Multi-level DC-DC converter with galvanic isolation and adaptive conversion ratio

A multi-level DC-DC converter comprising:

• an input side to receive a DC power having an input voltage and current;
• an output side to provide power to a load at a desired output voltage and current;
• a plurality of tranformer isolated DC-DC converters connected between the input side and the output side such that the plurality of tranformer isolated DC-DC converters are connected in series on one side and connected in parallel on the other side, each of the plurality of tranformer isolated DC-DC converters including a bridge circuit therein;
• and
• a controller in operable communication with each of the plurality of tranformer isolated DC-DC converters to selectively operate each respective bridge circuit, the controller being programmed to:
• determine a desired value of a voltage conversion ratio between the input voltage and the output voltage;
• and
• control operation of the bridge circuit in each respective tranformer isolated DC-DC converter based on the desired value of the voltage conversion ratio;
• wherein one or more of the tranformer isolated DC-DC converters may be shorted based on the controlled operation of the respective bridge circuits, so as to bypass one or more of the tranformer isolated DC-DC converters and set the voltage conversion ratio to the desired value.

A method of manufacturing a multi-level DC-DC converter, the method comprising:

• providing a plurality of tranformer isolated DC-DC converters, each of the plurality of tranformer isolated DC-DC converters comprising:
• a power transformer comprising a primary winding arranged in an input side converter stage and a secondary winding arranged in an output side converter stage;
• and
• a plurality of switching devices arranged in the input side converter stage, with each of the plurality of switching devices being selectively operable in one of an On state and an Off state to control voltage and current flow to the primary winding;
• connecting the plurality of tranformer isolated DC-DC converters in series on one side of the multi-level DC-DC converter and in parallel on another side of the multi-level DC-DC converter;
• and
• providing a controller that is in operable communication with each of the plurality of tranformer isolated DC-DC converters and the plurality of switching devices therein, with the controller being programmed to operate the plurality of switching devices in each respective tranformer isolated DC-DC converter in one of the On state and the Off state so as to selectively engage and disengage the respective tranformer isolated DC-DC converter.