Composite material structure and method for producing composite material structure

Abstract

The present invention provides a composite material structure that prevents electrochemical corrosion from occurring while a portion of a conductor embedded in a conductive resin portion is exposed as a connection portion. The composite material structure includes: a conductive resin portion formed of a conductive reinforcement resin, in which conductive fibers are contained in a base material; a conductor formed of a conductive material and embedded in the conductive resin portion, a portion of the conductor being exposed as a connection portion for electrical connection with another component; and an insulator formed of an insulating material and at least partially embedded in the conductive resin portion to be sandwiched between the conductive reinforcement resin and the conductor, thereby preventing the connection portion of the conductor from contacting the conductive reinforcement resin.

Description

Technical Field

[0001] The present invention relates to a composite material structure in which a conductor is embedded in a conductive resin part formed of a conductive reinforcing resin, and to a composite material structure production method for obtaining the composite material structure. Background Art

[0002] In recent years, with the multi-materialization of vehicle bodies, carbon fiber reinforced reinforced resins such as CFRP (carbon fiber reinforced plastic) and CFRTP (carbon fiber reinforced thermoplastic) have begun to be used in vehicle body structures (for example, refer to Patent Document 1). When such reinforced resins are used for vehicle body structures, there is a problem of ensuring a grounding point, and one possible solution may be, for example, a composite material structure in which a conductor is embedded in a resin portion formed by a reinforced resin, and an electrical connection portion is exposed from the conductor to the outside of the resin as a grounding point. Although it is not intended to ensure a grounding point, Patent Document 1 exemplarily shows a composite material structure in which a connection portion as described above is provided in a conductor, which is embedded in a resin portion formed by a reinforced resin.

[0003] Prior art literature

[0004] Patent Document 1: JP2016-183885A Summary of the invention

[0005] Problems to be solved by the present invention

[0006] In the composite material structure exemplified in Patent Document 1, the resin portion itself in which the conductor is embedded corresponds to a conductive resin portion formed of a conductive reinforced resin containing conductive fibers such as carbon fibers. As a result, as the connection portion and the conductive resin portion are in contact with each other, a contact state equivalent to contact between different metals is generated at, for example, the base of the connection portion where the conductor exposed as the connection portion and the conductive resin portion are in contact with each other. When a liquid such as water reaches this portion, this may cause electrochemical corrosion due to contact between different metals.

[0007] In view of the above problems, an object of the present invention is to provide a composite material structure capable of preventing electrochemical corrosion while exposing a portion of a conductor embedded in a conductive resin portion as a connection portion. Another object of the present invention is to provide a composite material structure production method for obtaining the composite material structure.

[0008] Solution to the problem

[0009] To achieve the above-mentioned object, the present invention provides a composite material structure, comprising: a conductive resin portion formed of a conductive reinforced resin, wherein conductive fibers are contained in a base material; a conductor, which is formed of a conductive material and embedded in the conductive resin portion in a state where a portion of the conductor is exposed to serve as a connection portion for electrical connection with another component; and an insulator, which is formed of an insulating material and at least a portion of which is embedded in the conductive resin portion to be sandwiched between the conductive reinforced resin and the conductor, thereby preventing the connection portion of the conductor from contacting the conductive reinforced resin.

[0010] In order to achieve the above-mentioned purpose, the present invention also provides a method for producing a composite material structure, which comprises: a first step of covering at least a portion of a conductor formed of a conductive material with an insulating material; and a second step of forming a conductive resin portion and an insulator using a conductor covered with an insulating material and a conductive reinforced resin containing conductive fibers in a base material, wherein the conductor is embedded in the conductive resin portion in a state where a portion of the conductor is exposed as a connection portion for electrical connection to another component, and the insulator is at least partially embedded in the conductive resin portion to be sandwiched between the conductive reinforced resin and the conductor, thereby preventing the connection portion of the conductor from contacting the conductive reinforced resin.

[0011] Advantageous Effects of the Invention

[0012] According to the composite material structure and the composite material structure production method as described above, the contact between the connection portion where a part of the conductor is exposed and the conductive reinforcing resin forming the conductive resin portion is prevented by the insulator, which is at least partially embedded in the conductive resin portion to be sandwiched between the conductive reinforcing resin and the conductor. This prevention of contact can avoid a contact state equivalent to contact between different metals at a portion such as the base of the connection portion, thereby preventing electrochemical corrosion. Therefore, according to the above-mentioned composite material structure and composite material structure production method, electrochemical corrosion can be prevented while exposing a part of the conductor embedded in the conductive resin portion as a connection portion. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a schematic perspective view showing a composite material structure of a first embodiment;

[0014] Figure 2 It is shown Figure 1 A schematic diagram of the internal structure of the composite material structure shown in;

[0015] Figure 3 is a schematic perspective view showing a composite material structure of a second embodiment;

[0016] Figure 4 is a schematic cross-sectional view showing a composite material structure of a third embodiment;

[0017] Figure 5 is a schematic perspective view showing a first connection example of the connection portion of the conductor related to the first embodiment;

[0018] Figure 6 is a schematic perspective view showing a second connection example of the connection portion of the conductor related to the first embodiment;

[0019] Figure 7 is a schematic perspective view showing a composite material structure of a fourth embodiment;

[0020] Figure 8 is a schematic perspective view showing a composite material structure of a fifth embodiment;

[0021] Fig. 9 is a schematic perspective view showing a composite material structure of a sixth embodiment;

[0022] Fig.10 is a schematic perspective view showing a composite material structure of a seventh embodiment;

[0023] Fig.11 is a schematic perspective view showing a composite material structure of an eighth embodiment;

[0024] Fig.12 is a schematic cross-sectional view showing a first connection example of a connection portion of a conductor related to the eighth embodiment;

[0025] Fig.13 is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the eighth embodiment;

[0026] Fig.14 is a schematic perspective view showing a composite material structure of a ninth embodiment;

[0027] Fig.15 is a schematic perspective view showing a composite material structure of a tenth embodiment;

[0028] Fig.16 It is along Fig.15 A schematic cross-sectional view taken along line V101-V101 in FIG. Fig.15 The internal structure of the composite structure shown in;

[0029] Fig.17 is a schematic cross-sectional view showing a first connection example of a connection portion of a conductor related to a tenth embodiment;

[0030] Fig.18 is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the tenth embodiment;

[0031] Fig.19is a schematic perspective view showing a composite material structure of an eleventh embodiment;

[0032] Fig. 20 It is along Fig.19 A schematic cross-sectional view taken along line V111-V111 in FIG. Fig.19 The internal structure of the composite structure shown in;

[0033] Fig.21 is a schematic perspective view showing a first connection example of the connection portion of the conductor according to the eleventh embodiment;

[0034] Fig. 22 is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the eleventh embodiment;

[0035] Fig.23 is a schematic perspective view showing a composite material structure of a twelfth embodiment;

[0036] Fig.24 It is along Fig.23 A schematic cross-sectional view taken along line V121-V121 in FIG. Fig.23 The internal structure of the composite structure shown in;

[0037] Fig.25 is a schematic perspective view showing a composite material structure of a thirteenth embodiment;

[0038] Fig.26 It is along Fig.25 A schematic cross-sectional view taken along line V131-V131 in FIG. Fig.25 the internal configuration of the composite structure shown in ; and

[0039] Fig. 27 1 is a schematic diagram showing the flow of a composite material structure production method for obtaining the composite material structure of the first embodiment.

