Switched-Capacitor PV DC Optimizer Without Inductors

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Solution Overview

Problem

Conventional DC optimizers for photovoltaic systems require inductors, which are large, expensive, and inefficient, leading to decreased energy conversion efficiency and increased failure rates.

Innovation Solution

A switched capacitor-based DC optimizer replaces inductors with capacitors, using a buck-boost converter to regulate voltage and improve efficiency, reduce size, and enhance reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If inductors are used in DC optimizers, then voltage regulation is achieved, but device size increases, cost increases, and energy conversion efficiency decreases

Engineering Contradiction:

Improveenergy conversion efficiencyVSAvoiddevice size

Core Design Contradiction:

PowerVSVolume of stationary object

Solution Approach 1:

The patent removes the inductor component from the DC optimizer circuit and replaces it with a switched capacitor-based voltage regulation mechanism. This extraction of the inductor eliminates the associated problems of large size, high cost, and energy losses while maintaining the essential voltage regulation function through capacitor charging and discharging cycles controlled by switches.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent substitutes the magnetic field-based inductor with an electric field-based capacitor system. This replacement transitions from magnetic energy storage and transfer to electric energy storage and transfer, achieving voltage regulation through capacitive coupling and switch-controlled charge redistribution, thereby eliminating the bulk and inefficiency of inductive components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If inductors are used in DC optimizers, then voltage regulation is achieved, but failure rate increases

Engineering Contradiction:

Improvefailure rateVSAvoidenergy conversion efficiency

Core Design Contradiction:

ReliabilityVSPower

Solution Approach 1:

By removing the inductor from the circuit, the patent eliminates the primary source of failures associated with magnetic components such as core saturation, winding insulation breakdown, and magnetic interference. The capacitor-based system offers higher reliability as capacitors have no moving parts, no magnetic fields to interfere with, and simpler construction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs capacitors which are generally more reliable, longer-lasting, and easier to replace than inductors. Capacitors have simpler construction without magnetic cores or windings, leading to fewer failure modes and lower maintenance requirements, thus improving overall system reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If inductors are used in DC optimizers, then voltage regulation function is provided, but manufacturing cost increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidphysical size

Core Design Contradiction:

Ease of manufactureVSVolume of stationary object

Solution Approach 1:

The removal of the inductor component directly reduces manufacturing costs by eliminating the need for magnetic core materials, copper windings, and associated assembly processes. Capacitors are generally cheaper to manufacture, have smaller footprints, and can be more easily integrated into printed circuit boards, thereby reducing both material and assembly costs.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the fundamental operating parameters of the voltage regulation circuit from inductive (magnetic field-based) to capacitive (electric field-based). This parameter change enables the use of smaller, cheaper components while achieving the same voltage regulation function through different physical mechanisms, thereby reducing overall device size and manufacturing cost.

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 switched capacitor-based optimizer reduces physical size, cost, and failure rates while increasing energy conversion efficiency and maintaining optimal power output.

Implementation Method 1

each PV module of the plurality of PV modules includes at least one capacitor configured to store the harvested solar energy

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS12444952B2Switched capacitor based DC optimizer for PV module level energy harvesting

Publication Date: 2025.10.14 HANWHA SOLUTIONS CORP

AI summary

A photovoltaic (PV) system may include a plurality of PV modules connected in series, each PV module of the plurality of PV modules being configured to harvest solar energy, and output the harvested solar energy as direct current (DC); at least one inverter connected to the plurality of PV modules, the at least one inverter configured to, receive the DC output by the plurality of PV modules, and convert the DC output into alternating current (AC); each PV module of the plurality of PV modules includes at least one capacitor configured to store the harvested solar energy; and processing circuitry configured to, monitor a charging voltage of the at least one capacitor, and control the DC output of the PV module based on the monitored charging voltage of the at least one capacitor.