AU2020201996A1 - A portable lighting unit - Google Patents

Abstract

The invention relates to a portable flood light unit comprising a transportable rigid housing with a frame defining an envelope having a base, at least two sides, and a top. A power supply comprising a solar panel and a battery is mounted and contained within the frame envelope. A light source is also mounted and contained within the frame envelope and configured to be powered by the power supply. The housing defines a plurality of apertures and the solar panel is positioned or positionable within the frame envelope to receive solar energy through at least one housing aperture. The light source is positioned or positionable within the frame envelope to emit light through at least one housing aperture. 1/4 m Ln r-. CA ( -J F1 ,-E CAr "-E-

Description

1/4

m Ln

r-.

CA ( -J

F1 ,-E

CAr

"-E- A PORTABLE LIGHTING UNIT

FIELD OF THE INVENTION This invention relates to a portable lighting unit, in particular a transportable solar powered unit for providing flood lighting to sites.

BACKGROUND The provision of lighting for temporary worksites, remote sites, outdoor festivals and other events typically requires significant set-up that may involve the assembly of multiple components such as numerous stands or towers, lamps, electrical connections, and the installation of generators. Lamps mounted on stands or towers in particular, have a small footprint and can be unsuitable for some locations, for example locations with dirt, gravel, or uneven surfaces. These lighting installations are also unsuitable for use in windy conditions.

When the temporary lighting is no longer required, it is necessary to disassemble the lighting systems and, in some cases, box components into crates for transport. This is a labour intensive process.

It is an object of at least preferred embodiments of the present invention to address one or more of the above mentioned disadvantages and/or to at least provide the public with a useful alternative.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally to provide a context for discussing features of the invention. Unless specifically stated otherwise, reference to such external documents or sources of information is not to be construed as an admission that such documents or such sources of information, in any jurisdiction, are prior art or form part of the common general knowledge in the art.

SUMMARY OF THE INVENTION

The present invention broadly consists in a portable flood light unit, comprising a transportable rigid housing, a power supply, and a light source. The transportable rigid housing comprises the frame of an intermodal shipping container, the frame defining an envelope having a base, at least two sides, and a top; the power supply comprises a solar panel and a battery, mounted and contained within the frame envelope; and the light source is mounted and contained within the frame envelope and configured to be powered by the power supply. The housing defines a plurality of apertures, wherein the solar panel is positioned or positionable within the frame envelope to receive solar energy through at least one housing aperture, and wherein the light source is positioned or positionable within the frame envelope to emit light through at least one housing aperture.

In an embodiment, the portable unit comprises an array of solar panels.

In an embodiment, the portable unit comprises a solar panel support frame. The frame may be attached to the rigid housing and adjustable within the housing envelope to a plurality of positions to position the solar panel(s) to receive solar energy via a housing aperture. The unit may have two solar panel support frames, each supporting one or more solar panels, the frames being attached to the rigid housing and independently adjustable within the housing to a plurality of positions to position the solar panels for receive solar energy via a housing aperture

In an embodiment, the, or each, solar panel support frame is adjustable through an arc of between 30 and 75 degrees, for example through an arc of about 45 degrees.

In an embodiment, the portable unit comprises a lighting support frame. The frame may be attached to the rigid housing and adjustable within the housing envelope to a plurality of positions to position the light source to direct light in a desired direction via a housing aperture.

In an embodiment, the, or each, lighting support frame is adjustable through an arc of between 30 and 75 degrees, for example, through an arc of about 45 degrees.

In an embodiment, the light source comprises an LED array. Alternatively the light source may comprise alternative suitable lamps such as metal-halide, sodium-vapour, or compact fluorescent lamps. The light source preferably emits over 60,000 lumens of light, more preferably over 100,000 lumens of light.

In an embodiment, the housing comprises a base wall, a top wall, two side walls and two end walls, and wherein an aperture is provided in the top wall and each of the side walls. The area of the aperture in the top wall may be at least 70% of the area of the top wall. The area of the aperture in each side wall may be at least 70% of the area of each side wall. The housing may further comprise apertures provided in the each of the end walls. The area of each end aperture may be at least 70% of the area of each end wall.

In an embodiment, the housing frame is reinforced by way of a plurality of bracing struts. These may be diagonal struts, for example in a cross-hatch configuration.