[0040] Reference Mark List

[0041] 1, 2, 3, 4, 5, 6, 7, 8, 9, 100, 110, 120, 130 composite material structure

[0042] 1a Pre-exposed structure

[0043] 11, 81, 91, 101, 111, 121, 131 Conductive resin part

[0044] 11a Conductive fiber

[0045] 11a-1 Conductive fiber sheet

[0046] 11b Substrate

[0047] 12, 22, 42, 62, 72, 82, 92, 102, 112, 122, 132 conductors

[0048] 12a, 102a, 112a, 122a, 132a first conductor

[0049] 12b, 42b, 62b, 72b, 82b, 92b, 102b, 112b, 122b, 132b second conductor

[0050] 12b-1, 62b-1, 72b-1, 92b-1, 102b-1, 112b-1, 132b-1 connection part

[0051] 12b-2, 8a, 100a through hole

[0052] 12b-3 Covered part

[0053] 13, 33, 53, 63, 73, 83, 93, 103, 113, 123, 133 insulator

[0054] 42c, 53a protrusion

[0055] 64, 124 covered wire

[0056] 64a, 124a round terminals

[0057] 72b-2, 92b-2, 132b-2 common terminal

[0058] 74, 94, 134 connectors

[0059] 81a, 91a First plane

[0060] 81b, 91b Second plane

[0061] 81c, 91c upright plane

[0062] 101a, 111a, 121a, 131a surface

[0063] 101b recess

[0064] B1, B8, B10, B11 bolts

[0065] N1, N8, N10, N11 nuts

[0066] W1, W8, W10, W11 Wires with terminals

[0067] W11, W81, W101, W111 Exposed core wire

[0068] W12, W82, W102, W112 round terminals

[0069] WS8, WS10 Insulation Washers

[0070] D101 Depth direction

[0071] Z1 Insulation material

[0072] Z2 Conductive Reinforced Resin

[0073] S11 First step

[0074] S12 Second step

[0075] S121 Pre-exposure step

[0076] S122 Exposure Steps

[0077] S121a Sheet placement steps

[0078] S121b Substrate impregnation step

[0079] S121c Machining / Polishing / Cleaning Steps DETAILED DESCRIPTION

[0080] An embodiment of a composite material structure and a composite material structure production method according to the present invention will be described. Figure 1 and Figure 2 A first embodiment of a composite material structure is described.

[0081] Figure 1 is a schematic perspective view showing the composite material structure of the first embodiment, and Figure 2 It is shown Figure 1 Schematic diagram of the internal structure of the composite structure shown in . Figure 2 Show Figure 1 A schematic exploded perspective view of the composite material structure 1 shown in FIG. Figure 1 Schematic cross-sectional view taken along line V1-V1 in FIG.

[0082] The composite material structure 1 of this embodiment is a structure in which a conductor 12 is embedded in a conductive resin portion 11 and a portion of the conductor 12 is exposed as a connection portion 12 b - 1 for connection with another component. The composite material structure 1 includes a conductive resin portion 11 , a conductor 12 , and an insulator 13 .

[0083] like Figure 2As shown, the conductive resin portion 11 is a portion formed of a conductive reinforcing resin in which conductive fibers 11a are contained in a resin insulating base material 11b. In this embodiment, although the conductive resin portion 11 is shown in the shape of a flat rectangular parallelepiped as an example, its shape is not limited thereto and may be any shape according to its actual application.

[0084] An example of the conductive fiber 11a is a reinforcing fiber having conductivity, such as carbon fiber. Other examples of the reinforcing fiber include aluminum fiber, copper fiber, stainless steel fiber, and the like.

[0085] As the substrate 11b, an insulating resin or a conductive resin can be used. Examples of insulating resins include thermosetting resins, such as epoxy resins, phenols, unsaturated polyesters, vinyl esters, cyanates, polyimides, etc. Examples of insulating resins may also include thermoplastic resins, such as polyamides, polycarbonates, polyphenylene sulfides, polyetheretherketones, etc. Conductive resins are obtained by adding the following additives to the above-mentioned insulating resins to impart conductivity. Examples of additives for imparting conductivity include conductive polymers, such as polythiophene, oligothiophene, polypyrrole, and polyaniline. In addition, examples of additives may also include conductive fillers, such as carbon-based, metal-based, metal-oxide-based, metal-coated, and metal-oxide-coated conductive fillers.

[0086] In this embodiment, if Figure 2 As shown, in order to incorporate the conductive fibers 11a into the base material 11b, the laminate of the conductive fiber sheet 11a-1 formed of the conductive fibers 11a is impregnated with the molten base material 11b. However, the method of incorporating the conductive fibers 11a into the base material 11b is not limited thereto, and for example, fiber fragments obtained by pulverizing the conductive fibers 11a may be kneaded into the molten base material 11b.

[0087] The conductor 12 is a portion formed of a conductive material, and is embedded in the conductive resin portion 11 in a state where a portion of the conductor 12 is exposed as a connection portion 12b-1 for electrical connection with another component. In this embodiment, the conductor 12 includes: a first conductor 12a completely embedded in the conductive resin portion 11; and a second conductor 12b, which is bonded to the first conductor 12a within the conductive resin portion 11, and a portion of the second conductor 12b is the connection portion 12b-1. The second conductor 12b is an electrode connected to another component such as an electric wire, as will be described later.

[0088] In this embodiment, as an example, the first conductor 12a and the second conductor 12b of the conductor 12 are shown in a rectangular flat plate shape. However, the shape is not limited to the rectangular flat plate shape, and the first conductor and the second conductor may each be any shape. In this embodiment, the first conductor 12a embedded in the conductive resin portion 11 is shown as a rectangular flat plate along the shape of the conductive resin portion 11, as shown in FIG. Figure 1 The stereogram and Figure 2 On the other hand, Figure 2 The cross-sectional view of FIG. 1 shows the first conductor 12a in a corrugated form to show that the first conductor 12a can also be in any shape within the conductive resin portion 11 regardless of the shape of the conductive resin portion 11. In addition, the second conductor 12b having a portion as a connection portion 12b-1 connected to another component can be in any shape that allows connection to another component such as an electric wire.

[0089] Examples of the material of the first conductor 12a include carbon fiber and the following metal materials generally used as materials for conductive parts. That is, examples of the metal material include aluminum, copper, gold, other metals and alloys thereof, etc. The shape of the first conductor 12a may be any shape as described above, and may be, for example, a plate, a foil, a sheet woven from metal fibers, a mesh made of metal wires, a wire, a rod, a tube, etc.

[0090] Examples of the material of the second conductor 12b used as an electrode include metal materials such as aluminum, copper, gold, other metals and alloys thereof, etc. In this embodiment, the second conductor 12b is shown in a rectangular flat plate shape. Figure 1 and Figure 2 However, the shape of the second conductor is not limited to the shape described above, and may be other shapes such as the shape of a round terminal, etc., as long as it allows connection with another component such as an electric wire.

[0091] In this embodiment, the first conductor 12a and the second conductor 12b as described above are combined in the conductive resin portion 11 with their ends in surface contact with each other to form the conductor 12. A method of combining them may include general combining methods such as melt combining, solid state combining, soldering, adhesion, and mechanical combining such as crimping, riveting, bolting, and the like.

[0092] The insulator 13 is formed of an insulating material and is a portion partially embedded in the conductive resin portion 11 to be sandwiched between the conductive reinforcing resin and the conductor 12, thereby preventing the connection portion 12b-1 of the conductor 12 from contacting the conductive reinforcing resin forming the conductive resin portion 11. In this embodiment, as an example, the insulator 13 is shown in a rectangular parallelepiped shape. This shape is an example of a shape that matches the second conductor 12b including a rectangular flat plate shape. However, the shape of the insulator 13 is not limited thereto, and may be any shape as long as it can be sandwiched between the conductive reinforcing resin forming the conductive resin portion 11 and the conductor 12.

[0093] The insulating material forming the insulator 13 may be any material capable of ensuring insulation, and examples thereof include resins, rubbers, elastomers, and ceramics. In the case where the insulator 13 is formed of a resin, rubber, or elastomer, its forming method may include injection molding, extrusion molding, blow molding, vacuum molding, pressure molding, compression molding, casting molding, foam molding, hot melt molding, potting, and the like. In the case where the insulator 13 is formed of ceramics, its forming method may include machining, and the like. The second conductor 12b of the conductor 12 is press-fitted into the insulator 13 formed in the manner described above, so that the insulator 13 is attached to the conductor 12. In addition, in the case where the insulator 13 is formed of a resin, rubber, or elastomer, the surface of the second conductor 12b of the conductor 12 may be coated with these materials to simultaneously perform the formation of the insulator 13 and the attachment of the insulator 13 to the conductor 12.

[0094] In this embodiment, the above-mentioned conductive resin part 11, conductor 12 and insulator 13 are combined in the manner described below to form the composite material structure 1. First, a part of the insulator 13 is made to protrude from one end face which is a surface of the conductive resin part 11 formed into a rectangular parallelepiped. The conductor 12 includes a connecting portion 12b-1 corresponding to a portion of the second conductor 12b that further protrudes from a part of the insulator 13 that protrudes from the conductive resin part 11 and is exposed.

[0095] In another embodiment, the insulator 13 may be configured not to protrude from one end face of the conductive resin portion 11 and have an exposed surface flush with the one end face. In this case, the connection portion 12b-1 of the conductor 12 is configured to protrude from the exposed surface of the insulator 13 flush with the one end face of the conductive resin portion 11.

[0096] Next, we will refer to Figure 3 A composite material structure according to a second embodiment is described.

