A portable solar charging device based on foldable structure and folding method

Abstract

The application discloses a portable solar charging device based on a folding and unfolding structure and a folding and unfolding method, which comprises a driving mechanism, a lead screw and a folding and unfolding mechanism, the driving end of the driving mechanism is connected with the lead screw, the driving mechanism drives the lead screw to drive the folding and unfolding mechanism to rotate and unfold or fold; the folding and unfolding framework can be unfolded in the shape of an umbrella and stored in the shape of a column, has a high folding and unfolding ratio and a small storage volume. Relying on the folding paper space truss and the telescopic lead screw structure, the equipment improves portability, maximizes light receiving area and improves energy utilization rate, and enhances wind resistance and wear resistance and prolongs service life. The application integrates the folding paper structure, the perovskite photovoltaic technology and the sound control technology, realizes intelligent folding and unfolding, is powered by solar energy, has no carbon emission, replaces the fuel generator, has practicability and environmental benefits, and is in line with the low-carbon trend.

Description

Technical Field

[0001] This invention relates to the field of new energy and renewable energy technology, and in particular to a portable solar charging device and folding method based on a folding structure. Background Technology

[0002] Traditional rigid photovoltaic panel technology: Wang Hao et al. published in the Journal of Solar Energy that the traditional rigid crystalline silicon photovoltaic panel technology is mature and has stable output, but it is bulky, fragile, non-foldable and non-deformable. It is only suitable for large-scale photovoltaic power stations and fixed roof installations, and is difficult to use for outdoor portable and mobile power supply scenarios [1]. This product adopts a flexible design and is more portable than rigid solar panels.

[0003] Conventional flexible photovoltaic panel technology: The flexible photovoltaic panels described in the origami and crease design review published by Li Xiao et al. in the *Acta Mechanica Sinica* can achieve a certain degree of bending, but their folding-to-unfold ratio is small, their storage volume is large, and repeated folding easily causes damage to the battery layer and circuit breakage, resulting in poor durability and difficult maintenance. Furthermore, they lack a stable support structure, have an unadjustable light-receiving angle, poor wind resistance, and are easily damaged in harsh environments such as high altitudes, strong winds, and low temperatures. This product uses an origami mechanism combined with the latest perovskite flexible photovoltaic material technology, achieving a higher folding-to-unfold ratio and higher module efficiency. Simultaneously, it employs a modular design and bistable composite materials, providing superior compressive strength and ease of maintenance.

[0004] Origami Structure and Folding Mechanism Technology: Existing patent CN113193125A describes an origami structure and origami metamaterial that possess characteristics such as large deformation, high folding-to-unfold ratio, and excellent mechanical properties. These technologies have been researched and applied in fields such as spacecraft deployment mechanisms and flexible equipment, providing theoretical and engineering references for the design of foldable photovoltaic structures. This device employs a novel origami mechanism to significantly improve the folding-to-unfold ratio of foldable solar panel mechanisms.

[0005] Perovskite Flexible Photovoltaic Panel Technology: The research progress of flexible perovskite solar cells published by Zhao Zhengjing et al. in the Journal of Beijing University of Aeronautics and Astronautics utilizes ABX flexible photovoltaic panels. Using perovskite as the light-absorbing layer, this low-temperature fabricated thin-film photovoltaic device achieves photoelectric conversion through the photovoltaic effect. It features ultra-thinness, flexibility, high efficiency, and lightweight characteristics, making it suitable for foldable / portable photovoltaic devices. Advantages include: high absorption coefficient and wide spectrum, resulting in extremely high module efficiency and efficient light capture; low-temperature fabrication (≤150℃), less material usage, light weight, and low carbon footprint; compatibility with origami structures and intelligent control, making it suitable for outdoor / emergency / high-altitude off-grid power supply.

[0006] Bistable composite material: The skeleton of this device in the existing patent CN118063044A relies on PLA (Young's modulus 2.7–16 GPa) as the hard component and TPU (Young's modulus 10–100 MPa) as the soft component to prepare a bistable composite material. It utilizes the characteristics of being extremely light, having good toughness, being able to be molded by creases and indentations, being weather-resistant, inexpensive, environmentally friendly and recyclable to meet the requirements of this product.

