Feasibility study on photovoltaic module-integrated planar air-core inductors to facilitate embedded power electronics

Photovoltaic modules are typically not optimized for conditions of partial shading. One proposed approach to improve their shade tolerance is to implement maximum power point tracking on different strings of cells within the modules. However, this approach increases the demand for sub-module power converters, which poses a challenge. To address this, researchers have suggested integrating power electronic components directly into the module laminate, or even within the solar cells themselves. Despite these advancements, limited research has focused on integrating the most bulky component: the inductor. This study investigates through simulations whether planar air-core inductors can yield the required properties to support sub-module power conversion. The simulated inductors have an area that is as large as an industrial crystalline silicon solar cell. First, it is shown how the interplay between the different design parameters, such as track spacing, track width, number of turns, and middle gap size, plays an important role in the inductor properties at high frequency. The coil geometries that are simulated yield inductance values between 0.3 μH and 3.2 μH. Subsequently, the feasibility of implementing these inductors into an exemplary DC–DC boost converter is evaluated. To adequately reduce the ripple current, a significant switching frequency of at least several hundred kHz is required. Additionally, at 500 kHz, an inductor thickness of around 0.5 mm is necessary to keep the ohmic losses in the inductor below 2% of the total generated power in standard test conditions. While demonstrating feasible combinations, these findings also present significant challenges.