Photovoltaic devices and methods for charging electric vehicles (EVs) or their batteries

Abstract

A charging station includes a structure or enclosure for charging an electric vehicle's battery, either when the battery is removed from the EV for a charging cycle or when the EV is directly connected to a charging point. The present invention provides for housing or storage of an electric vehicle (EV) or a battery used therein, and facilitates charging via a means for charging the EV's battery cells using a majority of the power drawn from solar radiation via a photovoltaic (EV) or PV array. Embodiments include charging stations for electric vehicles (EVs), particularly motorcycles and scooters. Methods for forming charging stations with multiple access doors that allow the EV's battery or EV to be connected to a charging port are further described. In a preferred configuration, a standalone charging station for an EV scooter provides a means for mounting and storing the scooter during a charging cycle. A public scooter rental system is also disclosed.

Description

[Technical Field]

[0001] The present invention relates to designing and configuring charging stations for charging the batteries of electric vehicles (EVs) that utilize energy stored predominantly or exclusively via photovoltaic (PV) panels attached to or forming a major part of a structure or enclosure.

[0002] In particular, the present invention relates to providing a structure or enclosure for charging an EV vehicle battery, either when the battery is removed from the EV for a charging cycle or when the EV is directly connected to a charging point within the structure or enclosure, and more particularly to housing, securing, or storing an electric vehicle (EV) or a battery used therein to facilitate charging of the EV using power derived largely from solar radiation via PV panels or arrays thereof.

[0003] The present invention particularly relates to self-powered and freestanding charging stations for the batteries of electric vehicles (EVs), and in particular to single-person EVs such as electric two-wheelers, electric bicycles and electric foot scooters.

[0004] The present invention further relates to a method for charging and storing batteries of an EV, as well as a method for storing, securing and / or storing an EV, in particular a single-occupancy EV.

[0005] Additionally, the present invention relates to an optimized PV power generation system in which PV panels operatively form its vertical major surfaces and optimize collection of solar radiation in less than optimal conditions with respect to diurnal and seasonal variations in direct and indirect solar radiation incidence, the power generation system adapted for remote and / or culturally sensitive locations where mains supply is unavailable or where solar energy availability is absent or highly variable.

[0006] The present invention teaches an off-grid solar power plant that provides a consistent power rating in locations with large seasonal variations in solar energy, such as at all latitudes in the United Kingdom (UK), in all seasons, without the need for auxiliary energy sources. A second aspect relates to a hybrid grid power plant that can be connected to additional power plants of the present invention, auxiliary power sources, and / or primary power from local or national grid infrastructure. The UK mainland lies between latitudes 50°N and 59°N and experiences significant variations in the average angle of incidence of solar radiation between summer and winter. While many other countries share similar northern hemisphere latitudes (most of Canada, Scandinavia, and large parts of the Russian Federation), only the southern tip of Chile and Argentina have significant settlements in the corresponding southern hemisphere.

[0007] The present invention further provides an enclosure or monolithic structure that is waterproof, rugged, easily serviceable, and deployable or transportable to remote and off-grid locations, and provides useful daily power output in less than optimal conditions, particularly during the lowest average months of harvestable solar radiation.

[0008] The present invention further relates to a charging station for electric vehicles (EVs), which is suitable for use where connection to mains electricity is inconvenient, expensive, or a hindrance to high traffic locations, and in locations with significant cultural or natural value.

[0009] As used herein, the terms "power generation equipment unit" and "integral structure" refer primarily to an enclosure or enclosed cabinet in which control circuitry is secured and protected against weather and trolling interference. The terms also extend to structures adapted to support solar / photovoltaic panels and to connect auxiliary sources of electrical power, such as battery storage, motor-generators, wind turbines, and of course to the main power grid, among others. However, the scope of the invention is not intended to be so limited and should be taken to include any sturdy enclosure adapted to be deployed to a remote location and hoisted or lifted during positioning at or retrieval from the site. This is particularly relevant where the deployed or retrieved weight can be significantly heavier than the empty unit, and applies equally to enclosures containing battery packs.

[0010] As used herein, the terms "enclosure" and "cabinet" are intended to refer to a unit or structure made as a single unit of power generation equipment, which is adapted to couple to auxiliary power sources and additional units (which may be formed into groups or arrays). The term "useful quantity" is used with reference to the desired daily power output from the power generation equipment unit during seasons of minimum solar radiation (November, December, and January in the Northern Hemisphere), but should not be limited to the rated power of the equipment as a whole. This equipment is connected to, and its power output is augmented by, additional power generation equipment or external power sources, including primary power. Furthermore, the term "useful quantity" has specific meanings in various contexts, as will be explained below, with reference to the many uses to which the power generation equipment may be applied. [Background technology]

[0011] There are many methods and technologies used to extract energy from the sun, each with its own advantages and disadvantages depending on the application to which it is put and factors ranging from environmental impact to capital and maintenance costs.

[0012] One of the areas where the most technological improvements have been made is in the collection, storage, and distribution of solar energy, which is integrated through photovoltaic (PV) cells, most often arranged in groups of interconnected cells to form modules, with multiple modules being used to make a "solar panel."

[0013] When exposed to typical sunlight, each PV cell can generate roughly 0.6V, which, when combined in a 72-cell panel, can deliver 300W. Thus, modular panels can deliver useful amounts of electrical energy from direct sunlight. This has been demonstrated in practice for residential rooftop systems and large-scale commercial "solar farms." Solar farms include arrays of ground-mounted panels to generate electricity for commercial operations, from farms to data centers, and for connection to national or regional power grid systems.

[0014] As will be discussed in more detail below, factors related to collecting solar photovoltaic power differ for commercial and large-scale implementations from those for residential and remote (or off-grid) implementations, and it is in this latter area that the present invention is particularly relevant.

[0015] The capital costs of PV modules and panels have been significantly reduced in recent years with the industrialization of printed PV cell technology and the availability of modules with integrated DC-DC converters and microinverters. With the reduction in the cost of collecting solar energy and the need for a nearly constant supply in off-grid and domestic applications (even at low or nominal levels), the focus must now turn to the storage of the generated energy, especially when the cost of delivered energy can be set at a high price.