[0007] Intelligent voice control technology: This device adopts a voice control system and is equipped with a fully offline technology stack of Porcupine+Vosk+OpenClaw+Piper. It can achieve complete voice interaction without the need for a network connection, which can help realize the intelligent control of this device. Summary of the Invention

[0008] The purpose of this invention is to address the technical deficiencies in the prior art by providing a portable solar charging device based on a folding structure.

[0009] Another object of the present invention is to provide a method for unfolding the above-described device.

[0010] The technical solution adopted to achieve the purpose of this invention is: A portable solar charging device based on a folding structure includes a drive mechanism, a lead screw, and a folding mechanism. The drive end of the drive mechanism is connected to the lead screw, and the drive mechanism drives the lead screw to rotate and unfold or fold the folding mechanism. The folding mechanism includes a folding frame, telescopic rods, an upper top plate, a central rotating seat, and a nut connector. The upper top plate is inserted into the top of the central rotating seat and located at the top of the lead screw. The central rotating seat is rotatably mounted on the lead screw via bearings. The center of the nut connector is fixedly mounted on the lead screw nut that mates with the lead screw. Multiple supports are arranged circumferentially on the nut connector. The inner end of one of the telescopic rods is rotatably connected to each support. The outer end of each telescopic rod is rotatably connected to the bottom outer edge of the folding frame. Multiple folding frames are arranged sequentially to form an umbrella shape, with their inner ends fixedly surrounding the side of the central rotating seat. Flexible solar panels are installed inside the folding frame.

[0011] In the above technical solution, the outer end of the telescopic rod is connected to the bottom outer edge of the folding frame through a ball-and-socket structure.

[0012] In the above technical solution, the support is provided with a groove, and a universal joint is provided in the groove. The universal joint is rotatably connected to the inner end of the telescopic rod through a rotating shaft.

[0013] In the above technical solution, the drive mechanism is located at the bottom of the lead screw, the bottom of the drive mechanism is connected to the bottom bracket through a threaded connecting rod, and the drive mechanism is covered by a shell.

[0014] In the above technical solution, the driving mechanism is a stepper motor.

[0015] In the above technical solution, the material of the folding skeleton is prepared by mixing PLA as the hard component and TPU as the soft component.

[0016] In the above technical solution, multiple embedding slots are provided on the folding frame, the shape of the flexible solar panel matches the embedding slots, and the flexible solar panel is embedded in the embedding slots.

[0017] In the above technical solution, the flexible solar panel is made of perovskite photovoltaic material.

[0018] In the above technical solution, the flexible solar panel includes a flexible substrate, a light-absorbing layer, a charge transport layer, a hole transport layer, and a transparent electrode.

[0019] Another aspect of the present invention includes a method for operating the portable solar charging device, comprising the following steps: Deployment process: The drive mechanism drives the lead screw to rotate in the forward direction, causing the lead screw nut to move upward in a straight line on the lead screw; the nut connector moves upward, and the inner ends of multiple telescopic rods move upward under the drive of the nut connector, while their outer ends open downward and outward, pushing the flexible solar panel to unfold smoothly to the preset angle, thus completing the deployment operation; Folding and storage process: The drive mechanism drives the lead screw to rotate in the opposite direction, causing the lead screw nut to move downward in a straight line on the lead screw; the nut connector moves downward, and multiple telescopic rods retract under the drive of the lead screw helical surface, with their outer ends moving upward and inward until they are close to the lead screw. The flexible solar panel is simultaneously stacked, completing the storage.

[0020] Compared with the prior art, the beneficial effects of the present invention are: 1. The device of the present invention has a high folding-to-expansion ratio and higher power generation for the same volume: relying on the folding-to-expansion frame, it can achieve small volume storage and large area unfolding, improve the effective light-receiving area, and solve the pain point of difficulty in balancing portability and power generation.

[0021] 2. This invention achieves intelligent and convenient operation through voice-controlled retraction and extension: it supports automatic voice-controlled retraction and extension, replacing manual operation, realizing intelligent upgrade, and greatly improving ease of use.

[0022] 3. The folding skeleton of the present invention is made of recyclable materials, PLA is renewable, and TPU is reprocessable. Its lightweight and long lifespan further reduce carbon emissions throughout the entire life cycle, making it green and environmentally friendly.

