发明内容：
[0003]As mentioned above, there has been a shift in the classroom towards an education style that relies heavily on virtual resources. Additionally, many communities in developing countries are living in energy poverty, with limited resources of light as well as power to charge personal devices. Thus, a gap exists in educating children with hands-on, STEM-based (science, technology, engineering, and mathematics) activities, such as building a functional device, while also creating a lasting impact by donating the constructed device to children and families in need in developing countries.
[0004]The disclosed solar light kit joins two communities—those living in energy poverty and those in need of improved educational tools—by providing a system in which children have the opportunity to learn, build, and donate a solar light device to communities with limited energy resources. The program includes learning about solar lights and energy poverty in developing countries, building a solar light device from a kit with instructions, and donating the solar light to a child in need. The learning experience may additionally include the opportunity to write a letter to accompany the donated solar light to the child receiving the device. Children and families living in energy poverty may intuitively operate the light to complete schoolwork, work, play, and travel in an otherwise dark environment, thereby improving their living standard. The knowledge gained not only from learning how to construct a solar light but also from spreading awareness of energy poverty also contributes to the education of children in developed countries. Additionally, in obtaining the solar light, children in developing countries can learn about solar light systems and learn how to maintain their personal device, thereby improving children's education in developing countries, too.
[0005]The disclosed solar light kit may include various custom-shaped, modular, removably connectable components for building a solar panel and torch-style solar light that may be used in a variety of situations. Once constructed, the solar panel device and the solar light device may be electrically connected (e.g., via a cable) to transfer energy generated by the solar panel to the solar light device to power light sources on the solar light device. In some embodiments, the torch-style solar light may include one or more charging ports for charging other devices (e.g., mobile devices, such as phones, tablets, etc.). The solar panel and light may be portable and constructed from materials that are environmentally sustainable, lightweight, and weather-resistant to adverse environmental conditions, such as rain and UV sun exposure.
[0006]In some embodiments, a method of assembling a solar light kit is provided, the method comprising: connecting a first printed circuit board (PCB) comprising an array of light sources and a set of leads and a second PCB comprising a plurality of electrical ports, wherein connecting the first PCB and the second PCB comprises aligning the set of leads on the first PCB with a first electrical port of the plurality of electrical ports on the second PCB and applying pressure between the first PCB and second PCB; inserting the connected first PCB and second PCB to a PCB housing, wherein the connected first PCB and second PCB fit within the PCB housing in one orientation; connecting the PCB housing and a battery housing enclosing a rechargeable battery by aligning an end of the PCB housing with an end of the battery housing and applying pressure between the PCB housing and the battery housing; inserting the connected PCB housing and battery housing into a casing; and connecting a solar panel to a second electrical port of the plurality of electrical ports on the second PCB using a connector cable, wherein the connector cable is removably connectable to the solar panel and to the second electrical port.
[0007]In some embodiments, the method comprises attaching a lens to the first printed circuit board (PCB), wherein the lens is configured to disperse light from the array of light sources on the first PCB.
[0008]In some embodiments, the first printed circuit board comprises a switch configured to activate and deactivate the array of light sources.
[0009]In some embodiments, a third electrical port of the plurality of electrical ports on the second printed circuit board is configured to charge a mobile device.
[0010]In some embodiments, the first printed circuit board (PCB) comprises one or more through-holes, and a through-hole of the one or more through-holes is configured to receive the second electrical port on the second PCB.
[0011]In some embodiments, the method comprises, prior to inserting the connected first printed circuit board (PCB) and second PCB into the PCB housing, attaching an end cap to an end of the connected first PCB and second PCB.
[0012]In some embodiments, inserting the connected first printed circuit board (PCB) and second PCB to the PCB housing comprises inserting an end of the connected first PCB and second PCB opposite from the end cap into the PCB housing.
[0013]In some embodiments, the method comprises, prior to inserting the connected printed circuit board (PCB) housing and battery housing into the casing, attaching an electrical port plate to the PCB housing by aligning the electrical port plate with a corresponding portion of the PCB housing and applying pressure between the electrical port plate and the PCB housing.
[0014]In some embodiments, the electrical port plate comprises one or more through-holes configured to align with one or more electrical ports of the plurality of electrical ports on the second printed circuit board.
[0015]In some embodiments, the electrical port plate comprises a button configured to align and engage with a switch on the first printed circuit board.
[0016]In some embodiments, the method comprises, prior to inserting the connected printed circuit board (PCB) housing and battery housing into the casing, attaching an electrical port cover to the PCB housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing.
[0017]In some embodiments, the electrical port cover comprises one or more electrical port caps configured to removably cover one or more electrical ports of the plurality of electrical ports on the second printed circuit board.
[0018]In some embodiments, the method comprises, prior to connecting the printed circuit board housing and the battery housing, inserting the rechargeable battery into an end of the battery housing.
[0019]In some embodiments, the method comprises, after inserting the rechargeable battery into the end of the battery housing, enclosing the rechargeable battery in the battery housing using one or more end caps.
[0020]In some embodiments, enclosing the rechargeable battery in the battery housing comprises inserting a portion of an end cap of the one or more end caps into the end of the battery housing by aligning the portion of the end cap with the end of the battery housing and applying pressure between the end cap and the battery housing.
