Ultra-Efficient Intra-Module Balancing DC Optimizer for Solar Systems

Shading, dust, snow, or debris can reduce a solar module's output by 90% even when only a small portion (5% area) is affected. Intra-module imbalance losses from cell mismatch, microcracks, and degradation, add to the problem, resulting in waste of about 10 TWh of potential U.S. solar generation annually, disproportionately affecting residential solar sites. Existing module-level power electronics (MLPE) cannot mitigate these losses. Optivoltĺs current MLPE product, B1, mitigates intra-module losses effectively using novel, patented circuitry to balance power generation across a solar panel. Based on prototype field test data, this sub-module balancing results in a 20-30% annual energy increase for a typical shaded residential PV (photovoltaic) installation. B1, launching late 2024, is efficient enough to be the most economical choice for PV sites with any significant shading, and maintains price parity with premium DC optimizers. In power electronics simulation experiments, Optivolt has discovered a new patent-pending circuit architecture which matches the intra-module balancing functionality of B1, but with significant improvement to cost and unshaded efficiency. These improvements would make sub-module balancing economical to include in almost all (shaded and unshaded) residential, commercial, and utility PV installations, even where existing MLPE would not be economical. Leveraging this new discovery, Optivolt will develop an ultra-efficient sub-module balancing DC optimizer called BX to recover intra-module mismatch losses at minimum cost while maintaining unshaded efficiency of 99%+. At this efficiency, BX could actually allow an attached solar panel to output >100% of the panelĺs standalone power by eliminating at least 1% in cell mismatch and microcrack losses. In this Phase I effort, extensive simulation will further develop the BX design before iterative prototyping, testing, and reliability validation. The primary goals are demonstrating >98.8% efficiency, validating product lifetime, and confirming >30% cost reduction vs. Optivolt's existing B1 optimizer. Commercial Applications and Other Benefits: Deployed at scale, BX would increase U.S. solar generation by 8.5 TWh annually in 2026 while bringing the average homeownerĺs payback period for solar down from 10 to 8 years, accelerating solar adoption. BX would also expand the addressable residential and commercial solar markets by enabling cost-effective PV on more heavily shaded install sites. Series-connected output, low cost, and energy advantage in unshaded systems makes BX a viable (LCoE advantage) for use in large commercial and utility systems where existing MLPE would not be useful or advantageous.