Ideal Diode Bypass Circuit With Voltage Clamping for PV Module Failure

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Solution Overview

Problem

Failure of one photovoltaic module in a series-connected solar panel system can lead to power loss and potential damage to bypass circuits due to high voltages generated across the bypass circuits.

Innovation Solution

An ideal diode controller with a voltage clamp circuit and a bypass switch that operates in two modes: conducting bypass current when a module fails and clamping voltage to a predefined threshold in normal operation, using a depletion-mode FET to mitigate damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a bypass circuit is arranged in parallel with each photovoltaic module to provide an alternate current path upon module failure, then system reliability is improved, but the bypass circuit is susceptible to breakdown from high voltage generated across it

Engineering Contradiction:

Improvesystem reliabilityVSAvoidhigh voltage damage to bypass circuit

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an ideal diode controller as an intermediary device between the photovoltaic module and the bypass circuit. This controller includes a voltage clamp circuit that actively monitors and limits the voltage across the bypass circuit to a predetermined safe level, preventing high voltage damage while allowing the bypass circuit to function as intended for maintaining system reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The voltage clamp circuit provides beforehand protection by clamping the voltage across the bypass circuit to a predetermined maximum level before dangerous high voltages can develop. This preemptive voltage limiting protects the bypass circuit from breakdown while allowing it to serve its reliability function

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Loss of energy

If a bypass circuit conducts bypass current when a photovoltaic module fails, then power loss is reduced, but the bypass circuit may experience breakdown due to excessive voltage

Engineering Contradiction:

Improvepower lossVSAvoidbypass circuit reliability

Core Design Contradiction:

Loss of energyVSReliability

Solution Approach 1:

The ideal diode controller acts as a protective intermediary that allows bypass current to flow when needed (reducing power loss) while simultaneously clamping the voltage to safe levels (protecting bypass circuit reliability). The controller monitors both current direction and voltage magnitude to provide intelligent protection

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The voltage clamp circuit dynamically changes the voltage parameter across the bypass circuit by clamping it to a predetermined safe level when excessive voltage is detected, while allowing normal voltage operation when the bypass circuit is not conducting high currents. This dynamic parameter control enables the bypass circuit to function reliably under both normal and failure conditions

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system allows the solar power system to continue operating without the failed module by providing an alternate current path and protecting the bypass circuit from excessive voltages, enhancing system reliability and efficiency.

Implementation Method 1

The voltage clamp circuit can be configured to clamp an amplitude of the second voltage to a predefined threshold amplitude relative to an amplitude of the first voltage in the second mode

Methodology Applied

Scientific EffectVoltage clamping:

Implementation Method 2

The bypass switch can operate in a closed state in a first mode in which a first voltage at the anode terminal is greater than or approximately equal to a second voltage at the cathode terminal to conduct a bypass current

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 3

using a depletion-mode FET to mitigate damage

Methodology Applied

Scientific EffectField effect transistor conduction:

Data Source

PatentUS20250338373A1Ideal diode bypass circuit control system

Publication Date: 2025.10.30 TEXAS INSTRUMENTS INC

AI summary

One example circuit includes an ideal diode controller including a voltage clamp circuit, an anode terminal, a cathode terminal, and a control terminal arranged between the anode and the cathode. The circuit also includes a bypass switch controlled by a switch signal provided from the control terminal. The bypass switch can operate in a closed state in a first mode in which a first voltage at the anode terminal is greater than or approximately equal to a second voltage at the cathode terminal to conduct a bypass current. The bypass switch can operate in an open state in a second mode in which the first voltage is less than the second voltage. The voltage clamp circuit can be configured to clamp an amplitude of the second voltage to a predefined threshold amplitude relative to an amplitude of the first voltage in the second mode.