The housing may comprise a plurality of top and bottom twist-lock fittings to facilitate transport and stacking of the lighting unit. Preferably both the top and bottom fittings are female fittings, but alternatively male twist-locks may be provide at the top of the housing.

Preferably no part of the light source or power supply projects beyond the envelope of the housing during transport or during use. More preferably the components are not adjustable to project beyond the housing envelope to minimise the risk of components not being retracted and thereby bring damaged during transport.

In an embodiment the unit further comprises a power socket powered by the power supply, for receiving and powering an electrical appliance external to the flood light unit.

The portable flood light unit may comprise a controller and/or a charging regulator. The light source may be operated remotely, for example, the controller may comprise a receiver for receiving wireless signals from a remote device such as a user-operated remote control to operate the lighting unit to allow remote operation of the unit. This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features. Where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually described.

The term 'comprising' as used in this specification and claims means 'consisting at least in part of'. When interpreting statements in this specification and claims that include the term 'comprising', other features besides those prefaced by this term can also be present. Related terms such as 'comprise' and 'comprised' are to be interpreted in a similar manner.

It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range and any range of rational numbers within that range (for example, 1 to 6, 1.5 to 5.5 and 3.1 to 10). Therefore, all sub-ranges of all ranges expressly disclosed herein are hereby expressly disclosed.

As used herein the term '(s)' following a noun means the plural and/or singular form of that noun. As used herein the term 'and/or' means 'and' or 'or', or where the context allows, both.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention will now be described by way of example only and with reference to the accompanying drawings in which: Figure 1 is a schematic showing a first embodiment transportable lighting unit, where Figure 1(i) is a top view, Figure 1(ii) is and end view, and Figure 1(iii) is a side view; Figure 2 is a schematic showing indicative sizing for the housing apertures for the embodiment of Figure 1, where Figure 2(i) is a top view, Figure 2(ii) is and end view, and Figure 2(iii) is a side view; Figure 3 is a schematic showing a second embodiment transportable lighting unit having a reinforced frame, where Figure 3(i) is a top view, Figure 3(ii) is a first end view, Figure 3(iii) is a second end view, and Figure 3(iv) is a side view; and Figure 4 is an isometric view of the lighting unit of Figures 1(i) to 1(iii).

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

The present invention will now be described with reference to Figures 1 to 3 which show exemplary embodiment portable flood light units 1, 101. The flood light unit comprises a transportable rigid housing, a solar power supply, and a light source, with the power supply and the light source contained within the envelope of the housing both during transportation and use.

The housing comprises at least the frame 3, 103 of an intermodal shipping container. The frame has a base 5, 105, at least two sides, and a top 7, 107, defining an envelope. The power supply and light source are contained within the envelope of the frame 3, 103. The power supply comprises one or more solar panels 9, a battery 11, and associated circuitry to power the light source.

Referring to Figures 1(i) to 2(iii), the housing 3 consists of a rectangular shipping container of a standard size having a base wall, a top wall, two side walls and two end walls. For example, the housing 3 in the embodiment shown in Figures 1 and 2 has a length of about 6069mm, a width of about 2438mm, and a height of about 2438mm. However, it will be appreciated that these dimensions may vary between embodiments and other size units are envisaged.

A plurality of apertures are provided in one or more of the walls of the shipping container. These apertures are of a sufficient size and/or position to allow solar energy through the apertures to the solar panels 9, and to allow light emitted from the light source out through the apertures. The apertures are provided at least in the top wall and in one of the side walls, but are more preferably provided in both side walls along with both end walls, extending along at least a major part of the length, width, and/or height of the housing 3.

Figure 2 illustrates an embodiment having rectangular apertures 15, 17, 19 in the top, side and end walls that are created by removing material from the wall of the housing 3 substantially along the length, width, and height, of the container, leaving only the base wall, the frame, and a framing border of the side and top walls to allow for maximum passage of light into and out of the housing 3. In the embodiment shown, the area of each aperture is about 95% of the area of the respective wall in which the aperture is provided, with the maximum percentage area of the aperture limited only by the size of the frame required for structural integrity of the container. In alternative embodiments, the apertures may be smaller or otherwise shaped, for example having an area of around 70% of the area of the respective wall, or the housing 3 may comprise a higher number of smaller apertures.

