[ 1 ] The present invention relates to a portable power station and a solar panel array module attachment for a portable power station

Background of the Invention

[2] Globally, climate change has driven the requirement for Emissions Reduction Targets and mandatory Carbon Emissions reporting. Together with the increasing electricity generation costs such as labour, logistics and fuels (e.g. coal, natural gas, diesel and LPG), these factors are increasing the demand for renewable energy technologies.

[3] It is desirable to provide an alternative way of producing electricity and reduce carbon emissions and fuel cost.

[4] The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[5] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Invention

[6] According to a first aspect, the present invention provides a portable power station comprising: a housing, and at least one panel structure having at least one solar panel thereon, wherein the panel structure is movable between a stowed position from within the housing to an extended position at which it extends from the housing and exposes the at least one solar panel, wherein the at least one solar panel comprises an adjustable tilt mounting.

[7] In a preferred embodiment, the housing comprises a base wall, side walls, end walls and a top wall and is configured substantially as a shipping container.

[8] In another preferred embodiment, the housing comprises container corners.

[9] In another preferred embodiment, at least upper sections of the side walls and end walls are removable from the housing. [10] In another preferred embodiment, the portable power station comprises a plurality of panel structures forming a solar array.

[11] In another preferred embodiment, the solar array comprises four generally horizontal panel structures.

[12] In another preferred embodiment, in the stowed position, the panel structures are arranged in a stacked manner under a top wall of the housing.

[13] In another preferred embodiment, in the extended position, each panel structure extends outwardly out of the housing in a respective lateral direction.

[14] In another preferred embodiment, internal surfaces of the upper sections comprises solar panels thereon.

[15] In another preferred embodiment, the top wall comprises solar panels thereon.

[16] In another preferred embodiment, the housing includes a top cover for protecting the top wall solar panels.

[17] In another preferred embodiment, internal components of the portable power station comprise at least one of: a generator, a battery bank, a solar inverter, a solar controller, a battery inverter, an AC/DC switchboard, a satellite communication modem and antenna, next G modem and antenna, CCTV, weather station, desalination - 46 a split system air conditioner and a water filtration unit.

[18] In another preferred embodiment, the housing comprises a movable bracket assembly for allowing the panel structures to be moved between their stowed and extended positions.

[19] In another preferred embodiment, the housing comprises a tilt mechanism to provide tilt adjustment of the respective panel structure.

[20] In another preferred embodiment, the tilt mechanism comprises one or more of a tilting brace, a ball joint, and/or position lockable telescopic poles.

[21] In another preferred embodiment, the stowed position of the panel structures comprises a vertical orientation thereof parallel to its respective adjacent wall.

[22] In another preferred embodiment, each panel structure is pivotable about its top edge.

[23] In another preferred embodiment, the housing further comprises an internal roof aligned with lower edges of the upper sections. [24] In another preferred embodiment, the portable power station further comprises at least one access door in at least one of the side walls and end walls.

[25] In another aspect, the present invention provides a solar panel array attachment assembly module comprising: a frame having an internal space, the frame having container corners; a solar array housed within the internal space and movable between stowed and extended positions; wherein the assembly is attachable to a shipping container via the container corners.

[26] Preferably, the frame comprises a rectangular base, a rectangular top and corner uprights extending therebetween.

[27] Preferably, the array attachment assembly comprise side covers and a top cover which are removable. .

[28] Preferably, the solar array comprises four horizontally movable panel structures and a top panel.

[29] Preferably, the panel structures in the stowed position are arranged in a stacked manner under the top panel

[30] Preferably, the panel structures in the extended position extends outwardly out of the frame in a respective lateral direction.

