modules for payment verification can be mounted on the interior rear wall or more conveniently near the cabinet opening.

[0108] Figure 9A variant of the first embodiment of the charging station 10' is shown, in which the face that faces away from the sun's arc and thus generally receives more reflected or incident light to the PV panels 13' is replaced by a face having a plurality of battery receptacles R disposed therein. Each receptacle is adapted to receive a removable EV battery, for example from an electric motorcycle, bicycle or scooter. If the charging station is commissioned by the same manufacturer, the receptacles can include a charging coupler that connects directly to the EV battery. This arrangement facilitates a battery swap scheme, in which a fully charged battery is removed from the receptacle upon opening the receptacle when it is confirmed that a valid and chargeable battery has been deposited and payment verification is complete. In other cases, a terminal connection can be provided for a series of batteries, however, charging will only begin when the receptacle is closed and payment verification (if any) is complete. To facilitate card payments, a communications module for payment verification can be installed within the cabinet. In the preferred arrangement, newly deposited batteries are accelerated to charge and fully charged batteries are part of the working bank WB or the reserve bank RB according to predetermined charging criteria.

[0109] Figure 10a A fourth embodiment of the charging station 40 is shown, comprising a self-supporting, grounded structural framework of substantially octagonal cross-section, having eight upright frame elements 41 to which PV panels 45 are attached vertically. The upright frame elements support a top portion 44 on which four PV panels 45 are disposed at an angle to optimize solar energy collection. The top portion further comprises a support plate 51 that defines a central aperture 52.

[0110] Sealed within the framework, the reserve and working battery units and control circuitry are arranged in a configuration determined by the intended use of the generator. If the generator is designed as a self-contained device, the feet 41a at the bottom of each upright frame element can be anchored to the ground or a concrete base. If the generator is designed to be hoisted or lifted to remote or inaccessible areas, the support plate 51 includes attachment points such as lifting lugs rated for the weight of the generator with batteries. In an alternative configuration, the support plate aperture 52 can accommodate a support pole of a wind turbine to enhance the power harvesting reliability of the generator. The generator is configured as a self-contained device, but can be connected with other devices to form an array.

[0111] Figure 10b and 10c is a perspective view of the hinged detail of at least one framed panel 45 adapted to facilitate access Figure 10a to the interior of the cabinet body shown.

[0112] A pair of vertical solar panels 45 are attached to the frame uprights 41 by 3D printed plate joints from a profiled pivot component 56 which is rotatably housed in a clamping member 57 which operably supports the weight of the framed PV panels 45 and has a biasing mechanism to return the panels to their normally closed position where they can be locked closed. A magnetic latching mechanism electrically operated from a payment card validation can be used to provide enhanced security. The pivot component 56 and clamping member 57 can be 3D printed or formed from a thermoplastic material such as TPU and have internal features to prevent rotation beyond the desired range of movement.

[0113] Finally, with reference to Figure 11a and 11b a specific combination of the fourth embodiment 40 of the present application includes a charging station 42, ideally for electric bicycles and electric scooters EV. Similar to the device shown in Figure 10a the charging station 42 includes a self-supporting, grounded framework of octagonal cross-section with upright frame elements 41 each provided with an anchor plate 41a for securing the charging station to the ground. As before, PV panels 45 are secured between the upright elements, however, pairs of panels are locked on one side to provide a passageway gate for a centrally disposed charging column 61 which can have a foldable electric scooter EV attached to or on it for storage while charging, using the mechanisms described with reference to Figure 10b and 10c The upright frame elements 41 also provide support for a top section 44 on which further PV panels 45 are arranged.

[0114] As shown in Figure 11c the central charging column 61 houses the battery packs WB, RB and charge regulator required for charging the electric scooter. A socket protected by an RCD is located on the central charging column for providing an AC output for the charging transformer. A communications module for facilitating card payment validation can also be integrated in the charging column. In the preferred arrangement, mounting hooks 63 are arranged around the charging column 61 at discrete heights to allow the folded scooters EV to be stacked on them, thereby providing maximum internal space for the geometry of the folded electric scooters or other electric mobility aids.

[0115] Ideally, a pocket is provided to accommodate the user's own AC charger to ensure compatibility with the widest range of electric scooters or other mobility aids.

[0116] It will be appreciated by the skilled person that the above embodiment 40 is not limited to rectangular or octagonal cross-sections, in some cases other shapes including hexagonal and triangular can be preferred.

[0117] Of course, it should be understood that the application is not limited to the particular details described herein, which are given by way of example only and that various modifications and changes can be made within the scope of the appended claims.

Claims

1. A photovoltaic (PV) charging station for charging batteries of electric vehicles (EVs), the charging station comprising: The cabinet has structural frame elements and grounding elements attached thereto; Multiple PV panels fixed to the frame components; A control circuit for regulating the electrical energy generated by the PV panel and an energy storage device connected to the control circuit are sealed and installed inside the cabinet; and Charging coupler, At least two of the PV panels are positioned in the vertical plane and include the outside of the cabinet.