[0021]In some embodiments, connecting the printed circuit board (PCB) housing and the battery housing comprises aligning an end of the battery housing comprising the one or more end caps with an open end of the PCB housing.
[0022]In some embodiments, connecting the printed circuit board (PCB) housing and the battery housing comprises connecting a lead extending from the rechargeable battery to the connected first PCB and second PCB.
[0023]In some embodiments, the method comprises, prior to inserting the connected printed circuit board housing and battery housing into the casing, connecting a first end cap of a plurality of end caps to a first end of the casing.
[0024]In some embodiments, inserting the connected printed circuit board (PCB) housing and battery housing into the casing comprises, after connecting the first end cap to the first end of the casing, inserting the connected PCB housing and battery housing into the casing at a second end of the casing.
[0025]In some embodiments, the method comprises, after inserting the connected printed circuit board housing and battery housing into the casing, connecting a second end cap of the plurality of end caps to the second end of the casing.
[0026]In some embodiments, connecting the first end cap and second end cap of the plurality of end caps to the casing comprises using at least one handheld tool and a plurality of removable fasteners.
[0027]In some embodiments, assembling the solar light kit comprises assembling a solar panel stand and a solar panel frame.
[0028]In some embodiments, assembling the solar panel frame comprises connecting a plurality of corner members and a plurality of edge members around a perimeter of the solar panel.
[0029]In some embodiments, connecting the plurality of corner members and the plurality of edge members comprises using a plurality of removable fasteners and at least one handheld tool.
[0030]In some embodiments, assembling the solar panel stand comprises connecting an arm connecting member to a pair of stand arms.
[0031]In some embodiments, connecting the stand connecting member to the pair of stand arms comprises using a plurality of removable fasteners and at least one handheld tool.
[0032]In some embodiments, assembling the solar panel comprises connecting the assembled solar panel stand and the solar panel frame.
[0033]In some embodiments, connecting the assembled solar panel stand and assembled the solar panel frame comprises using one or more stand connectors, a plurality of removable fasteners, and at least one handheld tool.
[0034]In some embodiments, the solar light kit is provided in a kit package comprising a plurality of handheld tools and instructions for assembling the solar light kit.
[0035]In some embodiments, a solar light kit is provided, comprising: a printed circuit board (PCB) housing configured to enclose a first PCB and second PCB, wherein the first PCB comprises an array of light sources and a set of leads and the second PCB comprises a plurality of electrical ports, the first PCB and second PCB are configured to connect by aligning the set of leads on the first PCB with a first electrical port of the plurality of electrical ports on the second PCB and applying pressure between the first PCB and the second PCB, and the connected first PCB and second PCB are configured to fit in the PCB housing in one orientation; a battery housing configured to enclose at least one rechargeable battery, wherein the battery housing is configured to connect to the PCB housing by aligning an end of the PCB housing with an end of the battery housing and applying pressure between the PCB housing and the battery housing; a casing configured to enclose the connected PCB housing and battery housing; and a solar panel configured to connect to the second PCB using a connector cable, wherein the connector cable is removably connectable to the solar panel and to the second electrical port on the second PCB, and the PCB housing, the first PCB, the second PCB, the battery housing, the rechargeable battery, the casing, the solar panel, and the connector cable are bundled together unassembled in a kit package.
[0036]In some embodiments, the solar light kit comprises a lens configured to attach to the first printed circuit board (PCB) to disperse light generated from the array of light sources on the first PCB.
[0037]In some embodiments, the first printed circuit board comprises a switch configured to activate and deactivate the array of light sources.
[0038]In some embodiments, a third electrical port of the plurality of electrical ports on the second printed circuit board is configured to charge a mobile device.
[0039]In some embodiments, the first printed circuit board (PCB) comprises one or more through-holes, and a through-hole of the one or more through-holes is configured to receive the second electrical port on the second PCB.
[0040]In some embodiments, the solar light kit comprises an end cap configured to attach to an end of the connected first printed circuit board (PCB) and second PCB.
[0041]In some embodiments, the connected first printed circuit board (PCB) and second PCB are configured to be inserted into the PCB housing at an end of the connected first PCB and second PCB opposite from the end cap.
[0042]In some embodiments, the solar light kit comprises an electrical port plate configured to attach to the printed circuit board (PCB) housing by aligning the electrical port plate with a corresponding portion of the PCB housing and applying pressure between the electrical port plate and the PCB housing.
[0043]In some embodiments, the electrical port plate comprises one or more through-holes configured to align with one or more electrical ports of the plurality of electrical ports on the second printed circuit board.
[0044]In some embodiments, the electrical port plate comprises a button configured to align and engage with a switch on the first printed circuit board.
[0045]In some embodiments, the solar light kit comprises an electrical port cover configured to attach to the printed circuit board (PCB) housing by aligning the electrical port cover with a corresponding portion of the PCB housing and applying pressure between a portion of the electrical port cover and the PCB housing.
[0046]In some embodiments, the electrical port cover comprises one or more electrical port caps configured to removably cover one or more electrical ports of the plurality of electrical ports on the second printed circuit board.
[0047]In some embodiments, the solar light kit comprises one or more end caps configured to be inserted into an end of the battery housing to enclose the rechargeable battery in the battery housing.
