Compact universal bidirectional efficient DC-to-DC converter for high capacity alternative energy systems

A high power density DC-to-DC converter, comprising:

• a converter enclosure;
• a converter input and a converter output housed in the converter enclosure, the converter input configured to connect to a DC output of a high power renewable energy source, and the converter output configured to connect to a DC inverter input of a DC-to-AC inverter having an AC inverter output connected to an electrical grid;
• a converter bus bar within the converter enclosure
• an arrangement of high switching frequency Silicon-Carbide power MOSFET semiconductor power modules forming a selectable converter half-bridge or full-bridge in the converter enclosure by reconnection of the converter bus bar;
• and
• a converter forced fluid closed cooling system disposed within the converter enclosure and having one or more chill plates configured to cool the arrangement of high switching frequency Silicon-Carbide power MOSFET semiconductor power modules, wherein the converter forced fluid closed cooling system further comprises:
• a fluid-to-air plated heat exchanger disposed within the converter enclosure for a heated air transfer from the converter enclosure to ambient air;
• a closed-system cooling fluid circulating pump disposed within the converter enclosure for circulating a cooling fluid in the converter forced fluid closed cooling system;
• an expansion tank disposed within the converter enclosure for accumulating heat-expanded cooling fluid within the converter forced fluid closed cooling system;
• and
• an energy storing compact inductor comprising a hollow tube wound inductor for circulation of the cooling fluid within the hollow tube wound inductor.

A method of forming an electric power supply system from a renewable energy source having a DC power output, the method comprising:

• converting the DC power output of the renewable energy source with a high power density DC-to-DC converter, the high power density DC-to-DC converter having a converter input and a converter output housed in a converter enclosure, the converter input of the high power density DC-to-DC converter connected to the DC power output of the renewable energy source, and the converter output of the high power density DC-to-DC converter connected to a DC inverter input of a DC-to-AC inverter having an AC inverter output connected to an electrical grid;
• forming a selectable converter half-bridge or full-bridge in the converter enclosure by reconnection of a converter bus bar within the converter enclosure using an arrangement of high switching frequency Silicon-Carbide power MOSFET semiconductor power modules;
• and
• cooling the arrangement of high switching frequency Silicon-Carbide power MOSFET semiconductor power modules using a converter forced fluid closed cooling system disposed within the converter enclosure, the converter forced fluid closed cooling system including an interconnecting fluid cooled hollow copper tubing and one or more chill plates.