[0097] Figure 3 is a schematic perspective view showing the composite material structure of the second embodiment. Figure 3 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. Figure 1 and Figure 2 The same reference numerals are used to designate the components in the drawings, and in the following, repeated descriptions of these equivalent components are omitted.

[0098] In the composite material structure 2 of this embodiment, unlike the conductor 12 of the above-described first embodiment which is composed of two parts bonded together, the conductor 22 is a single part. In this embodiment, the conductor 22 as a rectangular flat plate embedded in the conductive resin part 11 is extended to the outside of the conductive resin part 11 as it is, and is exposed to provide a connection part 22b-1 in a state where a part of the conductor 22 protrudes from the insulator 13. In this embodiment, the conductor 22 has a thickness and strength sufficient to function as an electrode including the connection part 22b-1 for connection with another part, and therefore, a part of the conductor 22 functions as an electrode, thus eliminating the need to provide a separate electrode as in the first embodiment.

[0099] Next, we will refer to Figure 4 A composite material structure according to a third embodiment is described.

[0100] Figure 4 is a schematic cross-sectional view showing the composite material structure of the third embodiment. Figure 4 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. Figure 1 and Figure 2 The components in FIG. 1 are shown with the same figure marks, and in the following, repeated descriptions about those components are omitted.

[0101] In the composite material structure 3 of this embodiment, the insulator 33 is formed to cover not only a part of the second conductor 12b of the conductor 12, but also the entire first conductor 12a including the part combined with the second conductor 12b. That is, in this embodiment, the entire embedded portion of the conductor 12 embedded in the conductive resin portion 11 is insulated by the insulator 33 so as not to come into contact with the conductive reinforcing resin forming the conductive resin portion 11. Therefore, the embedded portion of the conductor 12 embedded in the conductive resin portion 11 can be used not only as a chassis ground but also as a circuit pattern. In this case, various electrical / electronic components connected to the conductor 12 as a circuit pattern can also be embedded in the conductive resin portion 11.

[0102] Next, two connection examples of connecting another component to the connection portions 12b-1, 22b-1 of the conductors 12, 22 of the above-mentioned first to third embodiments will be described. These connection examples are common between the first embodiment and the third embodiment, so the following description is given with reference to the composite material structure 1 of the first embodiment as a representative example.

[0103] Figure 5 1 is a schematic perspective view showing a first connection example of the connection portion of the conductor according to the first embodiment.

[0104] In the first connection example, a through hole 12b-2 for connection is provided at the connection portion 12b-1 of the conductor 12 of the composite material structure 1. Another component is fastened and connected to the connection portion 12b-1 by a bolt B1 inserted through the through hole 12b-2 and a nut N1 screwed to the bolt B1. Examples of another component in this example include a bus bar formed of a metal plate, an electric wire including a connection component at its end, the connection component such as a round terminal that can be fastened using the bolt B1 and the nut N1, etc.

[0105] As a modification of the first connection example, for example, a screw hole into which the bolt B1 can be screwed may be provided instead of the through hole 12b-2, or the nut N1 may be welded and fixed to the connection portion 12b-1. In addition, as another example, the bolt B1 may be welded and fixed to the connection portion 12b-1 in a state where the threaded portion passes through the through hole 12b-2 and protrudes therefrom.

[0106] Figure 6 1 is a schematic perspective view showing a second connection example of the connection portion of the conductor according to the first embodiment.

[0107] In the second connection example, the exposed core wire W11 on one end side of the electric wire W1 with a terminal as another component is welded and fixed to the connection portion 12b-1 of the conductor 12 of the composite structure 1. A round terminal W12 for connection with an electric / electronic device is crimped to the other end side of the electric wire W1 with a terminal.

[0108] As a modification of the second connection example, instead of the wire W1 with terminal, one end of the connector terminal of the connector may be welded and fixed, for example. In addition, as an example of a connection method for connection of the connection portion 12b-1, ultrasonic welding, crimping, etc. may be used instead of welding.

[0109] According to the composite material structures 1, 2, 3 of the first to third embodiments described above, the following advantageous effects can be obtained. That is, according to the composite material structures 1, 2, 3 described above, the insulator 13 can prevent contact between the connection portion 12b-1, 22b-1 in which a part of the conductor 12, 22 is exposed and the conductive reinforcing resin forming the conductive resin portion 11. The insulator 13 is a portion at least partially embedded in the conductive resin portion 11 in a state where the insulator 13 is sandwiched between the conductive reinforcing resin and the conductors 12, 22. With the insulator 13 sandwiched in this manner, contact between the connection portion 12b-1, 22b-1 and the conductive reinforcing resin is prevented.

[0110] Unlike the first to third embodiments, if there is no insulator 13, the base of the connection parts 12b-1, 12b-1 is exposed in a state of contact with the conductive reinforcing resin. Since the contact between the connection parts 12b-1, 22b-1 and the conductive reinforcing resin is a contact state equivalent to the contact between different metals, when water or the like reaches the base, electrochemical corrosion may occur.

[0111] In contrast, in the first to third embodiments, the insulator 13 prevents the contact state equivalent to the contact between different metals at the base of the connection portion 12b-1, 22b-1, thereby preventing electrochemical corrosion. Therefore, the composite material structures 1, 2, 3 according to the first to third embodiments prevent electrochemical corrosion while being able to expose a portion of the conductor 12, 22 embedded in the conductive resin portion 11 as the connection portion 12b-1, 22b-1.

[0112] In the first to third embodiments, a portion of the insulator 13 protrudes from the surface of the conductive resin portion 11, and the connection portions 12b-1, 22b-1 of the conductors 12, 22 are exposed from the protruding portion. According to this configuration, the reliability of preventing the contact between the connection portions 12b-1, 22b-1 and the conductive reinforcing resin can be improved, thereby further preventing electrochemical corrosion.

[0113] Furthermore, in the first to third embodiments, the connection portions 12b-1, 22b-1 are portions of the conductors 12, 22 that protrude from the portion of the insulator 13 that is exposed to the conductive resin portion 11. According to this configuration, since the connection portions 12b-1, 22b-1 protrude from the insulator 13, attachment of an electric wire or the like to the connection portions 12b-1, 22b-1 can be performed with good operability.

[0114] Furthermore, in the first embodiment and the third embodiment, the conductor 12 includes a first conductor 12a completely embedded in the conductive resin portion 11 and a second conductor 12b bonded to the first conductor 12a and partially formed as a connecting portion 12b-1. According to this configuration, the conductor 12 is divided into the first conductor 12a and the second conductor 12b, the first conductor 12a is completely embedded in the conductive resin portion 11 to serve as a chassis ground, and the second conductor 12b is partially formed as the connecting portion 12b-1. Since the conductor is divided in this way, the respective portions of the conductor 12 can be formed of a conductive material suitable for the purpose of use.

[0115] Furthermore, in the first to third embodiments, the second conductor 12b is an electrode. This configuration is preferred because, for example, Figure 5 and Figure 6 The connection example shown in FIG. 1 makes it easy to connect an electric wire or the like as another component.

[0116] Next, we will refer to Figure 7 A composite material structure according to a fourth embodiment is described.

[0117] Figure 7 is a schematic perspective view showing the composite material structure of the fourth embodiment. Figure 7 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. Figure 1 and Figure 2 The same reference numerals are used to designate the components in the drawings, and repeated descriptions of these equivalent components are omitted hereinafter.

[0118] In the composite material structure 4 of this embodiment, the second conductor 42b of the conductor 42 connected to the first conductor 12a and partially exposed is provided with a protrusion 42c, and the protrusion 42c is arranged to be in close contact with the insulator 13 within the conductive resin part 11. The protrusion 42c is arranged in the shape of a rectangular parallelepiped and is arranged to cross the middle of the strip-shaped second conductor 42b, and one side surface of the protrusion 42c along the length direction is in close contact with the insulator 13.

[0119] In the composite material structure 4 of the fourth embodiment described above, it is also possible to prevent electrochemical corrosion while exposing a portion of the conductor 42 embedded in the conductive resin portion 11 as the connection portion 12 b - 1 , as in the first embodiment described above.

[0120] Furthermore, according to this embodiment, the conductor 42 is provided with the protrusion 42c, which is arranged to be in close contact with the insulator 13 within the conductive resin portion 11, thereby reinforcing the contact between the conductor 42 and the insulator 13. Furthermore, since the protrusion 42c serves as a stopper against an external force applied to the connecting portion 12b-1 in a direction to pull the conductor 42 out of the insulator 13, the strength of the composite material structure 4 against such an external force can be improved.