[0016] Solar radiation is a term that describes the amount of radiation or irradiance at a particular location, but in terms of collecting solar energy, many factors come into play, most notably seasonal variations at certain latitudes where the intensity of solar radiation, even at its seasonal maximum, is insufficient to provide usable power levels, and additional sources of power must be utilized.

[0017] For any given latitude, an average or optimum panel angle can be calculated, but any chosen angle oriented toward the vertical is a factor in consideration of structural strength to resist incident wind forces, etc. Similarly, structural strength must also be considered for horizontally oriented panel angles where snow loads become significant. Clearly, snow coverage has a significant impact on collecting solar radiation. In less severe conditions, dust or debris buildup on the panels means that the panels need to be cleaned periodically to maintain optimal collection.

[0018] It is well established practice to align solar panels to an azimuth angle corresponding to a particular latitude, or to select different azimuth angles for selected panels in a solar array to account for seasonal variations.

[0019] The prior art is replete with structures and devices for tracking the sun's path to optimize the incidence of solar radiation on the light-receiving surfaces of PV cells. However, whether single-axis tracking is utilized (e.g., diurnal tracking) or dual-axis tracking is utilized to track both diurnal and seasonal variations, all are accomplished at significant additional cost and are inherently complex. For remotely transportable, or at least mobile, PV power generation equipment, robustness and a long operational life are essential.

[0020] As can be readily seen from the patent literature, there are many different approaches that have been taken to address some of the technical shortcomings, and although each area represents a particular concern, many aspects are common and will be discussed below.

[0021] Chinese Patent No. 107733067 (applicant: XIAOGAN QILE CREATIVE DESIGN CO LTD) describes a solar-charging car garage that includes a structure (which can be used as a parking / garage for vehicles) with support columns for roof-mounted solar panels and sidewall solar panels. These panels are connected to a battery pack, which includes a current stabilizing device with a charging interface disposed therein. The garage facilitates storing solar energy in a battery bank that is used to charge vehicles.

[0022] British Patent No. 2,574,373 (applicant: SOLIVUS LIMITED) relates to a solar charging assembly (either as an array or a standalone structure) that includes at least one structure shaped like a tree, with a plurality of solar cells connected to branches that are connected to a trunk. A storage battery may be installed in the trunk or underground below the structure. A charging station (outlet port) is connected to the battery or batteries for charging electric vehicles (EVs). [Prior art documents] [Patent documents]

[0023] [Patent Document 1] Chinese Patent No. 107733067 [Patent Document 2] British Patent No. 2,574,373 Summary of the Invention [Problem to be solved by the invention]

[0024] The object of the present invention is to seek to alleviate the drawbacks of prior art devices and to provide a charging station comprising a structure or enclosure for charging the battery of an EV vehicle, either when the battery is removed from the EV for a charging cycle or when the EV is directly connected to a charging point.

[0025] The primary objective of the present invention is to provide a means for charging the battery cells of an electric vehicle (EV) using a large portion of the energy derived from solar radiation via photovoltaic (PV) panels.

[0026] Another object of the present invention is to provide a structure or enclosure for containing, securing, and storing electric vehicles (EVs) or batteries used therein, and facilitating their charging using a large portion of the power derived from solar radiation via photovoltaic panels or PV arrays.

[0027] It is yet another object of the present invention to provide a self-powered and freestanding charging station for batteries of electric vehicles (EVs), in particular for single-person EVs such as electric two-wheelers, electric bicycles, and electric foot scooters.

[0028] It is yet another object of the present invention to provide means and methods for charging and storing batteries of an EV, and particularly for storing, securing, and / or storing an EV, particularly a single-occupancy EV. [Means for solving the problem]

[0029] The present invention provides a photovoltaic (PV) charging station for charging the batteries of an electric vehicle (EV), the charging station comprising: an enclosure having a structural frame element and a ground engaging element attached to the structural frame element; A number of PV panels are fixed to this frame element; a control circuit hermetically disposed within the enclosure for regulating electrical energy generated via the PV panel and an energy storage device connected to the control circuit; and charging connection part, Equipped with At least two of the PV panels are arranged on vertical surfaces to form the exterior surface of the enclosure.

[0030] Preferably, the PV panels are integrated with the frame elements.

[0031] Advantageously, the enclosure comprises a wall section and a roof section to which the PV panels are fixed.

[0032] Preferably, the enclosure is in box form, with frame elements providing peripheral corners between which the PV panels are secured.

[0033] Preferably, each wall section comprises a framed PV panel arranged in the vertical orientation shown facing the exterior of the enclosure.

[0034] The total surface area of ​​the PV panels is optimized to produce an average daytime power generation of at least 200Wh.

[0035] In one configuration, the housing includes multiple receptacles for removable EV batteries, each receptacle having a charging connection for connecting to a terminal of the EV battery.

[0036] In an alternative configuration, the station is adapted to provide a means for directly charging electric vehicles (EVs).

[0037] Advantageously, the power plant includes storage, anchoring or storage space for at least one EV within a structure or enclosure.

[0038] In yet another alternative configuration, the structure or enclosure is a building having multiple receiving bays for EVs.

[0039] Preferably, the charging station includes mounting means for at least one EV.

[0040] In configurations designed for public use, the charging station includes a communications module.

[0041] Preferably, the charging station includes a payment authentication means.

[0042] In another configuration, the structural frame elements define an octagonal enclosure between which the PV panels are disposed, presenting eight solar collecting surfaces, at least one of which is hinged to a corresponding frame element to facilitate access to the interior of the enclosure.

[0043] Advantageously, the energy storage device comprises batteries with deep cycle characteristics and high power delivery characteristics, combined with cell technology, charge controllers and voltage monitoring circuits to optimize both charging and delivery of power in less than optimal conditions.

[0044] In a preferred arrangement, the first battery group comprises a working group of frequently and deeply charged / discharged cells with excellent weight-to-kWh ratio, the second battery group comprises a reserve group providing additional charge capacity and cold-water charging capability, and each group of working group cells has a charge balancer to compensate for differences in state of charge during charge and discharge cycles.

[0045] Advantageously, the first group of batteries comprises lithium-ion or lithium iron phosphate batteries and the second group of batteries comprises absorbent glass mat (AGM) cells, each provided in a configuration associated with the required system voltage.