[31] Other aspects of the invention are also disclosed. Brief Description of the Drawings

[32] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of examples only, with reference to the accompanying drawings in which:

[33] Fig. 1 is a perspective of a portable power station in accordance with a preferred embodiment of the present invention, in an open operational configuration thereof;

[34] Fig. 2 is a perspective of the portable power station of Figure 1, in closed configuration thereof;

[35] Fig. 3 is a schematic perspective view of a movable bracket assembly for solar panels of the portable power station of Figure 1 ; [36] Fig. 4 shows components of the movable bracket assembly, where (a) is a top view of a solar panel in an extended position, (b) is a side view of (a), (c) shows a roller in a C-channel and (d) shows a stop tab in the C-channel;

[37] Fig. 5 is a perspective view showing the tilt assembly for the solar panels of the portable power station of Figure 1 where (a) is an exploded view and (b) is an assembled view;

[38] Fig. 6 is a perspective view of an array attachment assembly module according to another aspect of the present invention, the array shown in the deployed position;

[39] Fig. 7 is an end view of a power station shipping container housing having the array attachment assembly module Of Figure 6 attached thereto;

[40] Fig. 8 is a perspective view of the assembly of Figure 7; and

[41] Fig. 8 is a perspective view of the assembly of Figure 7 with the array attachment assembly in the stowed position.

Description of Embodiments

[42] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[43] Figures 1 and 2 show a portable power station 10 according to a preferred embodiment of the present invention. The portable power station 10 is designed as a 100% portable complete system configured to provide power, contained within a standard length shipping container (10 ft, 20 ft, 40 ft).

[44] The portable power station 10 comprises a housing 12 having a base wall 14, side walls 16, end walls 18 and a top wall 20. The housing 12 is a standard size shipping container having container corners 22 and provides the various structural advantages of a shipping container, such as rigidity, stackability and ease of handling, transport and shipping due to its standard size and the container corners 22. The container 12 can be of any standard length

[45] The side walls 16 and end walls 18 are omitted from Figure 1 for illustration purposes. As shown in figure 2, each of the side walls 16 and end walls 18 comprise a removable upper section 82. The upper sections 82 are rectangular elongate sections extending from the top wall 20 and cover about l/5 ^th of the area of the side wall 16 and end walls 18. The remainder of the side walls 16 and end walls 18 comprise a combination of permanent sections and access doors. [46] The housing 12 comprises an internal roof (not shown) extending across and aligned with lower edges of the upper sections 82. The internal roof divides the internal space of the housing 12 into an upper internal space 23 and a lower internal space 24. The internal roof is closed and provides a fluid seal for the lower internal space 24.

[47] One side wall 16 includes a permanent section 71, a double door 72 having a width of between 2.6 m to 3 m, and a single door 76. One end wall 18 includes a full door 74. The opposite end wall 18 also includes another full door (not shown).

[48] The opposite side wall (not shown) will be a standard closed shipping container wall, but can also have additional similar doors 72 and 76 disposed in a mirror configuration thereto. Doors opening from both side walls 16 of the container provide the ability to walk though and out the other side

[49] The upper sections 82 are removable from the housing 12. During transport, the upper sections 82 remain attached to the housing 12 to protect the internal components thereof housed within the upper internal space 23 of the portable power station 10. When in use, on site, the upper sections 82 are removed which allows access to the internal components and use thereof as required.

[50] The portable power station 10 comprises a solar array 30 which comprises four generally horizontal panel structures 32. The panel structures 32 are movable between a stowed position within the upper internal space 23 and an extended (in use) position. In the stowed position, the panel structures 32 are arranged in a stacked manner under the top wall 20 and can be enclosed within the housing 12 via the upper sections 82 as shown in Figure 2. In the extended position, each panel structure 32 extends outwardly out of the housing 12, in a respective lateral direction, as shown in Figure 1.

[51] The solar array 30 is thus an integrated structure contained within the portable power station 10 roof area. The panel structures 32 are slid out from under the container top wall 20, one panel structure on each side of the housing 12. Each panel structure 32 carries a number of solar panels 34 on its top surface which are thus exposed in the extended position thereof.

[52] The top wall 20, upper sections 82 and the internal roof thus act as covers for the solar array 30. The upper sections 82 act as covers which are removed and can be slid underneath its corresponding panel structure 32 or under the top wall 20. Alternatively, the upper sections 82 can be configured for other use, such as being connectable to provide a shade structure for personnel, or internal surfaces of such upper sections 82 can carry additional solar panels 34 which are then connectable to the portable power station 10. The top wall 20 can additionally carry solar panels 34, and the housing 12 can include another cover for protecting the top wall solar panels.