[0121] As a modification of the fourth embodiment, the shape of the protrusion 42c of the conductor 42 may be changed from a rectangular parallelepiped to a shape other than a rectangular parallelepiped, such as a polygonal column, a cylinder, etc. In another modification, as a configuration for strengthening the contact between the conductor 42 and the insulator 13 and serving as a stopper, the portion of the conductor 42 embedded in the insulator 13 may have a concave-convex shape, in which the protrusions and depressions relative to the direction intersecting the direction of the external force are alternately arranged along the direction of the external force. In another example, the portion of the conductor 42 embedded in the insulator 13 may be provided with a through hole, and the interior of the through hole may also be filled with an insulating material forming the insulator 13.

[0122] Next, we will refer to Figure 8 A composite material structure according to a fifth embodiment is described.

[0123] Figure 8 is a schematic perspective view showing the composite material structure of the fifth embodiment. Figure 8 In, with Figure 1 and Figure 2 Components equivalent to those of the first embodiment shown in FIG. 1 are shown with Figure 1 and Figure 2 The same reference symbols are used for the components in the drawings, and repeated descriptions about these equivalent components are omitted hereinafter.

[0124] In the composite material structure 5 of this embodiment, the end surface of the insulator 53 opposite to the connecting portion 12 b - 1 is provided with a single protrusion 53 a extending over the entire circumference.

[0125] Also, in the composite material structure 5 of the fifth embodiment described above, electrochemical corrosion can be prevented while a part of the conductor 12 embedded in the conductive resin portion 11 is exposed as the connection portion 12 b - 1 , as in the first embodiment described above and the like.

[0126] Furthermore, according to this embodiment, by providing the protrusions 53 a on the surface of the insulator 53 , the contact between the conductive resin portion 11 and the insulator 53 can be strengthened, thereby improving the strength of the composite material structure 5 .

[0127] As a modification of the fifth embodiment, the protrusion 53a may be formed at a position other than the end of the insulator 53, such as at the center of the insulator 53, and / or a plurality of protrusions 53a may be formed. In another example, the protrusion 53a may be provided at a portion of the insulator 53 in the circumferential direction instead of being provided on the entire circumference of the insulator 53, or the protrusion 53a may be provided intermittently in the circumferential direction.

[0128] Next, we will refer to Fig. 9 A composite material structure according to a sixth embodiment is described.

[0129] Fig. 9 is a schematic perspective view showing the composite material structure of the sixth embodiment. Fig. 9 In, with Figure 1 and Figure 2 Components equivalent to those of the first embodiment shown in FIG. 1 are shown with Figure 1 and Figure 2 The same reference symbols are used for the components in the drawings, and repeated descriptions about these equivalent components are omitted hereinafter.

[0130] In the composite material structure 6 of this embodiment, one end of the core wire of the covered electric wire 64 is bonded to the first conductor 12a embedded in the conductive resin part 11 within the conductive resin part 11. Examples of the bonding method herein include welding, ultrasonic welding, crimping, etc. In a state where a portion of the covering of the covered electric wire 64 remains within the conductive resin part 11, the other end side of the covered electric wire 64 protrudes from the conductive resin part 11, and a portion of the core wire is exposed at the other end side. As another component, a round terminal 64a for connection with an electric / electronic device is crimped and connected to the exposed core wire.

[0131] In the composite material structure 6 including the covered electric wire 64 as described above, the second conductor 62b constituting the conductor 62 together with the first conductor 12a is the core wire of the covered electric wire 64. In addition, the exposed core wire on the other end side of the covered electric wire 64 is a connection portion 62b-1 for connection with a round terminal 64a as another component. In addition, the covering of the covered electric wire 64 corresponds to the insulator 63 partially embedded in the conductive resin portion 11 to be sandwiched between the conductive reinforcement resin and the conductor 62, thereby preventing the connection portion 62b-1 of the conductor 62 from contacting the conductive reinforcement resin.

[0132] Also in the composite material structure 6 of the sixth embodiment described above, electrochemical corrosion can be prevented while a part of the conductor 62 embedded in the conductive resin portion 11 is exposed as the connection portion 62 b - 1 , as in the first embodiment described above and the like.

[0133] Furthermore, in this embodiment, since the insulator 63 is a coating of the coated electric wire 64 whose core wire is the second conductor 62b, it is sufficient to provide only the coated electric wire 64 and there is no need to form a separate insulator, so the number of components can be reduced, and thus this embodiment is preferred. Furthermore, since the size of the boundary between the conductive resin portion 11 and the insulator 63 can be reduced to about the thickness size of the coated electric wire 64, it is possible to prevent the strength of the composite material structure 6 from being reduced due to embedding the insulator 63 in the conductive resin portion 11, and thus this embodiment is preferred in this respect.

[0134] As a modification of the sixth embodiment, the covered electric wire 64 bonded to the first conductor 12a can be divided into a plurality of covered electric wires according to the required current capacity, thereby reducing the size of each of the covered electric wires. The plurality of covered electric wires are arranged in a one-dimensional arrangement in which a plurality of covered electric wires are arranged side by side, and the respective ends are bonded to the first conductor 12a. In this modification, since the size of one covered electric wire is reduced, the conductive resin portion 11 can be thinned by a corresponding amount. In another example, a flat cable can be used instead of a plurality of covered electric wires to further thin the conductive resin portion 11.

[0135] Next, we will refer to Fig.10 A composite material structure according to a seventh embodiment is described.

[0136] Fig.10 is a schematic perspective view showing the composite material structure of the seventh embodiment. Fig.10 In, with Figure 1 and Figure 2 Components equivalent to those of the first embodiment shown in FIG. 1 are shown with Figure 1 and Figure 2 The same reference symbols are used for the components in the drawings, and repeated descriptions about these equivalent components are omitted hereinafter.

[0137] In the composite material structure 7 of this embodiment, inside the conductive resin part 11, the first conductor 12a embedded in the conductive resin part 11 is bonded to the common end 72b-2 of the three connector terminals of the connector 74, and the common end 72b-2 corresponds to the opposite side of the other terminal connection side of the connector terminal (that is, the other terminal connection side is the side for connection with the other terminal). The connector 74 is arranged so that its connection side for connection with another connector protrudes from the conductive resin part 11, wherein a part of the connector housing is held in the conductive resin part 11, and at this connection side, the other terminal connection side of the connector terminal is exposed from the connector housing.

[0138] In the composite material structure 7 including the connector 74 as described above, the second conductor 72b constituting the conductor 72 together with the first conductor 12a corresponds to three connector terminals electrically connected by the common terminal 72b-2. In addition, the other terminal connection side of these three connector terminals is a connection portion 72b-1 for connection with another terminal as another component. In addition, the connector housing of the connector 74 is an insulator 73, which is partially embedded in the conductive resin portion 11 to be sandwiched between the conductive reinforcement resin and the conductor 72 to prevent the connection portion 72b-1 of the conductor 72 from contacting the conductive reinforcement resin.

[0139] Also in the composite material structure 7 of the seventh embodiment described above, electrochemical corrosion can be prevented while a part of the conductor 72 embedded in the conductive resin portion 11 is exposed as the connection portion 72 b - 1 , as in the first embodiment described above and the like.

[0140] In addition, in this embodiment, since the insulator 73 is a connector housing of the connector 74, in which the connector terminal is the second conductor 72b, it is sufficient to provide only the connector 74 and there is no need to form a separate insulator, so the number of components can be reduced, and therefore this embodiment is preferred. In addition, since the connector terminal originally having a connection structure for connecting to another terminal as another component is used as the second conductor 72b, it is possible to easily connect and disconnect another component, so this embodiment is also preferred in this respect.

[0141] As a modification of the seventh embodiment, the number of connector terminals coupled to the first conductor 12a may not be three, for example, it may be one, two or more than three. In another example, a plurality of connector terminals may be coupled to the first conductor 12a individually, instead of being placed together through the common end 72b-2. In another example, the first conductor 12a may be divided into a plurality of conductors, and the connector terminals may be independently connected to the plurality of conductors, respectively.

[0142] Next, we will refer to Fig.11 A composite material structure according to an eighth embodiment is described.

[0143] Fig.11 is a schematic perspective view showing the composite material structure of the eighth embodiment. Fig.11 middle, Figure 1 and Figure 2 Components equivalent to those of the first embodiment shown in FIG. 1 are shown with Figure 1 and Figure 2 The same reference symbols are used for the components in the drawings, and repeated descriptions about these equivalent components are omitted hereinafter.