Figure 3 illustrates an alternative embodiment unit 101 in which the corrugated walls of the shipping container housing are removed in their entirety, at least from the sides, ends and top of the container. In this embodiment, the base of the shipping container is left in place, preferably unaltered. The remaining frame 103 is strengthened using cross bracing 121 and/or steel edge reinforcing 122. The bracing 121 is typically includes diagonal struts, for example in the cross hatch configuration shown, however other bracing configurations are possible depending on the loading requirements for the frame 103 and to maximise the solar light that is able to reach the solar panels through the frame openings. The bracing strengthens the unit 103, so the unit can withstand increased loading, for example due to other containers stacked on top during transport. The reinforced embodiment shown in Figure 3 has a length of about 6069mm, and width of about 2438mm, and a height of about 2438mm and is able to support loading in excess of 10 metric tonnes on top of the unit 103.

In the embodiment of Figure 3, the housing frame 103 together with the bracing 121 define an array of triangular apertures 115, 117, 119 in each of the top, side, and ends of the housing. As for the first embodiment 1, these apertures 115, 117, 119 are of a sufficient size and/or position to allow solar energy through the apertures to the solar panels, and to allow for the projection of light out through the apertures.

To facilitate transport of the lighting unit 1, 101 by allowing carriage on any standard means of transportation capable of transporting a standard shipping container, the housing comprises twist lock fittings at the upper and lower corners of the frame 3, 103. The unit 3, 103, may be constructed from an existing intermodal shipping container, which includes eight female twist-lock fittings at its corners. The existing container is modified to provide the above described apertures while leaving the existing twist-lock fittings structurally intact.

The light source 13, 113 comprises an array of spaced apart lamps positioned within the housing. In the embodiment shown, the lamps comprise light emitting diodes (LEDs). However, it will be apparent that the light source may comprise alternative suitable lamps such as metal-halide, sodium-vapour, or compact fluorescent lamps.

The lamps are mounted directly to the housing frame 3, 103 or alternatively may be mounted to one or more support frames. The support frame or frames are contained within and attached to the rigid housing frame 3, 103. The support frame or frames may be attached to the frame 3 at or towards a top of the frame, with the lamps 13, 103 directed generally downwards. The support frame may be adjustable within the housing to a plurality of positions to enable the light source to be directed in a desired direction, for example by pivoting the frame about a side edge pivot. In an embodiment, each support frame is adjustable through an arc of about 30 to 75 degrees.

The LEDs or other lamps 13, 113 may be mounted to the support frame or housing via a bracket that allows the attached lamp to move relative to the respective frame, for example to swivel or tilt, to adjust the direction of light projection. The lamps 13, 113 are each arranged or are adjustable to direct light through one or more of the apertures 15, 17, 19, preferably directing light in a range of directions to provide light across a larger area. Preferably in all adjustment positions, each light remains within the envelope of the housing.

The light source preferably emits over 60,000 lumens of light to flood light an area adjacent to the lighting unit 1, 101. The embodiments shown comprise eight LED lamps 13, 113 and the units 1, 101 emit between about 100,000 and 120,000 lumens of light.

The unit 1, 101 comprises a plurality of solar panels 9 positioned within the envelope of the housing frame 3. The solar panels are mounted to a support frame 23, 123, for example forming an array. The embodiment shown in Figure 1 comprises an array of eight solar panels 9.

The frame 23, 123 can be adjusted to move or tilt the solar panels towards incoming solar radiation to increase power generation at a given site. In all positions of the frame 23, 123, the solar panels preferably contained within the envelope of the housing, and receive solar energy through at least one of the apertures 15, 17, 19 in the housing.

In the embodiment shown in Figure 1, the solar panel support frame 23 is pivotally attached to the rigid frame of the housing 3, at a pivot 25 at or near the front bottom edge or the housing. The frame is adjustable by pivoting the frame 23 about the pivot 25, for example, through an arc of between 30 and 75 degrees, depending on the size and placement of any other components within the unit, for example the battery housing 27. In the embodiment shown, the frame is hinged to the floor and adjustable through an arc of about 45 degrees, for example by way of a linear actuator. The solar panel frame 23 is hinged to the base of the housing 5 and manually adjustable using standard hand tools, however, alternatively the lighting unit may comprise a powered adjustment mechanism, for example a hydraulic ram.

The lamps 13 are positioned to direct a beam of light 14 past the solar panels 23. Preferably the solar panel support frame 23 is arranged such that in all itsl adjustment positions, the solar panels do not impede the projection of light from the lighting unit 1.