[0048]In some embodiments, enclosing the rechargeable battery in the battery housing comprises inserting a portion of an end cap of the one or more end caps into the end of the battery housing by aligning the portion of the end cap with the end of the battery housing and applying pressure between the end cap and the battery housing.
[0049]In some embodiments, connecting the printed circuit board (PCB) housing and the battery housing comprises aligning the end of the battery housing comprising the one or more end caps with an open end of the (PCB) housing.
[0050]In some embodiments, the rechargeable battery comprises a lead extending from the battery, the lead configured to connect to the connected first printed circuit board (PCB) and second PCB.
[0051]In some embodiments, the solar light kit comprises a first end cap of a plurality of end caps configured to connect to a first end of the casing.
[0052]In some embodiments, the connected printed circuit board (PCB) housing and battery housing are configured to be inserted into the casing at a second end of the casing.
[0053]In some embodiments, the solar light kit comprises a second end cap of the plurality of end caps configured to connect to a second end of the casing.
[0054]In some embodiments, the solar light kit comprises at least one handheld tool and a plurality of removable fasteners configured to connect the first end cap and second end cap of the plurality of end caps to the casing.
[0055]In some embodiments, the solar panel comprises a solar panel frame and a solar panel stand configured to be assembled.
[0056]In some embodiments, the solar panel frame comprises a plurality of corner members and a plurality of edge members configured to surround a perimeter of the solar panel.
[0057]In some embodiments, the plurality of corner members and the plurality of edge members are configured to connect around the perimeter of the solar panel using a plurality of removable fasteners and at least one handheld tool.
[0058]In some embodiments, the solar panel stand comprises a pair of stand arms and an arm connecting member configured to connect the pair of stand arms.
[0059]In some embodiments, the arm connecting member and the pair of arms are configured to connect using a plurality of removable fasteners and at least one handheld tool.
[0060]In some embodiments, the assembled solar panel stand and the assembled solar panel frame are configured to connect using one or more stand connectors, a plurality of removable fasteners, and at least one handheld tool.
[0061]In some embodiments, the kit package comprises a plurality of handheld tools and instructions for assembling the solar light kit.
[0062]In some embodiments, a solar light kit is provided, comprising: a solar light device comprising a first printed circuit board (PCB), a second PCB, and a rechargeable battery, wherein the first PCB comprises an array of light sources and a lens, and the second PCB comprises a plurality of electrical ports, wherein a first electrical port of the plurality of electrical ports is configured to receive a connector cable, and a second electrical port of the plurality of electrical ports is configured to receive a charging cable for charging a mobile device; and a solar panel device comprising a frame and a stand, wherein the solar panel device is configured to removably connect to the solar light device using the connector cable.
[0063]In some embodiments, the solar light device comprises a rectangular prism shape configured to be handheld for a human.
[0064]In some embodiments, the array of light sources on the first printed circuit board (PCB) and the plurality of electrical ports on the second PCB are disposed on a face of the solar light device.
[0065]In some embodiments, the array of light sources comprises a plurality of light emitting diodes (LEDs).
[0066]In some embodiments, the solar light device comprises a third electrical port configured to receive the charging cable for charging a mobile device.
[0067]In some embodiments, the second electrical port and third electrical port comprise a universal serial bus (USB) port.
[0068]In some embodiments, the first electrical port comprises a direct current (DC) barrel jack.
[0069]In some embodiments, the solar light device comprises an electrical port cover comprising a plurality of caps configured to removably cover the plurality of electrical ports on the second printed circuit board.
[0070]In some embodiments, the first printed circuit board comprises a button configured to activate and deactivate the array of light sources.
[0071]In some embodiments, engaging with the button toggles between a plurality of light illumination settings for the array of light sources.
[0072]In some embodiments, the connector cable is at least 2 meters in length.
[0073]In some embodiments, the solar panel device is a polycrystalline panel comprising a plurality of solar cells.
具体实施方式：
[0080]Reference will now be made in detail to implementations and embodiments of various aspects and variations of systems and methods described herein. Although several exemplary variations of the systems and methods are described herein, other variations of the systems and methods may include aspects of the systems and methods described herein combined in any suitable manner having combinations of all or some of the aspects described.
[0081]The disclosed solar light kit may comprise a modular solar panel device and a torch-style solar light device removably connected (e.g., via a cable) to transfer energy generated by the solar panel to the solar light. The solar light may comprise a rechargeable battery configured to receive the energy generated by the solar panel and provide power to the light sources of the solar light device. The solar light may comprise one or more charging ports for providing power stored from the solar panel to one or more personal devices (e.g., mobile devices, phones, tablets, etc.). One or more components of the solar light kit may be specifically designed to be assembled by children with a limited number of handheld tools, and without the use of solder, glue, or other adhesives. Additionally, the components for building the solar panel and solar light may be manufactured such that each piece must be assembled in a particular order and orientation. The torch-style solar light may be sized such that it is handheld and portable for a child when disconnected from the solar panel. The solar panel of the solar light kit may comprise a stand, which allows the device to be stood/hung in any preferred orientation.