[0144] In the composite material structure 8 of this embodiment, the conductive resin portion 81 includes a stepped portion including a first plane 81a, a second plane 81b arranged one step lower from the first plane 81a, and a vertical plane 81c connecting the first plane and the second plane. The insulator 83 is formed in a stepped shape similar to the conductive resin portion 81 and embedded in the conductive resin portion 81 so that a portion of the insulator 83 is exposed from the second plane 81b of the conductive resin portion 81 to the vertical plane 81c. The second conductor 82b constituting the conductor 82 together with the first conductor 12a includes a connecting portion 82b-1, which is a portion further exposed from the portion of the insulator 83 exposed from the second plane 81b of the conductive resin portion 81.

[0145] In this embodiment, the insulator 83 is formed so that a part thereof is exposed flush with the second plane 81b of the conductive resin portion 81. Furthermore, the second conductor 82b constituting the conductor 82 includes a connection portion 82b-1 which is further exposed in a flush manner with the surface of the portion of the insulator 83 exposed from the second plane 81b of the conductive resin portion 81. That is, in this embodiment, the second plane 81b of the conductive resin portion 81, the exposed surface of the insulator 83 exposed from the second plane 81b, and the surface of the connection portion 82b-1 are flush with each other.

[0146] Next, two connection examples of connecting another component to the connection portion 82b-1 of the conductor 82 of the above-described eighth embodiment will be described.

[0147] Fig.12 1 is a schematic cross-sectional view showing a first connection example of the connection portion of the conductor according to the eighth embodiment.

[0148] In the first connection example, a portion of the connection portion 82b-1 of the composite material structure 8 including the second conductor 82b constituting the conductor 82 together with the first conductor 12a is provided with a through hole 8a for connection. The through hole 8a is provided to penetrate the connection portion 82b-1, the insulator 83 located below, and the conductive resin portion 81 located further below and including the conductive fiber sheet 11a-1. Another component is fastened and connected to the connection portion 82b-1 by a bolt B8 passing through the through hole 8a, a nut N8 screwed to the bolt B8, and an insulating washer WS8 sandwiched between the nut N8 and the conductive resin portion 81. Examples of another component in this example include a bus bar formed of a metal plate, an electric wire including a connection component such as a round terminal at its end, which can be fastened using a bolt B8, a nut N8, an insulating washer WS8, and the like.

[0149] In addition, as a modification of the first connection example, for example, a screw hole into which the bolt B8 can be screwed can be provided instead of the through hole 8a, or a connector terminal can be provided as an electrode, the terminal shape of which enables another component to be attached to and detached from the connecting portion 82b-1.

[0150] Fig.13 2 is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the eighth embodiment.

[0151] In the second connection example, the exposed core wire W81 on one end side of the electric wire W8 with a terminal as another component is welded and fixed to the connection portion 82b-1 of the second conductor 82b constituting the conductor 82 together with the first conductor 12a of the composite structure 8. A round terminal W82 for connection with an electric / electronic device is crimped to the other end side of the electric wire W8 with a terminal.

[0152] As a modification of the second connection example, instead of the wire W8 with terminal, one end of the connector terminal of the connector may be welded and fixed, for example. In another example, as a connection method for connection of the connection portion 82b-1, ultrasonic welding, crimping, etc. may be used instead of welding.

[0153] Also in the composite material structure 8 of the eighth embodiment described above, electrochemical corrosion can be prevented while a part of the conductor 82 embedded in the conductive resin portion 81 is exposed as the connection portion 82 b - 1 , as in the first embodiment described above and the like.

[0154] Furthermore, in this embodiment, the insulator 83 is exposed at the second plane 81b of the step-shaped conductive resin portion 81, which is an easily accessible portion, and the connection portion 82b-1 of the conductor 82 is arranged to be further exposed from the exposed portion of the insulator 83. In the case where the connection portion 82b-1 is placed at such a position, for example, attachment of an electric wire or the like to the connection portion 82b-1 can be performed with good operability.

[0155] Furthermore, in this embodiment, the insulator 83 is formed so that a portion thereof is exposed flush with the surfaces such as the second plane 81b and the upright plane 81c of the conductive resin portion 81. Furthermore, the conductor 82 includes a connection portion 82b-1 which is a portion exposed from the portion of the insulator 83 exposed from the second plane 81b. According to this configuration, since the insulator 83 is flush with the surface of the conductive resin portion 81 without protruding therefrom, the size of the composite material structure 8 can be reduced by that amount.

[0156] Furthermore, in this embodiment, the conductor 82 includes a connection portion 82b-1 which is a portion exposed in a manner flush with the surface of the portion of the insulator 83 exposed from the second plane 81b of the conductive resin portion 81. According to this configuration, since the connection portion 82b-1 is flush with the surface of the insulator 83 and does not protrude therefrom, the size of the composite material structure 8 can be reduced by that amount. Furthermore, since the insulator 83 including the surface flush with the connection portion 82b-1 can support the entire connection portion 82b-1, the mechanical strength of the connection portion 82b-1 against external forces can be improved. In view of the improvement in the mechanical strength of the connection portion 82b-1, the thickness of the connection portion 82b-1 of the conductor 82 can also be reduced, and a conductive material that is excellent in electrical characteristics but slightly inferior in mechanical strength can also be used as a material for forming the connection portion 82b-1 of the conductor 82.

[0157] Next, we will refer to Fig.14 A composite material structure according to a ninth embodiment is described.

[0158] Fig.14 A schematic perspective view of a composite material structure of a ninth embodiment is shown. Fig.14 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. Figure 1 and Figure 2 The same reference numerals are used to designate the components in the drawings, and in the following, repeated descriptions of these equivalent components are omitted.

[0159] In the composite material structure 9 of the present embodiment, similar to the eighth embodiment, the conductive resin portion 91 includes a stepped portion including a first plane 91a, a second plane 91b, and a vertical plane 91c. The connector 94 is embedded in the conductive resin portion 91 so that a portion of the connector 94 is exposed to the vertical plane 91c across the second plane 91b. The common end 92b-2 of the four connector terminals of the connector 94 is bonded to the first conductor 12a in the conductive resin portion 91, and the common end 92b-2 is located on the opposite side of the other terminal connection side of the connector terminal. The connection side of the connector 94 for connecting to another connector is exposed from the conductive resin portion 91 in a state where a portion of the connector housing remains in the conductive resin portion 91, and at this connection side, the other terminal connection side of the connector terminal is exposed from the connector housing.

[0160] In the composite material structure 9 including the connector 94 as described above, the second conductor 92b constituting the conductor 92 together with the first conductor 12a corresponds to four connector terminals electrically connected by the common terminal 92-2. In addition, the other terminal connection side of these four connector terminals is a connection portion 92b-1 for connecting to another terminal as another component. In addition, the connector housing of the connector 94 is an insulator 93, which is partially embedded in the conductive resin portion 91 to be sandwiched between the conductive reinforcement resin and the conductor 92, so that the connection portion 92b-1 of the conductor 92 does not contact the conductive reinforcement resin.

[0161] Also in the composite material structure 9 of the above-described ninth embodiment, electrochemical corrosion can be prevented while a portion of the conductor 92 embedded in the conductive resin portion 91 is exposed as the connection portion 92 b - 1 , as in the above-described first embodiment and the like.

[0162] In addition, similar to the above-mentioned seventh embodiment, in this embodiment, since the insulator 93 is the connector housing of the connector 94, the number of components can be reduced, so this embodiment is preferred. In addition, similar to the above-mentioned seventh embodiment, since the connector terminal is used as the second conductor 92b, it is easy to connect and disconnect another component, so this embodiment is also preferred in this respect. As a modification of the ninth embodiment, similar to the above-mentioned seventh embodiment, the number of connector terminals coupled to the first conductor 12a may not be four, for example, it may be one, two, three or more than four. In another example, a plurality of connector terminals may each be coupled to the first conductor 12a, rather than being placed together through the common end 98b-2. In another example, the first conductor 12a may be divided into a plurality of conductors, and the connector terminals may be independently connected to the plurality of conductors, respectively.

[0163] Next, we will refer to Fig.15 and Fig.16 A composite material structure according to a tenth embodiment is described.

[0164] Fig.15 is a schematic perspective view showing a composite material structure of a tenth embodiment, and Fig.16 It is along Fig.15 A schematic cross-sectional view taken along line V101-V101 in FIG. Fig.15 The internal structure of the composite structure shown in Fig.15 and Fig.16 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. Figure 1 and Figure 2 The same figure marks are shown in the figures, and in the following, repeated descriptions about these equivalent components are omitted.

