Noise-cut LC filter for power converter with overlapping aligned coil patterns

An apparatus comprising:

• a plurality of noise-cut filters having distributed inductances and distributed capacitances;
• a case including first and second split cores, wherein said plurality of noise-cut filters are located between said first and second split cores;
• and
• a resin material located between said noise-cut filters and said split cores for sealing said case;
• wherein each of said plurality of noise-cut filters comprises:
• a first dielectric sheet;
• first and second spiral coil patterns formed on opposite surfaces of said first dielectric sheet, respectively, such that said first and second spiral coil patterns are aligned with each other in a direction perpendicular to a plane of said first dielectric sheet to continuously overlap, said first and second spiral coil patterns comprising a conductive paste;
• a first main circuit pattern comprising a first main circuit conductor bonded to said first spiral coil pattern, said first main circuit conductor having a cross sectional area large enough to allow a desired level of current to flow therethrough, and having substantially the same shape as said first spiral coil pattern;
• a first grounding wire bonded to said second spiral coil pattern formed on the other surface of said first dielectric sheet remote from said first main circuit pattern;
• a second dielectric sheet;
• third and fourth spiral coil patterns formed on opposite surfaces of said second dielectric sheet, respectively, such that said third and fourth spiral coil patterns are aligned with each other in a direction perpendicular to a plane of said second dielectric sheet to continuously overlap, said third and fourth spiral coil patterns comprising a conductive paste;
• a second main circuit pattern comprising a second main circuit conductor bonded to said third spiral coil pattern, said conductor having a cross sectional area large enough to allow a desired level of current to flow therethrough, and having substantially the same shape as said third spiral coil pattern;
• a second grounding wire bonded to said fourth spiral coil pattern formed on the other surface of said second dielectric sheet remote from said second main circuit pattern;
• and
• an insulating sheet which is interposed between said first dielectric sheet carrying said first main circuit pattern and said first grounding wire, and said second dielectric sheet carrying said second main circuit pattern and said second grounding wire thereon;
• wherein one of opposite ends of said first main circuit conductor is connected to one of opposite ends of said second main circuit conductor, such that the other ends of the first and second main circuit conductors are used as an input terminal and an output terminal, respectively.

A power converter comprising:

• a noise-cut filter;
• a rectifier device to which said noise-cut filter is connected at an input terminal thereof;
• and
• a switching device to which said noise-cut filter is connected at an output terminal thereof;
• wherein said noise-cut filter comprises:
• a first dielectric sheet;
• first and second spiral coil patterns formed on opposite surfaces of said first dielectric sheet, respectively, such that said first and second spiral coil patterns are aligned with each other in a direction perpendicular to a plane of said first dielectric sheet to continuously overlap, said first and second spiral coil patterns comprising a conductive paste;
• a first main circuit pattern comprising a first main circuit conductor bonded to said first spiral coil pattern, said first main circuit conductor having a cross sectional area large enough to allow a desired level of current to flow therethrough, and having substantially the same shape as said first spiral coil pattern;
• a first grounding wire bonded to said second spiral coil pattern formed on the other surface of said first dielectric sheet remote from said first main circuit pattern;
• a second dielectric sheet;
• third and fourth spiral coil patterns formed on opposite surfaces of said second dielectric sheet, respectively, such that said third and fourth spiral coil patterns are aligned with each other in a direction perpendicular to a plane of said second dielectric sheet to continuously overlap, said third and fourth spiral coil patterns comprising a conductive paste;
• a second main circuit pattern comprising a second main circuit conductor bonded to said third spiral coil pattern, said second main circuit conductor having a cross sectional area large enough to allow a desired level of current to flow therethrough, and having substantially the same shape as the third spiral coil pattern;
• a second grounding wire bonded to said fourth spiral coil pattern formed on the other surface of said second dielectric sheet remote from said second main circuit pattern;
• and
• an insulating sheet which is interposed between said first dielectric sheet carrying said first main circuit pattern and said first grounding wire, and said second dielectric sheet carrying said second main circuit pattern and said second grounding wire thereon;
• wherein one of opposite ends of said first main circuit pattern is connected to one of opposite ends of said second main circuit pattern, such that the other ends of the first and second main circuit patterns are used as an input terminal and an output terminal, respectively.