[0046] The present invention also relates to a method of charging a battery of an electric vehicle (EV), the method comprising: Access to the mounting points for the EV battery charging receptacles within a charging station enclosure of the type described above; Installing the EV battery in the charging receptacle and aligning the battery terminals of the battery to the charging connection with the installation points; connecting a charging connection for the EV battery to an electrical charging means; Accommodating charging cycles; and Ensuring EVs are ready for reuse; Includes:

[0047] The present invention further relates to a method of charging a battery of an electric vehicle (EV), the method comprising: Access to the EV mounting point within a charging station enclosure of the type described above; Mounting the EV at the mounting point; connecting the EV to an electric charging means; Accommodating charging cycles; and Ensuring EVs are ready for reuse; Includes:

[0048] Advantageously, the attachment point is set high.

[0049] Preferably, the charging cycle includes a payment authentication step.

[0050] Preferably, the method includes storing the EVs.

[0051] The present invention will now be described in more detail with reference to the accompanying drawings, which show, by way of example only, a freestanding, fixed electric vehicle (EV) charging station configuration in accordance with the present invention, as well as an illustrative embodiment in a charging station for charging the batteries of an electric vehicle (EV). [Brief explanation of the drawings]

[0052] [Figure 1a] FIG. 1 shows the sun's path in the UK, corresponding to both the winter and summer solstices and the optimum angles for solar panel positioning. [Figure 1b] A bar graph showing the average levels of direct and indirect solar radiation, useful for each month of the year, for a solar panel at a latitude corresponding to London, UK (51.5° North). [Figure 2] 1 is an elevated perspective view of a first embodiment of a charging station according to the present invention, with PV panels located on each exterior surface of the cabinet; FIG. [Figure 3] FIG. 1 is a schematic diagram showing components of a control circuit housed within a cabinet or enclosure. [Figure 4a] FIG. 10 is an angled side view of an improved configuration of the first embodiment of the charging station, with PV panels located on each exterior surface of the cabinet. [Figure 4b] FIG. 10 is an elevated perspective view of an improved configuration of the first embodiment of the charging station, in which a PV panel is located on each exterior surface of the cabinet. [Figure 4c] 4b is an exposed elevated perspective view similar to FIG. 4b, with the cells of the power storage device and control circuitry arranged in an alternative configuration. [Figure 4d] FIG. 10 is an elevated perspective view of another configuration of the first embodiment of the charging station, with substantially equal PV panel area present on each exterior face of the cabinet (each face is provided with an MPPT). [Figure 4e] FIG. 10 is an elevated perspective view of another configuration of the first embodiment of the charging station, with substantially equal PV panel area present on each exterior face of the cabinet (each face is provided with an MPPT). [Figure 5a] FIG. 4D is a detailed side view of a charging station configuration similar to that shown in FIGS. 4E and 4F, with a pivotable roof section representing a combined landing and charging platform for an autonomous electric vehicle (drone). [Figure 5b] FIG. 4D is an elevated perspective view of a charging station configuration similar to that shown in FIGS. 4E and 4F, with a pivotable roof section representing a combined landing and charging platform for an autonomous electric vehicle (drone). [Figure 6a] 1A-1C are elevated perspective views of various configurations of framed PV panels. [Figure 6b] 1A-1C are elevated perspective views of various configurations of framed PV panels. [Figure 6c] 1A-1C are elevated perspective views of various configurations of framed PV panels. [Figure 7a] FIG. 2 is an elevated perspective view of a second embodiment of a charging station according to the present invention. [Figure 7b] FIG. 2 is an elevated perspective view of a second embodiment of a charging station according to the present invention. [Figure 8a] FIG. 10 is an elevated perspective view of a third embodiment of a charging station according to the present invention, in which a PV panel is located on each exterior surface of the cabinet. [Figure 8b] FIG. 10 is an elevated perspective view of a third embodiment of a charging station according to the present invention, in which a PV panel is located on each exterior surface of the cabinet. [Figure 9] FIG. 10 is an elevated perspective view of a variation of the first embodiment of a charging station having multiple securable receiving receptacles for removable EV batteries. [Figure 10a] FIG. 10 is an elevated perspective view of a fourth embodiment of a charging station including a structural frame to which PV panels are fixed and within which battery banks and control electronics are sealed and fixed. [Figure 10b] 10b is an elevated perspective view of a hinge detail of at least one panel adapted to facilitate access to the interior of the embodiment shown in FIG. 10a. [Figure 10c] 10b is an elevated perspective view of a hinge detail of at least one panel adapted to facilitate access to the interior of the embodiment shown in FIG. 10a. [Figure 11a] FIG. 10 is an elevated perspective view of a particular configuration of a fourth embodiment of a charging station adapted as a storage enclosure for a foldable electric scooter. [Figure 11b] FIG. 10 is an elevated perspective view of a particular configuration of a fourth embodiment of a charging station adapted as a storage enclosure for a foldable electric scooter. [Figure 11c] FIG. 10 is an elevated perspective view of a particular configuration of a fourth embodiment of a charging station adapted as a storage enclosure for a foldable electric scooter. DETAILED DESCRIPTION OF THE INVENTION

[0053] Referring to the figures, initially to FIG. 1, as an example of the prior art, a power generating equipment assembly for supplying electrical energy to a small farm or remote dwelling comprises an array of solar panels (a) arranged in groups of three connected in a chain configuration via cable connectors (b). The panels are fixed at an angle corresponding to the latitude of the site and facing south for sites in the Northern Hemisphere. To increase the input power from the solar panels (and to provide additional power during dark hours), a wind turbine (c) is provided. For larger power plants, turbines operating at medium and high voltages offer a solution with a lower cost per configured kW. On the other hand, small wind turbines (SWTs) often cost two to four times more per configured kW due to the relative immaturity of the SWT market. Many "small" wind installations, i.e., 40m 2 Installations with rotor swept areas less than 1000kJ / s have power ratings between 1 kW and 7 kW. A 6 kW turbine can generate up to 9000kWh per year.

[0054] A typical residence uses approximately 11,000 kWh of electricity per year, which equates to a daily consumption of approximately 30 kWh.