[0082]In the following description of the various embodiments, it is to be understood that the singular forms “a,”“an,” and “the” used in the following description are intended to include the plural forms as well, unless the context clearly indicates otherwise. It is also to be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It is further to be understood that the terms “includes,”“including,”“comprises,” and/or “comprising,” when used herein, specify the presence of stated features, integers, steps, operations, elements, components, and/or units but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, units, and/or groups thereof.
[0083]Characteristics of a Solar Light Kit
[0084]FIG. 1 illustrates an assembled and connected solar panel and solar light, in accordance with some embodiments. Solar light 100 may comprise one or more features including a button 102 configured to toggle between states of the solar light, one or more charging ports 104, and an electrical port 106 configured to receive an electrical connector (e.g., cable 180) for transferring energy (e.g., electricity) generated by the solar panel to components within the solar light 100.
[0085]In some embodiments, button 102 may be configured to activate and deactivate the solar light (e.g., the light sources of the solar light). For example, a user may engage with button 102 by pressing the button a first time to turn on the light, and a second time to turn off the light. In some embodiments, solar light 100 may comprise a plurality of light settings. For example, the solar light may be configured to emit light in a variety of colors (e.g., red, green, blue, white, yellow, etc.) and/or at a plurality of intensities (e.g., low, medium, and high brightness). In some embodiments, the user may engage with button 102 to toggle between these light settings. For example, the user may press button 102 a first time to turn the light on, and by pressing and holding the button for a predefined amount of time (e.g., 1, 2, 3, or more seconds), the color and/or brightness of the light may be altered. In some embodiments, the user may toggle between light settings by pressing button 102 repeatedly.
[0086]In some embodiments, the duration that solar light 100 may illuminate with a full solar charge from a solar panel (e.g., solar panel 140) may be dependent on the intensity of light being provided. For example, at a low brightness (e.g., at or around 50 lumens), solar light 100 may be configured to provide at least 30, 35, 40, 45, 50, or more hours of light through an array of light sources. In some embodiments, at a high brightness (e.g., at or around 240 lumens), solar light 100 may be configured to provide at least 3, 3.5, 4, 4.5, 5, 5.5, 6, or more hours of light through an array of light sources. In some embodiments, the array of light sources may comprise at least 6, 7, 8, 9, 10 or more light-emitting diodes (LEDs). In some embodiments, solar light 100 may comprise a third light setting (e.g., “torch” setting) configured to provide a high-power light (e.g., around 150 lumens) through one light source (e.g., LED). In some embodiments, solar light 100 may be configured to provide at least 3, 3.5, 4, 4.5, 5, 5.5, 6, or more hours of light through the single high-power LED.
[0087]In some embodiments, solar light 100 may comprise one or more electrical ports, such as charging ports 104, configured to provide power (e.g., charge) to a personal device of the user. For example, a user may plug a charging cable (e.g., a universal serial bus (USB) cable, such as USB-A, USB-B, USB-C, etc.) into a charging port (e.g., USB port) on solar light 100 to charge their personal device (e.g., mobile device, smartwatch, tablet, etc.) using the energy stored in the solar light apparatus (e.g., via a rechargeable battery within the solar light). In some embodiments, solar light 100 may comprise one, two, three, or more charging ports 104. In some embodiments, the charging ports 104 may provide less than or equal to 5 V, 9 V, 15 V, or 20 V of electricity to a mobile device being charged. In some embodiments, the charging ports 104 may provide greater than or equal to 5 V, 9 V, 15 V, or 20 V of electricity to a mobile device being charged.
[0088]In some embodiments, the one or more electrical ports of solar light 100 may comprise an electrical port 106 configured to transfer electricity generated from solar panel 140 to solar light 100 via an electrical connector 180. In some embodiments, electrical port 106 may be a direct current (DC) port (e.g., a 5.5 V DC barrel jack). Electrical port 106 may be configured to removably connect to an end of a corresponding electrical connector 180, wherein the opposing end of electrical connector 180 may be configured to connect to solar panel 140. In some embodiments, the port on solar panel 140 for receiving electrical connector 180 may be a DC port (e.g., a 5.5 V DC barrel jack). In some embodiments, one or more ports on solar panel 140 and/or solar light 100 configured to correspond with electrical connector 180 may be a USB port. In some embodiments, one or more of the electrical ports may be plugged with a cap when not in use. For example, solar light 100 may comprise an electrical port cover comprising one or more caps configured to be inserted into the electrical ports 104 and/or 106 when the ports are not connected to a cable.
[0089]In some embodiments, solar light 100 may comprise a rechargeable battery configured to store energy (e.g., electricity) transferred to solar light 100 from solar panel 140 (e.g., via electrical connector cable 180). In some embodiments, the rechargeable battery may be a lithium-ion, lead-acid, nickel-cadmium, or nickel-metal hydride battery. For example, the rechargeable battery may be a 3000 mAh, 3.7 V lithium-ion battery. In some embodiments, solar light 100 may comprise more than one battery. In some embodiments, the battery may be electrically coupled to circuitry configured to provide additional features associated with the battery. For example, solar light 100 may be configured to provide an indication when the battery is charging, when the battery level is satisfactory (e.g., over 50%, 75%, 90%, etc. charged), and/or when the battery charge level is low. For example, the indicator may be comprised in one or more light sources (e.g., LEDs) of solar light 100, such that the indicator may illuminate in a different color (e.g., red, green, etc.) and/or flash to provide a battery status. In some embodiments, the circuitry coupled to the battery of solar light 100 may be configured to automatically shut down the device, for example, if a threshold battery level (e.g., 1%, 2%, 5%, 10%, etc.) is breached. In some embodiments, the circuitry may provide overcharge and/or over-discharge protection. In some embodiments, the rechargeable battery may be configured to store at least 6 months of standby battery charge.