[0165] In the composite material structure 100 of this embodiment, a square cylindrical concave portion 101b is provided at a wide surface 101a of a conductive resin portion 101 formed into a flat rectangular parallelepiped. Similar to the above-described first embodiment, the conductive resin portion 101 is formed of a conductive reinforcing resin in which a molten base material 11b is impregnated with a laminate of a conductive fiber sheet 11a-1 formed of conductive fibers 11a. The concave portion 101b is formed to pass through a portion of the conductive fiber sheet 11a-1. The shape of the concave portion 101b is not limited to a square cylindrical shape, and it may be a polygonal cylindrical shape other than a square cylindrical shape, or may be a cylindrical shape, as long as it is a cylindrical shape.

[0166] The conductor 102 in the composite material structure 100 includes a first conductor 102a and a second conductor 102b. The first conductor 102a is embedded in the conductive resin part 101 as a whole so as to be sandwiched between the conductive fiber sheets 11a-1 of the stack of conductive fiber sheets 11a-1. The second conductor 102b is also formed into a quadrilateral plate shape, and is placed near the center of the first conductor 102a and combined with it in a state where a part of the second conductor 102b is exposed as a connecting part 102b-1 at the bottom of the recess 101b in the conductive resin part 101. Therefore, the conductor 102 is embedded in the conductive resin part 101 so that a part of the second conductor 102b is exposed as a connecting part 102b-1 to form the bottom of the recess 101b. The shape of the second conductor 102b of the conductor 102 is not limited to the quadrilateral plate shape. The shape of the second conductor 102b may be another shape such as a circular plate shape as long as a part of the second conductor 102b can constitute the bottom of the recess 101b in the insulating resin portion 101. As a modification of the conductor 102, the second conductor 102b may be omitted, and instead of the second conductor 102b, a part of the first conductor 102a may be exposed at the bottom of the recess 101b.

[0167] The insulator 103 of the composite material structure 100 is embedded in the conductive resin part 101, and is sandwiched between the conductive reinforcement resin and the second conductor 102b in a state where a part of the insulator 103 is exposed at the bottom side of the inner peripheral surface of the recess 101b in the depth direction D101 of the recess 101b. The insulator 103 is sandwiched between the conductive reinforcement resin and the second conductor 102b to cover the outer peripheral portion over the entire circumference of the second conductor 102b, thereby preventing the connection portion 102b-1 of the second conductor 102b from contacting the conductive reinforcement resin. Herein, the insulator 103 is not limited to being partially exposed at the bottom side of the inner peripheral surface of the recess 101b, and it may be exposed at the entire circumferential surface of the inner peripheral surface of the recess 101b, that is, the inner peripheral surface of the insulator 103 may constitute the recess 101b itself.

[0168] Next, two connection examples of connecting another component to the connection portion 102 b - 1 of the conductor 102 of the above-described tenth embodiment will be described.

[0169] Fig.17 : is a schematic cross-sectional view showing a first connection example of the connection portion of the conductor related to the tenth embodiment.

[0170] In the first connection example, at a portion of the composite material structure 100 where the connection portion 102b-1 of the second conductor 102b constituting the conductor 102 is provided, a through hole 100a for connection is provided. The through hole 100a is provided to pass through the connection portion 102b-1, the first conductor 102a located below, and the conductive resin portion 101 located further below and including the conductive fiber sheet 11a-1. Another component is fastened and connected to the connection portion 102b-1 by a bolt B10 inserted through the through hole 100a, a nut N10 screwed to the bolt B10, and an insulating washer WS10 interposed between the nut N10 and the conductive resin portion 101. Examples of another component in this example include a bus bar formed of a metal plate, an electric wire including a connection component such as a round terminal at the end, which connection component can be fastened using a bolt B10, a nut N10, a washer WS10, and the like.

[0171] As a modification of the first connection example, a screw hole into which the bolt B10 can be screwed may be provided instead of the through hole 100a, or a connector terminal having a terminal shape enabling another component to be attached to and detached from the connection portion 102b-1 may be provided as an electrode.

[0172] Fig.18 : is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the tenth embodiment.

[0173] In the second connection example, the exposed core wire W101 on one end side of the electric wire W10 with a terminal as another component is welded and fixed to the connection portion 102b-1 of the second conductor 102b which, together with the first conductor 102a, constitutes the conductor 102 of the composite material structure 100. A round terminal W102 for connection with an electric / electronic device is crimped to the other end side of the electric wire W10 with a terminal.

[0174] As a modification of the second connection example, instead of the wire W10 with terminal, one end of the connector terminal of the connector may be welded and fixed, for example. In another example, as a connection method for connecting the connection portion 102b-1, ultrasonic welding, crimping, etc. may be used instead of welding.

[0175] Also in the composite material structure 100 of the above-described tenth embodiment, electrochemical corrosion can be prevented while a part of the conductor 102 embedded in the conductive resin portion 101 is exposed as the connection portion 102 b - 1 , as in the above-described first embodiment and the like.

[0176] Furthermore, in this embodiment, the insulator 103 partially exposed at the inner circumferential surface of the recess 101b in the conductive resin portion 101 can support the periphery of the connection portion 102b-1 exposed at the bottom of the recess 101b. With such support of the periphery by the insulator 103, the mechanical strength of the connection portion 102b-1 against external forces can be improved. In view of the improvement in the mechanical strength of the connection portion 102b-1 of the conductor 102, the thickness of the connection portion 102b-1 of the conductor 102 can also be reduced, and a conductive material that is excellent in electrical characteristics but slightly inferior in mechanical strength can also be used as a material for forming the connection portion 102b-1 of the conductor 102.

[0177] Next, we will refer to Fig.19 and Fig. 20 A composite material structure according to an eleventh embodiment is described.

[0178] Fig.19 is a schematic perspective view showing a composite material structure of an eleventh embodiment, Fig. 20 It is along Fig.19 A schematic cross-sectional view taken along line V111-V111 in FIG. Fig.19 The internal structure of the composite structure shown in.

[0179] Also in Fig.19 and Fig. 20 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. 1 are also replaced with Figure 1 and Figure 2 The same reference numerals are used to represent identical components, and repeated descriptions of these equivalent components are omitted.

[0180] In the composite material structure 110 of this embodiment, a rectangular parallelepiped-shaped insulator 113 protrudes and is exposed from approximately the center of a wide surface 111a of a conductive resin portion 111 formed as a flat rectangular parallelepiped. A quadrilateral plate-shaped connecting portion 112b-1 of the conductor 112 protrudes and is exposed from one end surface of the insulator 113. Similar to the above-described first embodiment, the conductive resin portion 111 is formed of a conductive reinforcing resin in which a laminate of conductive fiber sheets 11a-1 formed of conductive fibers 11a is impregnated with a molten base material 11b.

[0181] The conductor 112 of the composite material structure 110 includes a first conductor 112a and a second conductor 112b. The first conductor 112a is integrally embedded in the conductive resin part 111 to be sandwiched between the conductive fiber sheets 11a-1 of the stack of conductive fiber sheets 11a-1. The second conductor 112b has a shape in which a metal plate in the shape of a quadrilateral plate is bent to have an L-shaped cross section, and a portion of the second conductor 112b corresponding to the horizontal side of the L-shape is placed near the center of the first conductor 112a and bonded to the center of the first conductor 112a. A portion of the second conductor 112b corresponding to the vertical side of the L-shape penetrates the insulator 113 and partially protrudes and is exposed from one end face of the insulator 113 to serve as a quadrilateral plate-shaped connecting portion 112b-1. Here, the shape of the second conductor 112b of the conductor 112 is not limited to a shape including an L-shaped cross section. The shape of the second conductor 112b is not limited to a specific shape as long as it can be placed on and bonded to the first conductor 112a and a portion of the second conductor 112b can penetrate the insulator 113 and protrude from the insulator 113, and for example, can be a shape including a Z-shaped, T-shaped or C-shaped cross-section.

[0182] The insulator 113 is embedded in the conductive resin portion 111 to be sandwiched between the conductive reinforcing resin and the second conductor 112 b in a state where the second conductor 112 b penetrates the insulator 113 and a portion of the insulator 113 protrudes and is exposed from the conductive resin portion 111 .

[0183] Next, two connection examples of connecting another component to the connection portion 112 b - 1 of the conductor 112 of the above-described eleventh embodiment will be described.

[0184] Fig.21 1 is a schematic perspective view showing a first connection example of the connection portion of the conductor according to the eleventh embodiment.