[0055] The direct current (DC) output of the PV panels (a) and wind turbines (b) can be routed through a fixed power output junction box (d) to a battery bank housed in an enclosure (e), where voltage regulators, monitoring electronics, and control electronics are also housed in a waterproof cabinet. A power inverter can also be found in the enclosure (e), or optionally in the junction box (d). Power supply lines (f) then connect the power generation equipment assembly to the demand side. An auxiliary PV panel (g) for the control electronics is provided, mounted on a pole attached to the enclosure.

[0056] As mentioned above, prior art configurations of PV arrays and devices for charging electric vehicles do not readily lend themselves to small residential or off-grid applications and are unsuitable as power hubs for charging electric vehicles in most situations.

[0057] As detailed above, there are significant daily and seasonal variations in the angle of incidence of direct solar radiation at a surface. The primary influence during the day is the arc that the sun traces (relative to the incident surface, i.e., the stationary PV panel) over the course of a day, from sunrise to sunset. Additional diurnal variations include cloud cover and shadows from adjacent vegetation or buildings (such as buildings that may contain arrays of other PV panels). Using a tracking mechanism to track the arc of the sun's path and keep the PV panel face perpendicular to the sun overcomes many, if not all, of the diurnal variations, but adds significant overhead to power collection. For stationary PV panels, to maximize incident radiation collection, the stationary PV panels should be positioned facing directly south in the northern hemisphere and north in the southern hemisphere, i.e., facing east-west.

[0058] To account for seasonal variations, the angle at which the PV panels are tilted depends on the local latitude. In FIG. 1a, a housing 1 representing a charging station of the present invention is centrally positioned within a circle showing four directions N, S, E, and W. A first line ES represents the sun's daily orbital altitude at the summer solstice and indicates the optimal PV panel slope or tilt TS for collecting the maximum available solar radiation at this time of year. Similarly, a second line EW represents the sun's significantly lower orbital altitude at the winter solstice, but still indicates the optimal PV panel tilt TW for collecting solar radiation at this time of year. For stationary PV panels, the optimal tilt angle is represented by the midpoint of the two extremes (represented by lines ES and EW and their corresponding tilt angles TE and TW), which will likely be aligned near the vernal and autumnal equinoxes.

[0059] In calculating the available energy that can be collected from solar radiation, it is important to distinguish between "direct irradiance," which is the light that the panel collects from the sun, and "diffuse irradiance," which is the light energy that the panel collects that is scattered primarily by clouds or reflected ambient light. In Figure 1b, the bar graph shows both monthly direct and diffuse irradiance averaged over each month of the year, expressed as kilowatt-hours of energy per square meter per day (kWh / day m), at 51°N (London, UK). 2 ) from the average daily available direct light produced approximately 0.5 to 0.75 kWh of energy per square meter of exposed PV panel during November, December, and January. Additionally, the average ambient or diffuse light did not exceed 1 kWh per square meter of available PV panel during any period between October and February.

[0060] Combining the daily averages of direct and indirect irradiation (ambient, scattered, or reflected light), it is possible to calculate the minimum area of ​​PV panels required to achieve the nominal rating for an array or assembly of PV panels. Referring now to Figure 2, a first embodiment of a charging station 10 is shown, comprising a cabinet 12 defining an enclosure and having four flat sides 13 and a roof section 14.

[0061] In its most basic configuration, the charging station comprises a cabinet with vertically arranged PV panels fixed to the front, back, and sides. The front is the surface facing south in the Northern Hemisphere and has the total area of ​​the PV panels receiving light to provide the rated power output. For low power requirements, the average daily output in winter may be as little as 200 Wh, sufficient to charge many electronic devices or, in one very specific application of the present invention, to maintain operating current for recording, storing, and transmitting collected data at a remote monitoring station. The collected energy can be increased by the placement of reflectors that deflect direct incident light at an angle toward the receiving panels. In a preferred configuration, the roof 14 is equipped with PV panels, which may be sloped to optimize solar radiation collection and / or prevent the accumulation of snow and leaves.

[0062] In the modified orientation of the rectangular cross-section enclosure, the front is oriented eastward toward sunrise and the rear toward sunset to maximize the incident area during the winter months, while the south-facing side and roof panels allow for maximum collection of available light during the day.

[0063] The cabinet forms an enclosure for storing energy via a bank of storage batteries and energy management or control circuitry. In the basic embodiment shown in Figure 2, seven PV panels are distributed across five faces (two sides, the front, the back, and the roof).

[0064] PV panels are designed and rated to withstand harsh environmental conditions. In the case of cabinets made of extruded or formed aluminum frame elements, the resulting enclosure has excellent corrosion resistance and can withstand harsh heat and UV conditions. Anodized stainless steel is the preferred material for fabricating the enclosure, where the panels are secured to an existing surface via the attachment of a boundary frame.

[0065] Several environmental control features are integrated to enable the cabinet to survive in potentially very harsh outdoor settings.

[0066] Separate vents, internally guarded by a fine internal mesh (to prevent insect intrusion), are incorporated into either the roof frame or beneath the roof panels to allow hot air and any gases generated from battery charging to escape. Equivalent vents can be installed in the base or support floor, allowing cool air to enter and circulate. This feature is complemented by automatic, temperature-activated, waterproof cooling fans to encourage airflow from base to top. If operating temperatures are likely to exceed the thermal limits of internal components, a series of fans can be activated upon reaching a predetermined threshold. An additional, optional feature directs airflow over the PV panels to reduce surface temperatures and minimize negative temperature coefficients. The power generation of the PV panels can then be reduced in excess of the power utilized by the cooling fans.

[0067] Grounding rods (not shown) are installed before the enclosure is set up and connected to the frame elements to allow the enclosure and the equipment inside to be electrically grounded, with connections from the cabinet and the provided inner frame. If ground fixing screws are used to secure the cabinet, these screws can be used as grounding members for the charging station.

[0068] For cabinets deployed in harsher cold environments, fluted corrugated plastic sheets can be used alone or in combination with commercially available insulating materials to limit temperature extremes within the cabinet, allowing a greater operating range for equipment and cells within their design parameters. Air gaps between the exterior surfaces of the panels and the frame elements can also be provided to prevent thermal bridging.