[53] The internal components within the internal space 24 will include a generator 41, a battery bank 42 consisting of up to 120 battery cells, two solar inverters, two solar controllers, up to three (but at least one) battery inverters (off grid inverters), an AC / DC switchboard, a satellite communications modem and antenna, next G modem and aerial/ antenna, a split system air conditioner and a water filtration unit.

[54] The battery bank section 42 is accessible via the double doors 72, the inverter sections via the door 74, the generator section via the door 76 and the other door (not shown) installed in the other end wall 16 adjacent the door 76. The opposite side wall, if fitted with additional similar doors 72 and 76 allows walk-through access for the battery bank 42 and generator 41.

[55] The housing can also include two internal walls separating the inverter room from the battery room, and a wall separating the generator room from the battery room. The battery room is lined/insulated and ventilated. The generator room is also ventilated.

[56] Figures 3 and 4 show a movable bracket assembly 50 which allows the panel structures 32 to be moved between their stowed and extended positions. The bracket assembly 50 comprises a static brace member 51 mounted between corner structures 13 of the housing 12. A first pair of rollers 52 are mounted to the brace member 51 in a cantilevered manner. An intermediate member 53 having a C-shaped channel 54 receives the rollers 52 therein. The intermediate member 53 comprises a second pair of rollers 55 attached to its face 56 opposite the channel 54. A second member 57 also having a C-shaped channel 58 receives the second rollers 55 therein. The second members 57 are attached to or support the end edges of the panel structures 32.

[57] The bracket assembly 50 above thus allows the intermediate member 53 to slide relative to the brace member 51 , and the second member 57 to slide relative to the intermediate member 53. Stop tabs 61 are used to limit the outward movement of the members 53 and 57. This results in allowing the respective panel structure 32 to be slid from under the top wall 20 to its extended position thus exposing the solar panels 34 thereon.

[58] The bracket assembly 50 and/or panel structures 32 have been designed to provide tilting of the respective panel structure 32 to an optimum solar panel exposure angle. Referring to Figure 5, a proximal end 33 of each panel structure 32 is pivotably attached to the second member 57. A distal end 35 of the panel structure 32 is unattached, allowing the panel structure 32 to be tilted. In the example shown, a tilting brace 67 is used to extend between the distal end 35 and the second member 57 for supporting the tilted panel structure 32.

[59] As shown in Figure 5, the solar panels 34 can be supported by right angle brackets 59 to the second member 57. Joining tabs 58 can be used to join the solar panels 34 to each other.

[60] The array will output approx. 3.5kW on an 8ft container, 4.5kW on a 10ft container, up to 13kW on a 20ft container and up to 22kW on a 40ft container

[61] The bracket assembly 50 and/or panel structures 32 can be configured in other manner to provide tilting of the panel structures 32 in other directions. For example, the panel structures 32 can be made to tilt along a pivot point at the distal end 35, or the panel structures 32 can be supported by a ball joint or other suitable mechanism (such as position lockable telescopic poles) which will allow the panel structures 32 to be tilted in any lateral direction.

[62] The portable power station 10 has a number of features as follows:

• 100% Portable. I.e. a complete power system contained within a standard size shipping container.

• Transportable including shipping which means exportable. The portable power station 10 will includes component smart absorber mounting techniques including battery bank, which also has an encapsulated housing and structure in case of a container drop on side or roof.

• Quick and easy to install and commission. I.e. no technicians required. A simple process of unlocking plugging in and turning on is required and is expected to take approximately hour for two people to set up and turn on.

• Includes a Solar array as an integrated structure within the container roof area. The array area covers are simply removed and slid in underneath the array frame structure and the arrays slide out from within the container roof space one plane on each side. The array plane slide structure has been designed to allow tilting to an optimum insolation performance angle.

• Flexible design from an output power of 3 kW power output to 160 kW continuous.