2. The charging station according to claim 1, wherein the PV panel and the frame element are integrally formed.

3. The charging station according to claim 1 or 2, wherein the cabinet includes a wall portion and a top portion, and the PV panel is fixed to the wall portion and the top portion.

4. The charging station according to claim 1 or 2, wherein the cabinet has a box-like form, wherein structural frame members provide their peripheral corners and PV panels are fixed between the structural frame members.

5. The charging station according to any one of the preceding claims, wherein each wall portion includes a framed PV panel disposed in a vertical direction, presented as an outward surface of the cabinet.

6. The charging station according to any one of the preceding claims, wherein the total surface area of ​​the PV panels is optimized to generate at least 200Wh of daily power generation.

7. The charging station according to any one of the preceding claims, wherein the cabinet includes a plurality of receiving sections for a removable EV battery, each receiving section having a charging coupler for connecting to a terminal of the EV battery.

8. The charging station according to any one of claims 1 to 6, wherein the charging station is adapted to provide means for directly charging electric vehicles (EVs).

9. The charging station according to claim 8, wherein the charging station includes a structure or cabinet containing space for accommodating, fixing or storing at least one EV.

10. The charging station of claim 9, wherein the structure or cabinet is a building having a plurality of receiving compartments for EVs.

11. The charging station of claim 8, wherein the charging station includes mounting means for at least one EV.

12. The charging station according to any one of the preceding claims, wherein the charging station includes a communication module.

13. The charging station according to any one of the preceding claims, wherein the charging station includes a payment verification tool.

14. The charging station according to any one of the preceding claims, wherein a structural frame element defines an octagonal cabinet with a PV panel disposed therebetween to present eight solar energy collection surfaces, at least one of which is hingedly fixed to a corresponding frame element to facilitate access to the interior of the cabinet.

15. The charging station according to any one of the preceding claims, wherein the energy storage unit comprises a group of batteries having deep cycle characteristics and a group of batteries having high power transfer characteristics, and wherein the combination of battery technology with a charging controller and voltage monitoring circuitry optimizes charging and power transfer under suboptimal conditions.

16. A method for charging a battery of an electric vehicle (EV), the method comprising: A charging receiving unit for EV batteries is installed inside the cabinet of a charging station of the type described in claim 1. Install the EV battery inside the charging receiver and align the battery terminals with the charging coupler; Connect the charging coupler to the EV battery terminals; Perform a charging cycle; as well as; Verify that the EV is ready for reuse.

17. A method for charging an electric vehicle (EV) battery, the method comprising: An installation point for an EV is located inside the cabinet of a charging station of the type described in claim 1. Install the EV at the installation point; Connect the EV to the charging device; Perform a charging cycle; as well as; Verify that the EV is ready for reuse.

18. The method for charging an EV battery according to claim 17, wherein the mounting point is raised.

19. The method for charging an EV battery according to any one of claims 16 to 18, wherein the charging cycle includes a payment verification step.

20. A method for charging an EV battery according to any one of claims 17 to 19, wherein the method includes storing the EV.

21. The charging station according to claim 1, wherein the charging station has at least one vertically arranged main surface, wherein photovoltaic (PV) panels are operatively formed on at least the main surface of a structure or cabinet to optimize solar radiation collection under suboptimal conditions with respect to diurnal and seasonal variations in direct and indirect solar radiation incidence.

22. The charging station of claim 21, wherein each PV panel is attached to the structure or cabinet by a detachable frame, the detachable frame being adapted to enclose the PV panel and provide wiring for the cables associated with each panel.

23. The charging station according to any one of the preceding claims, wherein the cabinet includes a top portion, and one or more PV panels are attached to the top portion.

24. The charging station according to any one of the preceding claims, wherein the PV panels are mounted within a frame adapted to be connected to each other and form at least two sides of the cabinet.

25. The charging station according to any one of the preceding claims, wherein the frame includes an extruded profile having slots and channels to receive and retain the PV panel and associated cables.

26. The charging station according to any one of the preceding claims, wherein the frame releasably holds the PV panel and includes a hinge element at its periphery for easy access to the interior of the cabinet.

27. The charging station according to any one of the preceding claims, wherein each face having PV panels has a dedicated and appropriately rated charging controller associated therewith to manage the solar energy collected from each panel within the face, thereby maximizing the generated charging output efficiency.

28. The charging station according to any one of the preceding claims, wherein the battery array transmits direct current (DC) power output to the device or a local power connector, or provides alternating current (AC) power output via an inverter.

29. The charging station according to any one of the preceding claims, wherein the structure or cabinet is adapted to receive, store and charge electric mobile vehicles (EVs) from electric scooters, electric motorcycles and electric vehicles (without requiring an external or mains power supply connection).

30. The charging station according to any one of the preceding claims, wherein the cabinet has an octagonal cross-section, wherein the framed PV panels are hinged to form a passageway to a centrally located charging structure, on which electric scooters are suspended for storage and charging.

31. The charging station according to any one of the preceding claims, wherein the structure or cabinet is open on one side, and wherein at least one side of the PV panel includes an arrangement of PV panels formed in a back-to-back configuration to receive indirect or reflected solar radiation within the opening of the cabinet, and thereby the EV connects to the charging facility at its opening.

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