[0069] As shown in FIG. 3, seven 100 W PV panels (only five are shown) are connected to a charge controller 16 for each side to regulate the charge power provided to the battery cells. In the exemplary configuration, charge controller 16a (associated with one PV panel, hereafter identified as the "top panel") is connected to a reserve battery group RB of the type described herein, deep-cycle batteries capable of charging at temperatures below 5°C. The remaining four charge controller 16 channels collect power from the remaining panels and charge a battery group (referred to as the "working group" WB), ideally equipped with lithium-ion or lithium iron phosphate (LiFePO4) cells, both known to have good power characteristics. Power converted from DC to AC through a 2 kW inverter INV provides a voltage via a circuit breaker (RCD) or selected to optimize for the EV battery or for an EV connected directly to the inverter output.

[0070] The reserve group RB supplies power to an isolated DC-DC charger 17, which maintains operating voltage across the individual batteries of the working group WB. The DC-DC charger 17 is a 30A unit designed to charge the working group WB when the reserve group battery voltage exceeds 11V and the individual battery voltage drops below 12.5V.

[0071] Associated with the inverter is an actuation sensor 18, which enables a low voltage standby mode. A remote monitoring unit 19 may include a communications module to measure working and reserve battery voltages and inverter load and to alert the user or service contractor.

[0072] It has been recognized that, with both diurnal and seasonal variations, the PV panel uses multiple charge controllers 16 feeding the solar panels 15, each functioning differently on each side, to combine cell technologies to exploit their respective strengths and compensate for their respective weaknesses. By combining cell technologies in a power generation circuit of the type presented by this invention, it is possible to extend the life of both cell technologies. This is particularly relevant for frequent cycling or frequent loads applied throughout the summer.

[0073] Advantageously, the working group WB includes lithium-ion or lithium iron phosphate cell batteries connected together in series to produce the required circuit voltage (e.g., two 12V batteries to provide a 24V circuit). Additional batteries may be connected in parallel to provide additional capacity to the working group as needed. A charge balancer may be used to ensure that differences in the state of charge between cells are compensated for during the charging process.

[0074] In a preferred configuration, as described in more detail below, each side of the charging station is optimized to power a 48V battery pack in the battery bank, so that the PV panels at maximum irradiance produce an open circuit voltage of 60V and an approximate voltage under load of 51V, i.e., the charging voltage for each battery pack.

[0075] Commercially available lithium-ion and lithium iron phosphate cell batteries often feature embedded protection circuitry, cycle deeper and more frequently than alternative technologies, and have a more favorable weight-to-kWh ratio compared to alternative technologies.

[0076] However, it should be noted that these batteries may degrade over time at 80-100% state of charge, they are expensive per Wh compared to other battery technologies, and they have poor charging characteristics below 5°C.

[0077] The absorbent glass mat (AGM) cells that make up the reserve group RB are connected together in series to create a circuit up to 48V. AGM batteries can also be connected in parallel to create additional capacity if needed, with a limit of up to three parallel batteries per group. A charge balancer is always used to ensure that differences in state of charge between batteries are compensated for during the charging process. An overcurrent protection device is installed in the circuit to compensate for the lack of built-in protection features.

[0078] It should be noted that AGM batteries are less prone to degradation at 100% state of charge over long periods of time (compared to lithium-based batteries). AGM batteries are cheaper per kWh of capacity compared to other technologies, can be charged at temperatures below 0°C, and have deep discharge characteristics, allowing them to discharge up to 40% of their capacity for over 1000 daily cycles before beginning to degrade. However, the downside is that battery cells can degrade more rapidly if discharge rates are greater than 40% and the battery is frequently charged and discharged for periods greater than 2 hours.

[0079] Also during the winter minimum, the lowest temperatures are likely to occur, so it is important to focus on charging batteries that have the lowest operating temperature range.

[0080] Those skilled in the art will appreciate that the example figures provided above may change as battery technology improves and operating and charging characteristics allow for better performance.

[0081] As shown in Figure 3, the working group WB of lithium-based batteries is charged directly from the charge controller 16, except for the charge controller 16a associated with the top panel connected to the reserve group RB. The panels selected to charge the working group WB are those receiving the greatest solar radiation during the minimum winter months, thus preserving the bias toward a fully charged state as long as possible.

[0082] If there is frequent daily charging and discharging of the AGM reserve RB, it may be advantageous to add a lithium-based or alternative, frequently charged and discharged battery, or a sacrificial battery, charged from the top panel charge controller 16a and directing much of the charge and discharge to this battery, reducing the depth of discharge experienced by the AGM cells and the time the lithium cells remain fully charged. An isolated DC-DC converter (or charger) 17 transfers energy from the lithium batteries in the working group WB to the AGM batteries in the reserve RB. This isolated DC-DC converter should be sized to charge at a rate as close as feasible to the discharge rate of the AGM batteries. When a load is connected via inverter INV, any voltage sag experienced by the working group WB initiates a charging process from the reserve RB that continues until either the working group battery is fully charged or the reserve is depleted.

[0083] This approach reduces the cycle depth of the working battery, extending its life, while shortening the time the reserve battery spends at 100% state of charge, extending its life. This arrangement also channels stronger summer solar power from the top panel to the reserve battery, allowing it to charge and discharge more frequently, recovering more quickly when solar energy is more abundant, again reducing charging and discharging in the working battery. Advantageously, solar panels producing the most winter power generation to charge the battery that is actually powering the load do not need to use energy at the maximum solar intensity to keep the temperature of the working battery cells within their operating range. The extra energy consumption required to heat the lithium cells to accept charge or to convert energy via a DC-DC charging process when energy is most scarce is thus eliminated.

[0084] The use of dual cell technology to optimize collection at solar minimums provides additional capacity for a given system, economically reducing the overall cost of the system without any of the compromises that single cell technology entails.

[0085] Figures 4a and 4b show a cabinet 10 similar to Figure 2, but with a larger capacity and an internal structural frame 11. As previously mentioned, each wall 13 is fitted with solar panels 15, ideally mounted with a panel frame (as shown in Figures 6a-6c), which is secured to the structural frame elements 11 of the cabinet 12. Roof sections 14 are angled relative to the front or rear, thereby optimizing solar collection and ensuring optimal conditions during the summer months.