[0090]The solar light kit described herein may additionally comprise a solar panel 140. Solar panel 140 may be a thin-film (e.g., silicon amorphous), polycrystalline, or monocrystalline solar panel. For example, solar panel 140 may be a polycrystalline panel comprising a plurality of solar (e.g., photovoltaic (PV)) cells. In some embodiments, solar panel 140 may have a wattage rating of at least 5 W (e.g., 5.5 W). In some embodiments, solar panel 140 may be configured to provide a full solar charge to solar light 100 in less than 8 hours. For example, solar panel 140 may provide a full solar charge in 3, 4, 5, 6, 7, or 8 hours. The electrical cable described above and configured to removably connect solar panel 140 and solar light 100 may be selected such that the solar panel may be placed a distance away from the solar light when charging the light (e.g., the solar panel may be disposed outdoors, on a rooftop, etc.). For example, the electrical cable 180 may be at least 1 m, 1.5 m, 2 m, 2.5 m, 3 m or more in length to allow the panel and light to be stored in different environments (e.g., the panel may be placed outdoors, wherein the light may be stored indoors).
[0091]In some embodiments, solar panel 140 may comprise a solar panel stand 142. In some embodiments, solar panel stand 142 may be lockable, such that the solar panel 140 may be stood and operably locked at various angles as customized by the user. For example, as will be described in greater detail below at least with respect to FIGS. 4A-4H, the solar panel assembly may comprise stand connectors configured to removably lock solar panel stand 142 with solar panel 140. In some embodiments, the stand 142 may be folded such that it lies flat against the panel 140. In some embodiments, solar panel 140 may be hung from solar panel stand 142 (e.g., from a window, door frame, etc.).
[0092]In some embodiments, solar panel 140 and/or solar light 100 may comprise one or more hanging features. For example, one or more corners and/or sides of solar panel 140 may comprise hooks configured to hang solar panel 140, as described above with respect to stand 142. In some embodiments, one or more corners and/or sides of solar panel 140 may comprise through-holes configured to receive a hook such that the apparatus may be hung by inserting a hook through the hole(s). Likewise, solar light 100 may comprise one or more hooks and/or through-holes configured to receive hooks. For example, one or more ends of the solar light 100 may comprise hanging features. Thus, each of solar light 100 may be hung, for example, from a door frame, post, ceiling, etc. to illuminate an area, such as a room of a household. In some embodiments, solar panel 140 may be removably attached to a roof, post, or other object, for example, using removable fasteners and/or hooks inserted into the one or more through-holes on solar panel 140.
[0093]In some embodiments, solar panel 140 and/or solar light 100 may comprise one or more features configured to organize/maintain at least a portion of electrical connector 180 when connected to the one or more components. For example, solar panel 140 may comprise one or more slots configured to receive the cable of electrical connector 180 (e.g., at one or more corners and/or sides of solar panel 140) for cable management. In some embodiments, the slots may be disposed on one or more arms of the solar panel stand (as illustrated at least in FIG. 2A).
[0094]In some embodiments, each of the solar light 100 and solar panel 140 may be lightweight such that the device is portable for the intended user (e.g., children). For example, each of the solar light panel 140 and/or solar light 100 may weigh less than or equal to 1.5 kg, such as 1.4 kg, 1.3 kg, 1.2 kg, 1.1 kg, or less than 1.0 kg. In some embodiments, each of the solar light panel 140 and/or solar light 100 may weigh greater than 1.5 kg, such as 1.6 kg, 1.7 kg, 1.8 kg, 1.9 kg, or greater than 2.0 kg.
[0095]In some embodiments, the length of solar panel 140 may be less than or equal to 30 cm, 32 cm, 34 cm, 36 cm, 38 cm, or 40 cm. In some embodiments, the length of solar panel 140 may be greater than or equal to 30 cm, 32 cm, 34 cm, 36 cm, 38 cm, or 40 cm.
[0096]In some embodiments, the width of solar panel 140 may be less than or equal to 14 cm, 16 cm, 18 cm, 20 cm, 22 cm, or 24 cm. In some embodiments, the width of solar panel 140 may be greater than or equal to 14 cm, 16 cm, 18 cm, 20 cm, 22 cm, or 24 cm.
[0097]In some embodiments, the thickness (e.g., depth) of solar panel 140 may be less than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm. In some embodiments, the thickness (e.g., depth) of solar panel 140 may be greater than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm.
[0098]In some embodiments, the length of solar light 100 may be less than or equal to 32 cm, 34 cm, 36 cm, 38 cm, 40 cm, 42 cm, or 44 cm. In some embodiments, the length of solar light 100 may be greater than or equal to 32 cm, 34 cm, 36 cm, 38 cm, 40 cm, 42 cm, or 44 cm.