[0185] In the first connection example, a through hole 112b-2 for connection is provided through the connection portion 112b-1 of the second conductor 112b of the conductor 112 constituting the composite material structure 110. Another component is fastened and connected to the connection portion 112b-1 by a bolt B11 inserted through the through hole 112b-2 and a nut N11 screwed to the bolt B11. Examples of another component in this example include a bus bar formed of a metal plate, an electric wire including a connection component at its end, the connection component being a round terminal that can be fastened using a bolt B11 and a nut N11, etc.

[0186] As a modification of the first connection example, a screw hole into which the bolt B11 can be screwed can be provided instead of the through hole 112b-2, or a connector terminal can be provided as an electrode, the terminal shape of which enables another component to be attached to and detached from the connecting portion 112b-1.

[0187] Fig. 22 : is a schematic cross-sectional view showing a second connection example of the connection portion of the conductor related to the eleventh embodiment.

[0188] In the second connection example, the exposed core wire W111 on one end side of the electric wire W11 with a terminal as another component is welded and fixed to the connecting portion 112b-1 of the second conductor 112b which, together with the first conductor 112a, constitutes the conductor 112 of the composite material structure 110. A round terminal W112 for connection with an electric / electronic device is crimped to the other end side of the electric wire W11 with a terminal.

[0189] As a modification of the second connection example, instead of the terminal wire W11, one end of the connector terminal of the connector may be welded and fixed, for example. In another example, as a connection method for connecting the connection portion 112b-1, ultrasonic welding, crimping, etc. may be used instead of welding.

[0190] Also in the composite material structure 110 of the above-described eleventh embodiment, electrochemical corrosion can be prevented while a portion of the conductor 112 embedded in the conductive resin portion 111 is exposed as the connection portion 112 b - 1 , as in the above-described first embodiment and the like.

[0191] Furthermore, in this embodiment, a portion of the insulator 113 protrudes from the surface of the conductive resin portion 111, and the connection portion 112b-1 of the conductor 112 is exposed from the portion of the insulator 113. According to this configuration, the reliability of preventing contact between the connection portion 112b-1 and the conductive reinforcing resin is improved, thereby further preventing electrochemical corrosion.

[0192] Furthermore, in this embodiment, the portion of the conductor 112 that protrudes from the portion of the insulator 113 that is exposed from the conductive resin portion 111 is the connection portion 112b-1. According to this configuration, since the connection portion 112b-1 protrudes from the insulator 113, it is possible to attach, for example, an electric wire to the connection portion 112b-1 with good operability.

[0193] Next, we will refer to Fig.23 and Fig.24 A composite material structure according to a twelfth embodiment is described.

[0194] Fig.23 is a schematic perspective view showing a composite material structure of a twelfth embodiment, and Fig.24 It is along Fig.23 A schematic cross-sectional view taken along line V121-V121 in FIG. Fig.23 The internal structure of the composite structure shown in Fig.23 and Fig.24In, with Figure 1 and Figure 2 Components equivalent to those of the first embodiment shown in FIG. 1 are shown with the same Figure 1 and Figure 2 The same figure numbers are used in the drawings, and repeated descriptions about these equivalent parts are omitted.

[0195] In the composite material structure 120 of this embodiment, the covered electric wire 124 protrudes and is exposed from the approximate center of the wide surface 121a of the conductive resin part 121 formed into a flat rectangular parallelepiped. Similar to the first embodiment described above, the conductive resin part 121 is formed of a conductive reinforced resin in which a laminate of a conductive fiber sheet 11a-1 formed of conductive fibers 11a is impregnated with a molten base material 11b. Inside the conductive resin part 121, one end of the core wire of the covered electric wire 124 is bonded to the first conductor 122a embedded in the conductive resin part 121. Examples of bonding methods include welding, ultrasonic welding, crimping, and the like. In a state where a portion of the coating of the covered electric wire 124 remains in the conductive resin part 121, the other end side of the covered electric wire 124 protrudes from the conductive resin part 121, and a portion of the core wire is exposed at the other end side. A round terminal 124a for connecting to an electrical / electronic device as another component is crimped and connected to the exposed core wire.

[0196] In the composite material structure 120 including the covered electric wire 124 as described above, the second conductor 122b constituting the conductor 122 together with the first conductor 122a is the core wire of the covered electric wire 124. In addition, the exposed core wire on the other end side of the covered electric wire 124 is a connection portion 122b-1 for connection with a round terminal 124a as another component. In addition, the covering of the covered electric wire 124 is an insulator 123, which is partially embedded in the conductive resin portion 121 in a state where the connection portion 122b-1 of the conductor 122 is sandwiched between the conductive reinforcing resin and the conductor 122, so as to prevent the connection portion 122b-1 from contacting the conductive reinforcing resin.

[0197] Also in the composite material structure 120 of the above-described twelfth embodiment, electrochemical corrosion can be prevented while a portion of the conductor 122 embedded in the conductive resin portion 121 is exposed as the connection portion 122 b - 1 , as in the above-described first embodiment and the like.

[0198] In addition, in this embodiment, since the insulator 123 is a coating of the covered electric wire 124 whose core wire is the second conductor 122b, it is sufficient to provide only the covered electric wire 124, and there is no need to form a separate insulator, so the number of parts can be reduced, and this embodiment is preferred. In addition, since the size of the boundary between the conductive resin part 121 and the insulator 123 can be reduced to about the thickness size of the covered electric wire 124, it is possible to prevent the strength of the composite material structure 120 from being reduced due to the insulator 123 being embedded in the conductive resin part 121, so this embodiment is also preferred.

[0199] As a modification of the twelfth embodiment, the covered electric wire 124 coupled to the first conductor 122a can be divided into a plurality of covered electric wires according to the required current capacity to reduce the size of each covered electric wire. The plurality of covered electric wires are arranged in a one-dimensional arrangement in which the plurality of covered electric wires are arranged in a row, and the respective ends of the plurality of covered electric wires are coupled to the first conductor 122a. In this modification, since the size of one covered electric wire is reduced, the conductive resin portion 121 can be thinned by that amount. In another example, a flat cable can be used instead of a plurality of covered electric wires to further thin the conductive resin portion 121.

[0200] Next, we will refer to Fig.25 and Fig.26 A composite material structure according to a thirteenth embodiment is described.

[0201] Fig.25 is a schematic perspective view showing a composite material structure of a thirteenth embodiment, and Fig.26 It is along Fig.25 A schematic cross-sectional view taken along line V131-V131 in FIG. Fig.25 The internal structure of the composite structure shown in Fig.25 and Fig.26 In, with Figure 1 and Figure 2 Components equivalent to those in the first embodiment shown in FIG. 1 are also replaced with Figure 1 and Figure 2 The same figure marks are shown in the figures, and in the following, repeated descriptions about these equivalent components are omitted.

[0202] In the composite material structure 130 of this embodiment, the connector 134 protrudes and is exposed from the approximate center of the wide surface 131a of the conductive resin part 131 formed as a flat rectangular parallelepiped. Similar to the first embodiment described above, the conductive resin part 131 is formed of a conductive reinforced resin, in which a laminate of conductive fiber sheets 11a-1 formed of conductive fibers 11a is impregnated with a molten base material 11b. In the conductive resin part 131, the first conductor 132a embedded in the conductive resin part 131 is bonded to the common end 132b-2 of the four connector terminals for the connector 134, and the common end 132b-2 corresponds to the opposite side of the other terminal connection side of the connector terminal (i.e., the other terminal connection side for connecting to the other terminal). The connector 134 is arranged so that its connection side for connecting to the other connector protrudes from the conductive resin part 131 in a state where a part of the connector housing remains in the conductive resin part 131, and at this connection side, the other terminal connection side of the connector terminal is exposed from the connector housing.

[0203] In the composite material structure 130 including the connector 134 as described above, the second conductor 132b constituting the conductor 132 together with the first conductor 132a corresponds to four connector terminals electrically connected by the common terminal 132b-2. In addition, the other terminal connection side of these four connector terminals is a connection portion 132b-1 for connecting to another terminal as another component. In addition, the connector housing of the connector 134 is an insulator 133 partially embedded in the conductive resin portion 131 to be sandwiched between the conductive reinforcement resin and the conductor 132, thereby preventing the connection portion 132b-1 of the conductor 132 from contacting the conductive reinforcement resin.

[0204] Also in the composite material structure 130 of the above-described thirteenth embodiment, electrochemical corrosion can be prevented while a portion of the conductor 132 embedded in the conductive resin portion 131 is exposed as the connection portion 132 b - 1 , as in the above-described first embodiment and the like.