[0086] The cabinet is sized and shaped to house standard batteries to form the reserve group RB and the working group WB. Lithium-based batteries (lithium-ion or lithium iron phosphate) are used as the working cells, with sufficient capacity provided to ensure they reach less than 40% depth of discharge each day during less-than-optimal solar collection periods (especially in winter), maximizing cell life (each battery lasting anywhere between 25 and 40 years).

[0087] By stacking the batteries of the work group WB and connecting them in a 4S3P configuration (i.e., four batteries in series and three batteries in parallel), a maximum storage capacity of 33 kWh and a maximum power output of 15 kW (from 48 volts, 312 amps to 240 volts, 60 amps) is delivered via a wall-mounted inverter INV.

[0088] The described embodiment finds use in many forms and can be used as a charging cabinet in a hybrid grid with integrated solar power generation.

[0089] Figure 5c shows a minor but important modification to the layout of an embodiment of the photovoltaic enclosure in which the work groups are arranged in a linear stack. In a preferred configuration, a standard 19-inch rack structure is used, and selected components such as lithium battery packs, inverters, and charge control circuits can be stacked within the rack with easily removable connections.

[0090] 4d and 4e illustrate another configuration of the first embodiment of the charging station enclosure, in which the inner frame 11 provides support for standard industrial rack-mounted elements, such as the rack-mountable lithium packs described above. As production scales up, the availability of reliable, inexpensive, and potentially "plug-and-play" component modules, standardized in power connections including ground connections to the frame elements, will easily expand the capacity of the enclosure of the present invention. As noted below, the present invention may be provided in the form of a "kit of parts," allowing the purchaser to select the minimum operating elements, increase capacity, and, if necessary, add a spare battery or incorporate an external energy source.

[0091] In the embodiment shown, the charge controller 16 and inverter INV are mounted on the back panel (with a 10 cm gap around the inverter), although these components could alternatively be provided mounted on a rack.

[0092] The housing comprises sheet aluminum or steel panels to which the PV panels can be secured. This facilitates direct attachment of the PV panels to the housing. Alternatively, the PV panels are mounted within a frame. The frame is then secured to the sheet panels of the housing. In the most preferred configuration, the PV panels mounted within a rigid frame form the front, back, and sides (and ideally the roof section) of the housing.

[0093] 5a and 5b show a charging station according to the present invention, where at least one battery for charging is that of an autonomous vehicle, such as an aerial drone AD. The cabinet roof section 14 is adapted to pivot open about a motor-driven shaft 17. The drone is magnetically locked to the inside of the roof section, from which it can be deployed when release power is applied to override the magnetic lock. Charging of the drone's battery is wireless via inductive coupling. During drone deployment, the roof section is closed to avoid blocking the light from the PV panels 13 and to allow further charging via the PV panels of the roof section, if provided.

[0094] 6a-6c show a panel frame element F for holding a pair of panels. The first configuration of the panel frame includes a lip area L for attaching the panel to the existing face sheet in the housing, and fastening holes H through which tamper-proof bolts can be fixed. The cover section C of the PV panel includes a foldable box structure B to provide for routing of cables from the PV panel to the charge controller 16 in the housing.

[0095] In a preferred configuration of the first embodiment of the invention, the frame elements 11 comprise aluminum or steel extrusions joined at 90° angle joints to form the outer frame. As mentioned above, an internal rack may be utilized to form part of the structural integrity of the enclosure. The solar panels are seated within the outer frame elements and attached via shelf pins that position the panels within recesses in the extrusions. This assembly method allows the panels to be set upright within the pre-assembled frame.

[0096] The base element, as shown in Figures 4a-4e, may be made from thermoplastic polyurethane (TPU) and may have holes formed therein to allow the inner frame to be fastened therein and form the core of the inner frame shape. Additionally, ground fastening holes may be present, allowing the base to be ground-anchored or fastened to a concrete slab via bolts of appropriate strength. As mentioned above, ground fastening screws may be used to fasten the station cabinet. Ventilation holes in the base element allow air to enter the cabinet from the base and are protected by mesh to prevent insect intrusion. Drainage holes with mesh protection may also be provided to prevent water infiltration or condensation from forming inside the cabinet.

[0097] The roof sections 14 or any roof PV panels 15 are bonded to the internal frame via TPU moldings, which can be separately clad with exterior colored composite aluminum panels to achieve a desired aesthetic.

[0098] The inverter INV may be mounted in the top right or left corner of the cabinet with at least 10cm of air gap all around. The batteries are stacked vertically in the interior area opposite the inverter, ensuring that any gas leakage from the batteries does not affect the inverter.

[0099] A maximum power point tracking (MPPT) controller is mounted on the PV panels facing the cabinet to extract maximum energy from each PV panel 15. The controller 16 is located above the batteries on a fire-resistant backboard. Circuits such as a monitoring unit 19 that balances the charge rate of the batteries may also be located on the backboard.

[0100] A brushless motor-driven DC fan is located within the TPU roof molding of the cabinet. The fan, in combination with vents at the base and top of the cabinet, ensures rapid airflow from the base of the cabinet to the top and atmosphere as needed to keep the equipment cool. The fan is activated by a temperature sensor with a preset threshold.

[0101] A central LED lighting strip can be used to visually indicate the current status, capacity level, and charge or discharge level of the cells within the cabinet, as well as to provide a visual alert to the user of any issues that may require investigation.

[0102] 7a and 7b, there is shown a garden shed or small garage structure 20 having structural frame elements 21, front, back and side walls 23, and a sloped roof section 24. Each wall is clad in PV panels 25, which are either fixed to the existing wall or mounted within a frame that is fixed along its outer edge to the enclosure frame elements 21. One wall may include a door (not shown) or may be formed as a complete hinged section.

[0103] The roof section 24 is shown as a sloped shingle-style configuration, with PV panels 25 replacing shingle tiles, although a single shingle roof to which the PV panels are fixed can also be provided. As mentioned above, the roof pitch angle can be determined by individual or site requirements and oriented toward the summer sun at peak daytime hours. In the exposed view of FIG. 7b, the front wall (or door) and side wall 13 have been removed to expose the interior layout, where a group of batteries WB, RB, along with associated inverters INV and control circuits, connected in a configuration similar to that described with reference to FIG. 5 or FIG. 6b, are disposed along the rear wall. Electrical outlets can be provided for illumination both inside and outside the enclosure, as well as for charging points for electric vehicles (EV), from scooters and e-bikes to electric motorcycles (shown) and cars. A wall-mounted reel (not shown) for EV cables can be provided adjacent to the garage to provide convenient connectivity.