Optionally the lighting unit 1, 101 may comprise a second solar panel support frame that is adjustable independently from the first solar panel support frame 23 to a plurality of positions. The second solar panel support frame may be identical to the first frame or different, for example, it may be smaller, and is pivotable about a pivot axis that is different to the pivot axis of the first solar panel support frame. The first and second solar panel support frames may be pivotable in different directions or through different angles to allow the solar panels to receive solar energy through a wider range of lighting conditions. The second frame may also enable a larger area of solar panels 9 to be accommodated so that the lighting unit is able to operate in low-light conditions.

The embodiments shown comprise an array of eight 250-500W solar panels. However, it will be understood that alternative embodiments may comprise more or fewer panels of differing capacities, depending on the application and the solar panel technology available. This solar panel array is used in combination with a 13.8kW LFP (lithium ion phosphate) battery, however, it will be appreciated that the battery size and type will be selected depending on the required application, load and run time. The solar panels 9 are electrically coupled to a battery 11 for storing electrical energy generated from the solar panels. The battery 11 is in turn electrically coupled to the light source 13, thereby allowing the light source to draw power from the battery and operate in low-light conditions.

The lighting unit 1, 101 comprises a battery compartment 27, 127 to house the battery 11, 111 and associated circuitry such as a charging regulator and a controller. The charging regulator protects the battery by limiting the rate at which electric current is added to or drawn from the batteries and/or by preventing overcharging or complete discharging.

The controller (not shown) is configured to control the operation of the solar panels and battery, including, for example regulating the draw current, monitoring power consumption, and other operational concerns. The controller may comprise a receiver for receiving wireless signals from a remote device such as a user-operated remote control to operate the lighting unit. This allows an operator to remotely turn the light source on and off. The controller may also control other aspects, such as the brightness of each lamp 13, 113, the number of lamps turned on, and the direction of the lamps.

The battery compartment is positioned wholly within the envelope of the housing frame 3, 103, and attached to an inner surface of the housing, for example to the floor 5 of the housing. In the embodiment shown, the battery compartment is a metal case with a lockable access door or hatch. The metal case is fixed to the floor by way of angular brackets, but may be otherwise attached or positioned.

In some embodiments, one or more power sockets powered by the power supply may be provided on the lighting unit. The power sockets are configured to receive a standard plug of an electrical appliance, to power the appliance. These power sockets are positioned to be accessible from the exterior of the lighting unit, for example, they may be positioned near an aperture 15, 17, 19, of on an external surface of the housing, thereby allowing convenient electrical connection of external electrical devices such as hand tools and speakers, or for connection to an extension lead.

The lighting unit may additionally have a power input for coupling the light source 13, 113 to a secondary, external power supply, for example to an external generator. This enables the light source to be powered in situations where insufficient power is generated by the solar panels 9, for example during prolonged periods of poor environment light.

The above described lighting unit 1, 101 has application in use to provide industrial lighting such as depot lighting, lighting for remote or temporary worksites, and for outdoor festival and event lighting. For use the lighting unit is placed in its desired location and the position of the solar panel frames 23, 123 may be adjusted to tilt the solar panels to best receive incoming solar radiation at the given site. The lamps 13, 113 may, be selectively adjusted manually to best provide lighting for specific uses. The unit 1, 101 is entirely self-contained and does not require unpacking, installing, or unfolding when it reaches the site.

Once the battery 11, 111 is at least partially charged, or the unit is connected to an external power source, the lighting unit may be used to light the surrounding area. It is not necessary for the lighting unit 1, 101 to be installed in an elevated position. The unit is compact, preferably with no part of the light source or power supply projecting beyond the envelope of the housing during use.

The lighting unit 1, 101 is suitable for placing on any substantially flat surface capable of supporting the weight of a standard shipping container. This includes dirt, sand, gravel, heavy vehicle trailers, concrete, tarmac, grass, or the roof of another container. The wide base and stability of the housing makes the unit suitable for use in high wind areas.

The lighting unit does not need to be elevated. However, depending on the application, it may be desirable to elevate the unit to produce a greater arc of light. The lighting unit can be readily placed on top of another shipping container or other platform capable of supporting its weight. Where more light is required, multiple lighting units may be employed, either at spaced apart locations, stacked, or placed side-by-side.