[0205] In addition, in this embodiment, since the insulator 133 is a connector housing including the connector 134 as the connector terminal of the second conductor 132b, it is sufficient to provide the connector 134 and there is no need to form a separate insulator, so the number of components can be reduced, and this embodiment is preferred. In addition, since the connector terminal originally having a connection structure for connecting to another terminal as another component is used as the second conductor 132b, it is possible to easily connect and disconnect another component, and this embodiment is preferred in this respect.

[0206] As a modification of the thirteenth embodiment, the number of connector terminals coupled to the first conductor 132a may not be four, for example, it may be one, two, three or more than four. In another example, a plurality of connector terminals may be coupled to the first conductor 132a, respectively, rather than being placed together through a common end 132b-2. In another example, the first conductor 132a may be divided into a plurality of conductors, and the connector terminals may be independently connected to the plurality of conductors, respectively.

[0207] Next, as an embodiment of the composite material structure production method, a composite material structure production method for obtaining the composite material structures 1, ..., 130 of the first to thirteenth embodiments will be described. The composite material structure production method is basically the same for the first to thirteenth embodiments, so the following description is given with reference to the composite material structure production method for obtaining the composite material structure 1 of the first embodiment as a representative example.

[0208] Fig. 27 1 is a schematic diagram showing the flow of a composite material structure production method for obtaining the composite material structure of the first embodiment.

[0209] Fig. 27 The composite material structure production method shown includes a first step S11 and a second step S12.

[0210] The first step S11 is a step of covering a portion of the conductor 12 in which the second conductor 12b is bonded to the first conductor 12a with the insulating material Z1 as a forming material for forming the insulator 13. In this embodiment, the first step S11 is a step of covering the covered portion 12b-3 including the connecting portion 12b-1 of the second conductor 12b with the insulating material Z1.

[0211] The subsequent second step S12 is a step of forming the conductive resin portion 11 and the insulator 13 using the conductor 12 partially covered by the insulating material Z1 and using the conductive reinforcing resin Z2 including the base material 11b containing the conductive fiber sheet 11a-1 to expose the connection portion 12b-1. The second step S12 includes a pre-exposure step S121 and an exposure step S122.

[0212] The pre-exposure step S121 is a step of forming a pre-exposure structure 1a in which the conductor 12 including the connection portion 12b-1 is in a non-exposed state as a whole. In the pre-exposure structure 1a, a portion of the conductor 12 including the connection portion 12b-1 is covered by both the insulating material Z1 and the conductive reinforcing resin Z2, and the other portion is covered by the conductive reinforcing resin Z2. The pre-exposure step S121 also includes a sheet placement step S121a, a substrate impregnation step S121b, and a processing / polishing / cleaning step S121c.

[0213] The sheet placement step S121a is a step of arranging a plurality of conductive fiber sheets 11a-1 in layers to sandwich the conductor 12 partially covered by the insulating material Z1. At this time, the conductive fiber sheets 11a-1 are arranged in layers so as to overlap with the insulating material Z1 except for the portion covering the connection portion 12b-1. The subsequent substrate impregnation step S121b is a step of covering a portion of the conductor 12 and the insulator 13 with the conductive reinforcing resin Z2 by impregnating the plurality of conductive fiber sheets 11a-1 with the molten substrate 11b and curing them. The subsequent processing / polishing / cleaning step S121c is a step of processing / polishing the cured conductive reinforcing resin Z2 formed in the substrate impregnation step S121b into the conductive resin portion 11 including the desired shape and then removing the polished powder. After this processing / polishing / cleaning step S121c, the pre-exposed structure 1a is completed.

[0214] The exposing step S122 after the pre-exposing step S121 is a step of exposing the connecting portion 12b-1 by removing the insulating material Z1 covering the connecting portion 12b-1 of the conductor 12 from the pre-exposing structure 1a. After the exposing step S122, the insulator 13 is completed and the composite material structure 1 is obtained.

[0215] According to the composite material structure production method described above, it is possible to obtain the composite material structure 1 which prevents the occurrence of electrochemical corrosion while exposing a portion of the conductor 12 embedded in the conductive resin portion 11 as the connection portion 12 b - 1 , as described above.

[0216] Furthermore, in this embodiment, the connection portion 12b-1 of the conductor 12 is protected by the insulating material Z1 provided as a cover in the first step S11 until the connection portion 12b-1 is exposed in the exposing step S122. This protection can prevent electrochemical corrosion during production, for example, during the processing / polishing / cleaning step S121c.

[0217] It should be noted that the above-described embodiments merely illustrate representative examples of the composite material structure and the composite material structure production method, and the composite material structure and the composite material structure production method are not limited thereto and may be variously modified and implemented.

[0218] For example, the above embodiments exemplarily show composite material structures 1, ..., 130, wherein various shapes are shown regarding the overall appearance and internal structure of the composite material structure, etc. However, the composite material structure is not limited thereto, and its appearance and internal structure may be arbitrarily set according to the purpose.

Claims

1. A composite material structure comprising: a conductive resin portion formed of a conductive reinforcing resin in which conductive fibers are contained in a base material; a conductor formed of a conductive material and embedded in the conductive resin portion in a state where a portion of the conductor is exposed from the conductive resin portion to serve as a connection portion for electrical connection with another component; as well as an insulator formed of an insulating material, at least a portion of which is embedded in the conductive resin portion to be sandwiched between the conductive reinforcing resin and the conductor, thereby preventing a connection portion of the conductor from contacting the conductive reinforcing resin, wherein The longest dimension among dimensions defining the shape of a portion of the insulator exposed from the conductive resin portion is smaller than or equal to the longest dimension among dimensions defining the shape of the conductive resin portion.

2. The composite material structure according to claim 1, wherein: A portion of the insulator protrudes from a surface of the conductive resin portion, and The connection portion of the conductor is a portion of the conductor that is exposed from a portion of the insulator that protrudes from the conductive resin portion.

3. The composite material structure according to claim 1, wherein: The insulator is formed so that a part of the insulator is exposed in a flush manner with a surface of the conductive resin portion, and The connection portion of the conductor is a portion of the conductor that is exposed from a portion of the insulator that is exposed to the conductive resin portion.

4. The composite material structure according to any one of claims 1 to 3, wherein: The connection portion of the conductor is a portion of the conductor that protrudes from a portion of the insulator exposed from the conductive resin portion.

5. The composite material structure according to any one of claims 1 to 3, wherein: The connection portion of the conductor is a portion of the conductor that is exposed from the surface of the insulator in a flush manner with a surface of a portion of the insulator that is exposed from the conductive resin portion.

6. The composite material structure according to claim 1, wherein: The conductive resin portion includes a stepped portion including a first plane and a second plane, the second plane being disposed one step lower than the first plane, The insulator is formed so that a portion of the insulator is exposed from the second plane of the conductive resin portion, and The connection portion of the conductor is a portion of the conductor that is exposed from a portion of the insulator that is exposed to the conductive resin portion.

7. The composite material structure according to claim 1, wherein: the conductive resin portion includes a cylindrical recessed portion formed on a surface of the conductive resin portion, The conductor is embedded in the conductive resin portion so that a portion of the conductor is exposed as the connection portion to form a bottom of the recessed portion, and The insulator is embedded in the conductive resin portion and sandwiched between the conductive reinforcing resin and the conductor in a state where a portion of the insulator is exposed at least at a bottom side of an inner peripheral surface of the recess in a depth direction of the recess.

8. The composite material structure according to claim 1, wherein: The conductor includes a first conductor and a second conductor, the first conductor being completely embedded in the conductive resin portion, the second conductor being bonded to the first conductor within the conductive resin portion, and a portion of the second conductor being the connecting portion.

9. The composite material structure according to claim 8, wherein: The second conductor is an electrode.

10. A method for producing a composite material structure, comprising: The first step is to cover at least a portion of a conductor formed of a conductive material with an insulating material; as well as A second step of forming a conductive resin portion and an insulator using the conductor covered with an insulating material and a conductive reinforcing resin containing conductive fibers in a base material, wherein the conductor is embedded in the conductive resin portion in a state where a part of the conductor is exposed from the conductive resin portion as a connecting portion for electrical connection with another component, and the insulator is at least partially embedded in the conductive resin portion to be sandwiched between the conductive reinforcing resin and the conductor, thereby preventing the connecting portion of the conductor from contacting the conductive reinforcing resin, wherein The longest dimension among dimensions defining the shape of a portion of the insulator exposed from the conductive resin portion is smaller than or equal to the longest dimension among dimensions defining the shape of the conductive resin portion.

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