[0099]In some embodiments, a first and/or second width of solar light 100 may be defined as the dimensions perpendicular to a longitudinal axis of solar light 100. The solar light 100 may be sized such that it may be handheld and portable for the intended user (e.g., children). In some embodiments, the first and/or second width of solar light 100 may be less than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm. In some embodiments, the width of solar light 100 may be greater than or equal to 2 cm, 2.5 cm, 3 cm, 3.5 cm, 4 cm, 4.5 cm, or 5 cm.
[0100]As mentioned above, solar panel 140 may be configured to be installed on a roof (e.g., a roof of a household), such that a removably attached cable 180 may be fed through a nearby window, rafter, or other opening to charge solar light 100 (e.g., wherein the solar light is stored indoors). In some embodiments, solar light 100 may be usable in extended outdoor travel in adverse weather. Thus, each of solar panel 140 and/or solar light 100 may be manufactured from durable, weather-resistant materials.
[0101]For example, one or more components of solar light 100 and/or solar panel 140 may be manufactured from aluminum and/or an aluminum alloy. Aluminum may be selected at least because it is lightweight yet strong, recyclable, and durable. For example, the solar panel frame and/or solar light frame may comprise aluminum (and/or an aluminum alloy). In some embodiments, one or more additional components of solar light 100 and/or solar panel 140 may be manufactured from a long-lasting, durable polymer (e.g., an elastomer). For example, one or more components may comprise polycarbonate, acrylonitrile butadiene styrene (ABS), 30% glass fiber reinforced polyamide, and/or silicone. For example, one or more corner members configured to connect edge members of solar panel 140 (wherein the corner and edge members may be assembled to create the frame of solar panel 140) may be manufactured from a polymer (e.g., 30% glass fiber reinforced polyamide). In some embodiments, one or more components of the solar light kit may be manufactured using injection molding, at least because injection molding techniques may allow for unique, customized geometries of the components.
[0102]Characteristics of a Solar Light Kit Package
[0103]FIGS. 2A-2D show components of a solar light kit package, in accordance with some embodiments. For example, FIG. 2A may illustrate unassembled components of a solar light device (200a) and a solar panel device (240a). Each of the components used to construct the solar light 200a and solar panel device 240a will be described in greater detail below with respect to FIGS. 3A-3P and 4A-4H, respectively. In some embodiments, components for building solar light 200a may comprise one or more printed circuit boards (PCBs) (208, 210), a plurality of end caps (212, 224, 226, 230, 234), a PCB storage component 214, a casing 228, an electrical port plate 216, an electrical port cover 218, and one or more battery storage components (220, 222). In some embodiments, PCB 208 may be configured to attach to (and/or may comprise) a lens 209 for dispersing light from one or more light sources (e.g., LEDs). In some embodiments, PCB 210 may comprise one or more electrical ports for providing charge to an additional device (e.g., a mobile device) and/or transferring electricity generated by the constructed solar panel to the constructed solar light device.
[0104]In some embodiments, components for building solar panel device 240a may comprise a solar panel 254, one or more edge members (244, 252), one or more corner members (246, 248), one or more stand components (256, 258), and one or more stand connectors 262. The solar light kit may comprise a plurality of removable fasteners (e.g., screws, nuts, bolts, etc.) for assembling the solar light panel and/or solar light device (not illustrated). For example, as will be described in greater detail below, the solar light kit may comprise a plurality of different-sized screws configured to be fastened with a limited number of wrenches (e.g., Allen keys).
[0105]FIG. 2B illustrates packaged components of a solar light kit comprising solar light components 200b and solar light panel components 240b. As shown, each of the components for assembling the solar light may be packaged together in a manner such that each component has a defined storage space (e.g., pocket, envelope) in the packing tray 290. The pockets in packing tray 290 may be configured to contain each of the components in a specified orientation, allowing for each component to be visible to the builder. For example, a pocket in the packing tray 290 may be configured to contain each of the arms used in assembling the stand of solar panel 240b, such that arms may be stacked in packing tray 290 in a shared pocket. Likewise, edge members of the same dimensions may be stacked in a shared pocket of packing tray 290.
[0106]In some embodiments, packing tray 290 may be constructed from recycled materials, such as recycled paper pulp, and may additionally be compostable after use. In some embodiments, packing tray 290 may be configured to store unassembled solar light kits (as shown in FIG. 2B) as well as assembled solar light kits, as shown in FIG. 2D. In some embodiments, packing tray 290 may be stackable such that a plurality of trays may be stacked for transporting the kits. For example, packing tray 290 may comprise tapered side walls, wherein one or more of the side walls of the packing tray may comprise built-in handles. The tapered side walls and/or handles may aid not only in stacking trays, but also separating one or more trays from a stack of trays. Thus, unassembled kits may be easily shipped to the builder (e.g., children in schools), and once constructed, the assembled solar lights may be returned to the packing tray for eventual shipment to the intended end user (e.g., children and/or families in developing communities). The packing trays may be reused, or as mentioned above, recycled and/or composted.
