Miniaturization and Optimization of a DC–DC Boost Converter for Photovoltaic Application by Designing an Integrated Dual-Layer Inductor Model

For the sake of reducing the size of the power converters for photovoltaic applications, the microelectronics industry knows a permanent race in order to reach out to integrated electronic components with high efficacy and low losses for different applications. This paper presents a detailed study for designing an integrated structure with a dual-layer inductor model associated with two layers of MPP Molypermaloy magnetic cores. This inductor is intended to a DC–DC boost converter for photovoltaic application purposes. With an input of 17 V, 220 V output and supports a maximum current of 7 A on an operating frequency of 500 kHz with an output ripple less than 0.8%. The research covered the impact of coil's conductor thickness on the inductance. The gap effect study reached to determine the optimum gap between coils permit for the better profiteering of the mutual inductance with low losses. The transmission lines method was used to determine the equivalent electrical circuit for the designed dual-layer inductor to investigate the losses due to the parasite-flowing currents, also, to validate the performance and the well operating of the inductor in the application. The study investigated the magnetic behaviour and current density in conductors by numerical simulation governed by Maxwell's equations and solved by finite element method. An algorithm has been associated with the converter to compensate all losses and ensure the stability of the output voltage. The designed inductor has an inductance of 14.2 µH and covering a volume of $$10\;{\text{mm}} \times 10\;{\text{mm}} \times 2.07\;{\text{mm}}$$ .