When the portable lighting unit is no longer required, it may be uplifted from site with no packing or disassembly required other than the disconnection of any external appliances or power supplies. Utilising the characteristics of a shipping container enables robust and easy transport of the lighting unit 1, 101 between locations. That is, the unit is capable of withstanding prolonged weight stacked atop it, and is capable of being moved by crane or a suitable loader-crane. The standardised shipping container shape of the unit, along with the top and bottom twist-lock fittings, make the unit 1, 101 readily transportable by standard vehicles and equipment, including by road, ship, and by rail, and facilitate stacking of the lighting unit with other units or with other standard shipping containers.

The unit may, in some embodiments, have side covers or panels to provide environmental protection during transport and/or to visually hide the components in the unit.

Preferred embodiments of the invention have been described by way of example only and modifications may be made thereto without departing from the scope of the invention.

Claims (22)

1. A portable flood light unit, comprising: a transportable rigid housing comprising the frame of an intermodal shipping container, the frame defining an envelope having a base, at least two sides, and a top; a power supply comprising a solar panel and a battery, mounted and contained within the frame envelope; and a light source, mounted and contained within the frame envelope and configured to be powered by the power supply; wherein the housing defines a plurality of apertures, and wherein the solar panel is positioned or positionable within the frame envelope to receive solar energy through at least one housing aperture, and wherein the light source is positioned or positionable within the frame envelope to emit light through at least one housing aperture.

2. A portable flood light unit as claimed in claim 1, comprising an array of solar panels.

3. A portable flood light unit as claimed in claim 1 or 2, comprising a solar panel support frame, the frame being attached to the rigid housing and adjustable within the housing envelope to a plurality of positions to position the solar panel(s) to receive solar energy via a housing aperture

4. A portable flood light unit as claimed in claim 3, comprising two solar panel support frames each supporting one or more solar panels, the frames being attached to the rigid housing and independently adjustable within the housing to a plurality of positions to position the solar panels for receive solar energy via a housing aperture

5. A portable flood light unit as claimed in claim 3 or 4, wherein the or each solar panel support frame is adjustable through an arc of between 30 and 75 degrees.

6. A portable flood light unit as claimed in claim 5, wherein the or each solar panel support frame is adjustable through an arc of about 45 degrees.

7. A portable flood light unit as claimed in any preceding claim, comprising a lighting support frame, the frame being attached to the rigid housing and adjustable within the housing to a plurality of positions to position the light source to direct light in a desired direction via a housing aperture.

8. A portable flood light unit as claimed in claim 7, wherein the or each lighting support frame is adjustable through an arc of between 30 and 75 degrees.

9. A portable flood light unit as claimed in claim 8, wherein the or each lighting support frame is adjustable through an arc of about 45 degrees.

10. A portable flood light unit as claimed in any preceding claim, wherein the light source comprises an LED array.

11. A portable flood light unit as claimed in any preceding claim, wherein the light source emits over 60,000 lumens of light.

12. A portable flood light unit as claimed in claim 11, wherein the light source emits over 100,000 lumens of light.

13. A portable flood light unit as claimed in any preceding claim, wherein the housing comprises a base wall, a top wall, two side walls and two end walls, and wherein an aperture is provided in the top wall and each of the side walls.

14. A portable flood light unit as claimed in claim 13, wherein the area of the aperture in the top wall is at least 70% of the area of the top wall.

15. A portable flood light unit as claimed in claim 13 or 14, wherein the area of the aperture in each side wall is at least 70% of the area of each side wall.

16. A portable flood light unit as claimed in any one of claims 13 to 15, wherein an aperture is provided in the each of the end walls, the area of each aperture being at least 70% of the area of each side wall.

17. A portable flood light unit as claimed in any one of claims 1 to 12, wherein the housing frame is reinforced by way of a plurality of bracing struts.

18. A portable flood light unit as claimed in any preceding claim, wherein the housing comprises a plurality of top and bottom twist-lock fittings to facilitate transport and stacking of the lighting unit.

19. A portable flood light unit as claimed in any preceding claim, wherein no part of the light source or power supply projects beyond the envelope of the housing during transport or during use.

20. A portable flood light unit as claimed in any preceding claim, further comprising a power socket powered by the power supply, for receiving and powering an electrical appliance external to the flood light unit.

21. A portable flood light unit as claimed in any preceding claim, comprising a controller and a charging regulator.

22. A portable flood light unit as claimed in any claim 21, wherein the light source can be operated remotely.