[0023] 4. The folding frame of this invention can unfold in an umbrella shape and fold into a column shape, achieving a high folding-to-fold ratio and a small storage volume. Utilizing an origami-style spatial truss and telescopic screw structure, the device improves portability, maximizes the light-receiving area, increases energy efficiency, enhances wind and wear resistance, and extends its lifespan. This invention integrates origami structure, perovskite photovoltaic technology, and voice control technology to achieve intelligent unfolding and folding. Powered by solar energy with zero carbon emissions, it replaces fuel generators, combining practicality and environmental benefits, aligning with the low-carbon trend.

[0024] 5. Outdoor Exploration and Camping: Outdoor exploration and camping are civilian applications where the device of this invention has significant advantages. In the wild, there are often problems such as insufficient power supply and inconvenient storage of traditional photovoltaic panels. The device of this invention has a small storage volume, supports voice-controlled automatic retraction and extension, can conveniently charge equipment, and is impact-resistant, weather-resistant, and highly adaptable to various environments. It can generate stable power, effectively solving the problem of power supply in the wild and improving the convenience and safety of outdoor travel.

[0025] 6. Temporary Power Generation at High Altitudes and Electricity Supply for Herders: The core of this invention's device is applied to temporary power generation and electricity supply for herders at high altitudes, perfectly suited for off-grid scenarios such as plateau pastoral areas and border outposts. The device is lightweight, portable, and easy to install, effectively solving the pain points of difficult transportation and cumbersome installation of traditional photovoltaic products in high-altitude areas. Its perovskite modules can withstand the strong ultraviolet radiation and low temperatures of high-altitude environments, exhibiting high power generation efficiency and stable output. It can provide clean, reliable, and convenient power supply to remote high-altitude areas, significantly improving local electricity consumption levels and emergency power supply capabilities. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the device of the present invention.

[0027] Figure 2 This is a top view of the device of the present invention.

[0028] Figure 3 This is a partial structural schematic diagram of the device of the present invention.

[0029] Figure 4 This is a partially enlarged view of the device of the present invention.

[0030] Figure 5 This is a partially enlarged view of the device of the present invention.

[0031] Figure 6 This is a partially enlarged view of the device of the present invention.

[0032] Figure 7 This is a partially enlarged view of the device of the present invention.

[0033] Among them, 1: drive mechanism; 2: lead screw; 3: folding mechanism; 3.1: folding frame; 3.2: telescopic rod; 3.3: top plate; 3.4: central rotating seat; 3.5: nut connector; 3.6: ball socket structure; 3.7: flexible solar panel; 3.8: through hole; 3.9: connecting column; 3.10: support; 3.11: groove; 3.12: universal joint; 4: threaded connecting rod; 5: bottom bracket; 6: control button. Detailed Implementation

[0034] The present invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0035] Example 1 like Figures 1-7 As shown, a portable solar charging device based on a folding structure includes a drive mechanism 1, a lead screw 2, and a folding mechanism 3. The drive end of the drive mechanism 1 is connected to the lead screw 2. The drive mechanism 1 drives the lead screw 2, thereby causing the folding mechanism 3 to rotate and unfold or fold. The folding mechanism 3 includes a folding frame 3.1, a telescopic rod 3.2, an upper top plate 3.3, a central rotating seat 3.4, and a nut connector 3.5. The upper top plate 3.3 is inserted into the top of the central rotating seat 3.4 and is located on the top of the lead screw 2. The central rotating seat 3.4 is rotatably mounted on the lead screw 2 via bearings. The center of the nut connector 3.5 is fixedly mounted on the lead screw nut that mates with the lead screw 2. Multiple supports 3.10 are arranged circumferentially on the nut connector 3.5. Each support 3.10 is rotatably connected to the inner end of the telescopic rod 3.2 via a universal joint 3.12. The outer end of each telescopic rod 3.2 is rotatably connected to the bottom outer edge of the folding frame 3.1. Multiple folding frames 3.1 are arranged sequentially to form an umbrella shape, with their inner ends fixedly surrounding the side of the central rotating seat 3.4. A flexible solar panel 3.7 is installed inside the folding frame 3.1. Preferably, the outer end of the telescopic rod 3.2 is connected to the bottom outer edge of the folding frame 3.1 through a ball-and-socket structure 3.6.