[0107]FIG. 2C illustrates a toolkit for assembling a solar light kit, according to some embodiments. For example, the toolkit 270 may comprise one or more handheld tools for tightening and/or loosening one or more fasteners in the solar light kit. In some embodiments, the one or more handheld tools may be sized for use by the intended builder (e.g., children). In some embodiments, toolkit 270 may comprise one or more wrenches, such as a hexagon (e.g., Allen key) wrench, open-ended wrench, and/or ratchet wrench. In some embodiments, toolkit 270 may comprise one or more screwdrivers, such as a flat head, Phillips, and/or hexagon screwdriver. In some embodiments, as shown in FIG. 2C, toolkit 270 may comprise a variety of handheld tools (e.g., wrenches), wherein each wrench in the toolkit is configured to correspond with a different size of fastener (e.g., screw). Each of the handheld tools may be bundled, for example, using a tool holder 272. In some embodiments, the tool holder 272 may be manufactured from a biodegradable material, such as polylactic acid (PLA), for example using 3D-printing manufacturing techniques.
[0108]In some embodiments, a sticker comprising a scannable barcode (e.g., QR code) may be attached to tool holder 272, such that the builder may scan the barcode to receive building instructions for the solar light kit, educational materials regarding the program associated with the solar light kit, etc. In some embodiments, tool holder 272 may comprise one or more markings for differentiating between each of the tools in toolkit 270. For example, the position of the handheld tools as bundled by the tool holder 272 may correspond with one or more markings on tool holder 272, and the one or more markings may be referenced throughout the building instructions. With the use of the toolkit and removable fasteners, the solar light kit (e.g., solar panel device and solar light device) may be assembled using a limited number of handheld tools and fasteners and may easily be disassembled in the instance one or more components of the devices requires replacement and/or fixing. Additionally, the solar light kit may not require any adhesives (e.g., glue, tape, etc.), power tools, or soldering to successfully assemble the solar light kit.
[0109]In some embodiments, one or more toolkits 270 and fasteners for assembling a solar light kit may be provided in a pouch, such that a group of users (e.g., a class of students) may be provided multiple toolkits and sets of fasteners in a single pouch. In some embodiments, the pouch may be fabricated from recycled materials.
[0110]Assembly of a Solar Light Device
[0111]FIGS. 3A-3P show assembly steps of a solar light device of the solar light kit, in accordance with some embodiments. In some embodiments, each of the components for assembling the solar light from the solar light kit may be assembled in a particular fashion such that each part may fit together in a limited number of (e.g., one) orientation(s). In some embodiments, assembling the solar light may require at least a portion of the steps described with respect to FIGS. 3A-3P to be followed sequentially such that a later described step may not be completed before an earlier described step. In some embodiments, each of the components of the kit may be removably attachable such that each of the steps described below may be completed in a reverse order to disassemble the solar light device.
[0112]As illustrated in FIG. 3A, a user (e.g., builder) may begin to assemble the solar light by first connecting a first printed circuit board (PCB) 308 and a second PCB 310. For example, the PCBs 308, 310 may be attached by aligning corresponding portions of the PCBs and applying pressure between the components. In some embodiments, PCB 308 and/or PCB 310 may comprise one or more receiving portions and one or more inserting portions. For example, PCB 308 may comprise a set of leads (e.g., inserting portions) configured to be inserted into a port (e.g., receiving portion) on PCB 310. For example, the port may be a communication port configured to receive the leads on PCB 308 in a press-fit manner. In some embodiments, PCB 308 may comprise one or more through-holes configured to receive one or more elevated portions (e.g., ports) on PCB 310 (e.g., in a slip-fit). Thus, in attaching PCB 308 and 310, the user may be required to align each of the components configured to match on the PCBs to successfully attach the PCBs. In some embodiments, rather than comprising multiple PCBs, wherein each PCB comprises a portion of the modules required to operate the solar light, the solar light kit may comprise a single PCB comprising all the electrical modules, and thus a connection step may not be required. In some embodiments, the solar light kit may comprise a plurality of PCBs, and the modules for operating the device may be disposed in a different manner from that which is described above.
[0113]As mentioned above, one or more ports on PCB 310 may be charging ports for external devices. In some embodiments, a port of the one or more electrical ports on PCB 310 may be configured to receive an electrical connector (e.g., cable) for connecting the assembled solar light to the assembled solar panel (e.g., to transfer charge generated from the solar panel to the light). In some embodiments, PCB 308 may comprise an array of light sources (e.g., light emitting diodes, LEDs). In some embodiments, PCB 308 may comprise a lens configured to disperse light from the array of LEDs. In some embodiments, the user may be required to attach a lens 309 packaged individually from PCB 308 to the PCB (e.g., as illustrated in FIG. 3B), such that the lens 309 may cover the array. In some embodiments, lens 309 may click (e.g., snap) onto a portion of PCB 308 such that the lens may only be attachable to PCB 308 on a particular side of and in a specific orientation on the PCB.
[0114]PCBs 308, 310 may be shaped such that they are insertable into and extend along a housing of the torch-style solar light. For example, the PCBs may be elongated strip-shaped members comprising a substantially flat top and bottom face with one or more modules (e.g., ports, leads, etc.) configured thereon. For example, each of the receiving and inserting portions described above may be disposed on the top and/or bottom face of PCBs 308, 310. In some embodiments, a first end of PCB 308 may comprise an LED array, and a second end of PCB 308 may comprise one or more through-holes configured to receive the extruded ports on PCB 310. In some embodiments, PCB 310 may be about half the length of PCB 308, such that PCB 310 extends the length of PCB 308 comprising the one or more through-holes and ends approximately when the LED array begins on PCB 308.