• Able to accept a wind turbine electrical input. • 100% monitorable, i.e. via next G and Satellite communications technology, the system can be monitored for performance, maintenance and fault finding. Other important monitoring requirements can also be setup including fuel level alarms, weather monitoring, CCTV etc. The portable power station 10 can provide communication where other systems have failed.

• Has the ability to incorporate water filtration or desalination plants for disaster relief applications or the like.

• Reliability of supply. Three separate means, of electricity generation are provided by the portable power station 10 namely: Diesel generator AC, Solar/Battery/Inverter AC, Battery bank DC. This provides two potential layers of redundancy, if one of the systems may fail.

• Replacement: where system service life is due or system components require replacement, the power station 10 as a whole unit can be easily swapped for another. I.e. where lease term or service life has ended, a new unit turns up, is commissioned and the old goes back to the supplier or owner.

• For use in controlling and regulating remotely mounted solar PV up to approximately double the inverters electrical rated continuous power output capacity.

• For use in providing peak demand support and load profile shaping in diesel powered mini grids.

[63] The portable power station 10 will effectively provide an alternative to power generation solution for sites currently powered by other unreliable or costly means such as various fuels. The portable power station 10 provides a portable turnkey solution for a range of different applications, such as monitoring stations, communications sites, mining camps, electricity grid support, emergency grid backup, emergency services natural disaster service, off grid residential and remote communities

[64] Whilst preferred embodiments of the present invention have been described, it will be apparent to skilled persons that modifications can be made to the embodiments described.

[65] In possible modification, the stowed position of the panel structures 32 can be a vertical orientation thereof where it is parallel and adjacent its respective side or end wall. Each panel structure 32 can then be pivotable about its top edge.

[66] Figures 6 to 9 show a solar panel array attachment assembly module 110 according to another aspect of the present invention. The array attachment assembly module 110 is designed as an attachment to a portable power system contained within a standard size shipping container 200, for adding solar capability to the portable power system.

[67] The array attachment assembly 110 comprises a rectangular prism frame 112 having a rectangular base 114, a rectangular top 116 and corner uprights 1 18 extending therebetween, which together define an internal space 123. The array attachment assembly 110 comprises container corners 122 and provides the various structural advantages, such as rigidity, stackability, connectivity and ease of handling, transport and shipping due to the frame 112 and the container corners 122. The frame 112 has a height of between l/5 ^th to ½ of the height of a standard shipping container.

[68] The array attachment assembly 110 comprise side covers 182 and top covers 184 which are removable. During transport, the covers 182 and 184 remain attached to protect the internal components housed within the internal space 123.

[69] The array attachment assembly 110 comprises a solar array 30 which comprises four horizontally movable panel structures 32 and a top panel 33. The panel structures 32 are movable between a stowed position within the internal space 123 and an extended (in use) position. In the stowed position, the panel structures 32 are arranged in a stacked manner under the top panel 33 and can be enclosed within the array attachment assembly 110 via the covers 182 and 184 as shown in Figure 2. In the extended position, each panel structure 32 extends outwardly out of the array attachment assembly 110, in a respective lateral direction.

[70] The panel structures 32 are slid out from under the top panel 33, one panel structure on each side of the housing 12. Each panel structure 32 comprises a movable bracket assembly similar to the embodiment shown above, or a suitable telescopic support assembly. Each panel structure 32 carries a number of solar panels on its top surface which are thus exposed in the extended position thereof. The top panel 33 additionally carries solar panels. The solar panels are pivotably attached to at least one edge and can be tilted to a desired angle via supports. The top cover 184 additionally comprises solar panels. In the embodiment shown, the top cover 184 is divided into three to six removable roof sections each having solar panels thereon.

[71] The array attachment assembly 110 is attachable to a portable power system housed in a shipping container 200 via twist lock connectors between the adjacent corners of the shipping container 200 and the array attachment assembly 110. Electric connection is then made between the solar array 30 and the power system. [72] The array attachment assembly thus provides solar capability which can be added to portable power systems, particularly those housed in a shipping container. The array attachment assembly can be easily transported with the shipping container.