[0036] Furthermore, the support 3.10 is provided with a groove 3.11, and a universal joint 3.12 is provided in the groove 3.11. The universal joint 3.12 is rotatably connected to the inner end of the telescopic rod 3.2 via a rotating shaft.

[0037] Furthermore, multiple vertically downward through holes 3.8 are opened on the central rotating seat 3.4, and multiple connecting posts 3.9 are installed at the bottom of the upper top plate 3.3, with the connecting posts 3.9 inserted into the through holes 3.8.

[0038] Furthermore, the drive mechanism 1 is located at the bottom of the lead screw 2. The bottom of the drive mechanism 1 is connected to the bottom bracket 5 via a threaded connecting rod 4. The drive mechanism 1 is encased in a shell and equipped with control buttons for controlling the motor rotation, or for unfolding or folding the entire device via voice control. Preferably, the drive mechanism 1 is a stepper motor. Stepper motors have the advantages of controllable speed, stable torque, low energy consumption, and low noise. They can precisely control the rotation angle and speed of the lead screw 2 according to the unfolding requirements of the solar panel, thereby achieving precise adjustment of the unfolding range of the solar panel.

[0039] Furthermore, the lead screw 2 is made of aluminum alloy Tr6, which has the characteristics of high strength and corrosion resistance, and can effectively withstand the weight pressure after the solar panel is deployed; the drive mechanism and the lead screw nut are both made of POM (polyoxymethylene) material, which has excellent wear resistance, fatigue resistance and mechanical strength, and can effectively reduce frictional wear between parts and extend the service life of the mechanism.

[0040] Furthermore, the folding frame 3.1 is made of PLA (Young's modulus 2.7–16 GPa) as the hard component and TPU (Young's modulus 10–100 MPa) as the soft component. PLA is a biodegradable material, and TPU is recyclable, which aligns with the concept of green and environmentally friendly development. This material is also extremely lightweight, has good toughness, can be creased and molded according to folds, is weather-resistant, inexpensive, environmentally friendly, and recyclable. The multiple folding frames 3.1 are designed in an umbrella shape, inspired by NASA's origami space truss design. Multiple embedding slots are provided on the folding frame 3.1, and the shape of the flexible solar panel 3.7 matches these slots, allowing the flexible solar panel 3.7 to be embedded in the flexible frame structure. This prevents the solar panel from shifting or falling off during folding and fully utilizes the support of the frame, ensuring the solar panel remains flat after unfolding and maximizing sunlight reception. Preferably, the folding ratio of the folding frame 3.1 is approximately 11.33:1, and it is portable and efficient.

[0041] Furthermore, the flexible solar panel 3.7 utilizes ultra-thin and lightweight perovskite photovoltaic material, reducing manufacturing costs, minimizing transportation and storage space, and efficiently capturing solar energy while improving photoelectric conversion efficiency. The flexible solar panel 3.7 comprises a flexible substrate, a light-absorbing layer, a charge transport layer, a hole transport layer, and a transparent electrode. Preferably, the light-absorbing layer is made of organic-inorganic hybrid perovskite (FA / MA / Cs-based), and its efficiency and bending resistance are improved through additives, component regulation, and grain boundary passivation. The charge transport layer is made of SnO. The electron transport layer is prepared from (low-temperature mainstream) and ZnO to achieve electron transport; the hole transport layer is composed of PCBM and NiO. The flexible solar panel 3.7 is made of PTAA; the flexible substrate is made of PET, PEN, PI, ultrathin glass, and metal foil; the transparent electrode is made of ITO (mainstream but brittle), Ag nanowires, graphene, CNTs, and composite conductive polymers. The working principle of the flexible solar panel 3.7 is the photoelectric effect. Simultaneously, the flexible solar panel 3.7 is paired with lithium iron phosphate pouch batteries to achieve long lifespan, and flexible FPC cables further enhance portability. Preferably, perovskite with a thickness of only 300nm can efficiently absorb light, significantly reducing material and production energy consumption; the preparation temperature is ≤150℃, far lower than that of crystalline silicon.