[0104] The solar power generated by the PV panels on the roof section 24 and the front, side, and rear 23 can provide a useful amount of energy and power the inverter INV, which can charge the EV at rates in excess of 2 kW using the energy stored in the work group WB.

[0105] The panels are joined together via optionally 3D printed joints that secure the interior of each solar panel face within the corners of each aluminum frame and have a central hub that bolts the panels together to form a rigid network of connections across the face. These can optionally be hinged, allowing the panels on each face to fold open, allowing full access to the interior of the facility.

[0106] Insulation can be placed within the apertures of the panels to provide improved temperature stability within the structure.

[0107] Apertures between the angled roof panel and the side and front panels can be illuminated using LED light strips to indicate charge status and solar power generation through changing colors and patterns.

[0108] A third embodiment of a charging station 30 is shown in Figures 8a and 8b, which is configured to present an open cabinet 32 ​​with structural frame elements 31 and a series of PV panels 35 disposed therebetween. Because the cabinet is open, diffuse light can be utilized using double-sided PV panels. Preferably, a panel frame is provided to mount the PV panels back-to-back. The panel frame may incorporate a charging controller / regulator to manage mismatched voltages generated by paired panels and to facilitate fastening the mounted panels 35 to the structural frame elements 31.

[0109] In the configuration shown, there are two panels 35 (each double-sided) arranged one above the other on each side wall, a pair of upper and lower panels (not necessarily double-sided) on the rear wall adapted to accommodate mounting hooks, and a foldable electric scooter EV as shown in FIG. 8b. The batteries forming the working group WB and the reserve group RB can be housed in a housing at ground level. The adapted use of the cabinet, i.e., as a charging station, obviates the need for an inverter. An additional communication module enabling payment verification can be mounted on the interior rear wall or, more advantageously, adjacent to the opening of the cabinet.

[0110] A variation on the first embodiment of the charging station 10′ is shown in FIG. 9 , in which the surface depicted away from the arc of the sun's path—and thus generally the surface of the PV panel 13′ that receives higher angles of reflected or incident light—is replaced by a surface in which multiple battery receptacles R are provided. Each receptacle is adapted to accept a removable EV battery, for example, from an electric motorcycle, electric bicycle, or electric foot scooter. If the charging station is mandated by a single manufacturer, the receptacle may include a charging connection that connects directly to the EV battery. This arrangement facilitates a battery swap scheme. Here, a fully charged battery can be retrieved from the receptacle when the receptacle door is opened after verifying that a valid, rechargeable battery has been deposited and payment authorization has been provided. In other situations, termination connections may be provided for various batteries, but charging will occur only after the receptacle door is closed and, if payment authorization is provided, payment authorization has been provided. To facilitate card payments, a communication module for payment authentication may be installed within the cabinet. In a preferred arrangement, battery charging is accelerated for newly installed batteries, and fully charged batteries become part of the working group WB or the reserve group RB according to predetermined charging criteria.

[0111] A fourth embodiment of a charging station 40 is shown in Figure 10a and comprises a free-standing, ground-engaging structural framework of substantially octagonal cross-section having eight upright frame elements 41 to which the PV panels are mounted in a vertical orientation. The upright frame elements support a roof section 44 on which four PV panels 45 are disposed at angles for optimal collection of solar energy. The roof section also includes a support plate 51 that defines a central aperture 52.

[0112] The spare and working battery cells, both sealed and enclosed within the framework, are arranged in a control circuit in a configuration determined by the proposed power generation equipment application. If the power generation equipment is designed as a standalone device, the feet 41a at the bottom of each upright frame element can be anchored to the ground or a concrete podium. If the power generation equipment is designed to be lifted or hoisted into remote or inaccessible areas, the support plate 51 includes attachment points, such as lifting eyes, rated for the weight of the power generation equipment with batteries. In an alternative configuration, the apertures 52 in the support plate can accommodate the support poles of a wind turbine, increasing the reliability of the power generation equipment's power collection. Although the power generation equipment is configured as a standalone device, it can be linked to another device to form an array.

[0113] Figures 10b and 10c are elevated perspective views of hinge details of at least one framed panel 4 adapted to facilitate access to the interior of the enclosure shown in Figure 10a.

[0114] The vertical pair of solar panels 45 are attached to the upright frame 41 at 3D printed panel joints by molded pivot elements 56. The pivot elements 56 are rotatably received in clamping members 57 that operatively support the weight of the framed PV panels 45 and have a biasing mechanism therein to return the panels to their normally closed position where they can be latched shut. A magnetic latching mechanism, electrically operated by payment card authentication, may be used to provide enhanced security. The pivot elements 56 and clamping members 57 may be 3D printed or formed from a thermoplastic material such as TPU and may have internal features to prevent rotation beyond a desired range of motion.

[0115] Finally, referring to FIGS. 11a and 11b, a specific combination in a fourth embodiment of the present invention includes a charging station 42, ideally for electric bicycles and electric scooters EV. Similar to the device shown in FIG. 10a, the charging station 42 comprises a free-standing, ground-engaging framework of octagonal cross section, including upright frame elements 41, each provided with an anchoring plate 41a for securing the station to the ground. As described above, panels 45 are secured between the upright elements, while pairs of panels latch to one side to provide access doors. Using the mechanism described with reference to FIGS. 10b and 10c, a centrally located charging pole 61 is used to mount or mount the folding electric scooter EV for storage while charging. The upright frame elements 41 also provide support for a roof section 44 on which additional PV panels 45 are located.

[0116] As detailed in FIG. 11c, a central charging pole 61 houses the batteries WB, RB and the charging regulator required to charge the electric scooter. A mains socket with RCD protection is located on the central charging pole to provide an AC output for the charging transformer. A communications module to facilitate card payment authentication may also be integrated into the charging pole. In a preferred arrangement, mounting hooks 63 are located at different heights on the charging pole 61 to load the foldable electric scooter EV onto the charging pole 61, providing maximum interior space for the shape of the foldable scooter or other electric mobility device.