[0115]Following connecting the PCBs 308, 310, the builder may attach an end cap (e.g., bracket) 312 to the end of the connected PCBs. As shown in FIG. 3B, bracket 312 may comprise one or more openings configured to receive a portion of PCB 308 and PCB 310 and may be configured to surround at least a portion of the connected PCBs. Due at least to the customized geometry of one or more of the PCBs and/or one or more modules on the PCB, the bracket 312 may comprise a customized configuration that may be attachable in a single orientation to the PCBs. In some embodiments, bracket 312 may be attached to the connected PCBs by applying pressure between the bracket 312 and connected PCBs 308, 310. In some embodiments, bracket 312 may click (or snap) into place on a portion of the connected PCBs.
[0116]FIG. 3C illustrates a subsequent step of the method of assembling the solar light. As mentioned above, the solar light may comprise one or more housings, such as PCB housing 314. In some embodiments, prior to inserting the connected PCBs into PCB housing 314 (as illustrated in FIG. 3D), an electrical port plate 216 may be attached to PCB housing 314. In some embodiments, electrical port plate 216 may be attached after inserting the connected PCBs 308, 310 into PCB housing 314. In determining the orientation with which to attach electrical port plate 316 to PCB housing 314, the plate may comprise one or more through-holes configured to align with one or more through-holes on PCB housing 314. Each of the aforementioned sets of through-holes on PCB housing 314 and electrical port plate 316 may be configured to align with and receive one or more raised (e.g., extruded) electrical ports on the connected PCBs (e.g., on PCB 310). In some embodiments, PCB housing 314 may comprise a receded portion configured to correspond with and receive the electrical port plate 316. In some embodiments, electrical port plate 316 may snap to one or more features on PCB housing 314 (e.g., by applying pressure between electrical port plate 316 and PCB housing 314). In some embodiments, electrical port plate 316 may comprise a clickable button (e.g., button 102 described above with respect to FIG. 1) configured to align with and activate/deactivate a switch on the connected PCBs. Thus, electrical port plate 316 may be configured to connect to PCB housing 314 in a specific orientation such that each of the button and/or through-holes/ports may be in proper alignment.
[0117]As mentioned above, the connected PCBs may be inserted into PCB housing 314. In some embodiments, PCB housing 314 may comprise an open end and a closed end. The connected PCBs 308, 310 may be inserted into PCB housing 314 such that a first end of the connected PCBs (e.g., the end opposite from bracket 312) is guided into the open end of the housing. In determining the correct orientation with which to insert the connected PCBs into PCB housing 314, the builder may orient the face of the connected PCBs comprising the receiving end of the electrical ports in the direction facing the port openings (e.g., through-holes) on PCB housing 314. In some embodiments, bracket 312 may be designed such that a top portion of the bracket is larger than a bottom portion, which may correspond with the perimeter of PCB housing 314. Thus, the connected PCBs with bracket 312 may only fit into PCB housing 314 in a particular orientation.
[0118]Once electrical port plate 316 is attached to PCB housing 314 and the connected PCBs 308, 310 are inserted into the housing, the builder may attach an electrical port cover 318 to the partially assembled device. Electrical port cover 318 may comprise a strip portion with one or more caps extending away from the strip and configured to cover the electrical ports on PCB 310 (e.g., through one or more openings mentioned above). For example, the strip portion of electrical port cover 318 may snap into a corresponding receded portion on a side of PCB housing 314 (e.g., by applying pressure between the strip portion and PCB housing 314). Each of the one or more caps on electrical port cover 318 may be configured to be removably inserted into the one or more ports when the ports are not in use. In some embodiments, at least a portion of electrical port cover 318 (e.g., the individual caps) may comprise a deformable, bendable polymer (e.g., elastomer) such that the user of the solar light may easily toggle the electrical port cover 318 from a state in which one or more of the individual caps are inserted into the ports and removed from the ports. In some embodiments, electrical port cover 318 may comprise a first color (e.g., red, blue, yellow, green, black, white, etc.), and electrical port plate 316 may comprise a second color different from the first, such that the user may easily determine the location of ports on the device.
[0119]In some embodiments, each of the individual caps may comprise a marking, for example, denoting the use of the port. For example, the one or more caps configured to cover a port for charging an external device may comprise a marking stating “out,” wherein power from the solar light device is transferred out of the device to charge other devices. Likewise, one or more caps configured to cover an electrical port for transferring electricity from the solar panel may comprise a marking stating “in,” wherein power may be transferred into the solar light to charge the solar light (e.g., from the solar panel). In some embodiments, the type of electrical connector (e.g., cable) configured to be inserted into each of the ports described above may be different. For example, the one or more ports for transferring electricity into the solar light may be a first type of port (e.g., DC barrel jack input, as mentioned above) and the one or more ports for charging other devices may be a second type of port (e.g., USB port, as mentioned above).
[0120]The solar light device described herein may comprise at least one, and in some