[0042] Example 2 This embodiment provides a method for operating the portable solar charging device described in Embodiment 1, including the following steps: Deployment process: The stepper motor drives the lead screw 2 to rotate in the forward direction, causing the lead screw nut to move upward in a straight line on the lead screw; the nut connector 3.5 moves upward, and the inner ends of the six telescopic rods 3.2 move upward under the drive of the nut connector 3.5, while their outer ends open downward and outward, pushing the flexible solar panel 3.7 to unfold smoothly to the preset angle, thus completing the deployment operation.

[0043] Folding and storage process: The stepper motor drives the lead screw 2 to rotate in the opposite direction, so that the lead screw nut moves downward in a straight line on the lead screw 2; the nut connector 3.5 moves downward, and the six telescopic rods 3.2 retract under the drive of the spiral surface of the lead screw 2, and their outer ends move upward and inward until they are close to the lead screw 2 to form a column shape. The flexible solar panel 3.7 is simultaneously stacked, completing the folding and storage.

[0044] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0045] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0046] The above description is only a preferred embodiment of the present invention. It should be noted that, for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A portable solar charging device based on a folding structure, characterized in that, It includes a drive mechanism, a lead screw, and a folding mechanism. The drive end of the drive mechanism is connected to the lead screw, and the drive mechanism drives the lead screw to rotate and unfold or fold the folding mechanism. The folding mechanism includes a folding frame, telescopic rods, an upper top plate, a central rotating seat, and a nut connector. The upper top plate is inserted into the top of the central rotating seat and located at the top of the lead screw. The central rotating seat is rotatably mounted on the lead screw via bearings. The center of the nut connector is fixedly mounted on the lead screw nut that mates with the lead screw. Multiple supports are arranged circumferentially on the nut connector. The inner end of one of the telescopic rods is rotatably connected to each support. The outer end of each telescopic rod is rotatably connected to the bottom outer edge of the folding frame. Multiple folding frames are arranged sequentially to form an umbrella shape, with their inner ends fixedly surrounding the side of the central rotating seat. Flexible solar panels are installed inside the folding frame.

2. The portable solar charging device according to claim 1, characterized in that, The outer end of the telescopic rod is connected to the bottom outer edge of the folding frame via a ball-and-socket structure.

3. The portable solar charging device according to claim 1, characterized in that, The support is provided with a groove, and a universal joint is provided in the groove. The universal joint is rotatably connected to the inner end of the telescopic rod via a pivot.

4. The portable solar charging device according to claim 1, characterized in that, The drive mechanism is located at the bottom of the lead screw, and the bottom of the drive mechanism is connected to the bottom bracket through a threaded connecting rod. The drive mechanism is covered by a housing.

5. The portable solar charging device according to claim 1, characterized in that, The driving mechanism is a stepper motor.

6. The portable solar charging device according to claim 1, characterized in that, The folding skeleton is made of PLA as the hard component and TPU as the soft component.

7. The portable solar charging device according to claim 1, characterized in that, Multiple embedding slots are provided on the folding frame, and the shape of the flexible solar panel matches the embedding slots. The flexible solar panel is embedded in the embedding slots.

8. The portable solar charging device according to claim 1, characterized in that, The flexible solar panel is made of perovskite photovoltaic material.

9. The portable solar charging device according to claim 1, characterized in that, The flexible solar panel includes a flexible substrate, a light-absorbing layer, a charge transport layer, a hole transport layer, and a transparent electrode.

10. The method of operating the portable solar charging device as described in any one of claims 1 to 9, characterized in that, Includes the following steps: Deployment process: The drive mechanism drives the lead screw to rotate in the forward direction, causing the lead screw nut to move upward in a straight line on the lead screw; the nut connector moves upward, and the inner ends of multiple telescopic rods move upward under the drive of the nut connector, while their outer ends open downward and outward, pushing the flexible solar panel to unfold smoothly to the preset angle, thus completing the deployment operation; Folding and storage process: The drive mechanism drives the lead screw to rotate in the opposite direction, causing the lead screw nut to move downward in a straight line on the lead screw; the nut connector moves downward, and multiple telescopic rods retract under the drive of the lead screw helical surface, with their outer ends moving upward and inward until they are close to the lead screw. The flexible solar panel is simultaneously stacked, completing the storage.

Images