[0117] Ideally, there will be a pocket to accommodate the user's own AC charger, ensuring compatibility with a wide range of e-scooters or other mobility devices.

[0118] Those skilled in the art will appreciate that the above embodiment 40 is not limited to rectangular or octagonal cross sections, and that other geometries, including hexagons and triangles, may be preferred in certain circumstances.

[0119] Of course, it will be understood that the invention is not limited to the particular details described herein, which are given by way of example only, and that various modifications and alternatives are possible within the scope of the appended claims.

Claims

1. 1. A photovoltaic (PV) charging station for charging a battery of an electric vehicle (EV), comprising: an enclosure having a structural frame element and a ground engaging element attached to the structural frame element; a plurality of PV panels secured to the frame element; a control circuit hermetically disposed within the housing for regulating electrical energy generated via the PV panel and an energy storage device connected to the control circuit; and charging connection part, Equipped with At least two of the PV panels are arranged on vertical surfaces and form exterior surfaces of the housing.

2. The charging station of claim 1 , wherein the PV panel is integrated with the frame element.

3. The charging station of claim 1 or 2, wherein the housing includes a wall section and a roof section to which PV panels are secured.

4. 3. The charging station of claim 1 or 2, wherein the enclosure is in a box-like form, with frame elements providing perimeter corners and the PV panel secured therebetween.

5. 5. A charging station as claimed in any one of claims 1 to 4, wherein each wall section comprises a framed PV panel arranged in a vertical orientation, the framed PV panel being shown as an exterior-facing surface of the housing.

6. 6. The charging station of any one of claims 1 to 5, wherein the total surface area of ​​the PV panels is optimized to produce an average daily power generation of at least 200 Wh.

7. 7. The charging station of claim 1, wherein the housing includes a plurality of receptacles for removable EV batteries, each receptacle having a charging connection for connecting to a terminal of the EV battery.

8. Charging station according to any one of claims 1 to 6, adapted to provide means for directly charging electric vehicles (EV).

9. 10. The charging station of claim 8, comprising storage, anchoring, or storage space within the structure or enclosure for at least one EV.

10. 10. The charging station of claim 9, wherein the structure or enclosure is a building having multiple receiving bays for EVs.

11. 10. The charging station of claim 8, including mounting means for at least one EV.

12. Charging station according to any one of claims 1 to 11, comprising a communication module.

13. Charging station according to any one of claims 1 to 12, including payment authentication means.

14. 14. The charging station of claim 1, wherein the structural frame elements define an octagonal enclosure between which the PV panels are disposed to present eight solar collecting surfaces, at least one of which is hinged to a corresponding frame element to facilitate access to the interior of the enclosure.

15. 15. The charging station of any one of claims 1 to 14, wherein the energy storage device comprises batteries with deep cycle characteristics and batteries with high power delivery characteristics, and wherein a combination of cell technology, charge controller and voltage monitoring circuitry optimizes both charging and delivery of power in less than optimal conditions.

16. 1. A method for charging a battery of an electric vehicle (EV), comprising: Accessing an EV battery charging receptacle within a charging station enclosure of the type set forth in claim 1; Installing an EV battery in the charging receptacle and aligning battery terminals of the battery with charging connections; connecting a charging connection to the EV battery terminal; Supports charging cycles, and confirming that the EV is ready for reuse; 1. A method for charging a battery of an electric vehicle (EV), comprising:

17. 1. A method for charging a battery of an electric vehicle (EV), comprising: accessing a mounting point for the EV within an enclosure in a charging station of the type described in claim 1; Attaching the EV to the attachment point; connecting the EV to an electric charging means; Supports charging cycles, and Confirming that the EV is ready for reuse; 1. A method for charging a battery of an electric vehicle (EV), comprising:

18. 20. The method of charging an EV battery of claim 17, wherein the attachment point is set high.

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

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

21. 10. The charging station of claim 1, having at least one vertically disposed major surface where photovoltaic (PV) panels operatively form at least the major surface of the structure or enclosure to optimize collection of solar radiation in less than optimal conditions with respect to diurnal and seasonal variations in direct and indirect incidence of solar radiation.

22. 22. The charging station of claim 21, wherein each PV panel is mounted to the structure or enclosure by a removable frame adapted to encapsulate the PV panel and to provide routing for cables associated with each panel.

23. 23. The charging station of claim 21 or 22, wherein the enclosure includes a roof section onto which one or more PV panels are mounted.

24. 24. A charging station according to any one of claims 21 to 23, wherein the PV panels are mounted within a frame adapted to connect to each other and to form at least two sides of the housing.

25. 25. A charging station as claimed in any one of claims 21 to 24, wherein the frame comprises an extruded profile element having grooves and channels for accommodating and retaining PV panels and associated cabling.

26. 26. An enclosure as claimed in any one of claims 21 to 25, wherein the frame releasably holds the PV panel and includes hinge elements on its outer edge to facilitate access to the interior of the enclosure.

27. 27. The enclosure of any one of claims 21 to 26, wherein each face carrying PV panels has associated therewith a dedicated, appropriately rated charge controller to manage the solar power collected from each panel within the face to maximize the efficiency of the charge output generated.

28. 28. The charging station of any one of claims 21 to 27, wherein the array of storage cells delivers a direct current (DC) power output to a device or a local power connector, or provides an alternating current (AC) power output via an inverter.

29. 29. A charging station as claimed in any one of claims 21 to 28, wherein the structure or enclosure is adapted to receive, store and charge electric mobility vehicles (EVs) from electric scooters, electric two-wheelers and electric cars (eliminating the need for an external or mains electrical connection).

30. 30. The charging station of any one of claims 21 to 29, wherein the housing has an octagonal cross section whereby the framed PV panel is hinged and forms an access door to a centrally located charging structure onto which the electric scooter is suspended for storage and charging.

31. 31. The charging station of claim 21, wherein the structure or housing is open on one of its sides, and at least one side of the PV panels comprises an arrangement of PV panels formed back-to-back, thereby admitting indirect or reflected solar radiation into the opening of the housing, and whereby EVs enter and exit the charging equipment at the opening.

Images