Composite material structure and method for producing a composite material structure

Abstract

Composite material structure (1'), comprising: a conductive resin section (11) formed from an electrically conductive reinforced resin in which conductive fibers (11a) are contained in an insulating base material (11b); a conductor (12) formed from an electrically conductive material, at least part of which is embedded in the conductive resin section (11); and a plurality of layers of insulating resin sections (13), which are layers of resin sections, each containing insulating fibers (13a) embedded in an insulating base material (13b), wherein the plurality of layers of insulating resin sections (13) is embedded in the conductive resin section (11) to accommodate the at least one part of the conductor (12) between them and to be arranged between the conductive fibers (11a) and the conductor (12), wherein the conductor (12) has an extended conductor section (12b-2) which extends to an outside of the conductive resin section (11) and of which at least a part is exposed as a connecting section (12b-2) for an electrical connection with another component, the insulating resin sections (13) are arranged such that they are positioned between the conductive fibers (11a) and the conductor (12) to prevent the connecting section (12b-1) exposed on the extended conductor section (12b-2) from touching the conductive fibers (11a), a part of the extended conductor section (12b-2) at a distal end face thereof, which is spaced apart from the conductive resin section (11), when the connecting section (12b-1) is exposed, Each of the multiple layers of the insulating resin sections (13) contains an extended insulating section (13c) which, together with the extended conductor section (12b-2), extends from the conductive resin section (11), such that the multiple layers of the insulating resin sections (13) in between enclose at least a part of a non-exposed section (12b-3) of the extended conductor section (12b-2), wherein the non-exposed section (12b-3) is located on a base side of the extended conductor section (12b-2) and excludes the connecting section (12b-1), wherein the composite material structure (1') further comprises an insulator (14) formed from an insulating material to cover the non-exposed section (12b-3) of the extended conductor section (12b-2), and the plurality of layers of insulating resin sections (13) is designed such that the extended insulating sections (13c) of the respective layers of insulating resin sections (13) accommodate a part of the non-exposed section (12b-3) over a part of the insulator (14) covering the non-exposed section (12b-3) in between.

Description

Technical area

[0001] The present invention relates to a composite material structure in which a conductor is embedded in a conductive resin portion formed of a conductive fiber and an insulating resin, and a method for manufacturing a composite material structure for obtaining such a composite material structure. background

[0002] In recent years, along with the multi-materialization of vehicle bodies, reinforced resins reinforced with carbon fibers, such as CFRP (carbon fiber reinforced plastics) and CFRTP (carbon fiber reinforced thermoplastics), have been increasingly used for frame structures (see, for example, Patent Document 1). When using such a reinforced resin for a frame structure, the problem of securing a grounding point arises, and one possible solution may be, for example, a composite material structure in which a conductor is embedded in a resin portion made of a reinforced resin. Although not intended for securing a grounding point, Patent Document 1 exemplifies a composite material structure in which a conductor used for transmitting an electrical signal and the like is embedded in a resin portion formed of a reinforced resin.In the composite material structure shown in Patent Document 1, the reinforced resin portion embedded in the conductor itself is the conductive resin portion formed of an electrically conductive reinforced resin containing conductive fibers such as carbon fibers, etc. Therefore, in the above-mentioned composite material structure, an insulating resin portion is provided for insulating the conductive reinforced resin and the conductor, which is sandwiched between them. State of the art

[0003] Patent document 1: JP 2018- 89 951 A

[0004] The document EP 2 716 437 A1 relates to a composite component made of plastic-fibre composite material with at least two layers of fibre-reinforced material, wherein at least one electrical line is inserted between the at least two layers of fibre-reinforced material, which electrical line can be connected to electrical terminals.

[0005] Document JP H05-193047 A relates to a composite material comprising a medium-sized tube as a carbon fiber-reinforced plastic part and a metal stud as a metal part. A plastic layer with insulating fibers as a reinforcing material is formed between the two parts. This impedes the flow of current and prevents the formation of electrolytic corrosion. Glass fibers or high-molecular-weight fibers such as polyethylene or similar can be used as the insulating fibers, and a thermosetting resin such as unsaturated polyester, epoxy, etc., is used as the plastic, which is mixed into the fibers at this time.

[0006] Document JP 2006-49550 A relates to an electronic component. In the electronic component, at least a portion of the metallic element is embedded in the fiber-reinforced resin having conductivity by injection molding, and the surface of at least the portion of the metallic element embedded in the fiber-reinforced resin is coated with an insulating resin film.

[0007] The document DE 103 08 663 A1 relates to a ribbon cable with electrical conductors which run parallel to one another and can be exposed at their conductor ends for the purpose of contacting, wherein the invention provides that the insulating sheath of the ribbon cable and / or the conductor ends are provided with a coating by means of thermal metal spraying.

[0008] The document DE 10 2014 004 431 A1 relates to a method and a device for covering a profile, the method comprising: providing an elongated profile having a profile main body and one or more outlets provided thereon; partially or completely covering the profile main body with a first plastic component, wherein the outlets are at least partially not covered with the first plastic component; and partially or completely covering the outlets with a second plastic component. Summary of the inventionProblem to be solved by the invention

[0009] However, when the insulating resin portion is arranged between the conductive reinforced resin and the conductor as shown in Patent Document 1, a connection between the conductive reinforced resin and the insulating resin portion is locally weakened at an interface, possibly causing a decrease in the strength of the composite material structure.

[0010] In view of the above-described problem, an object of the present invention is to provide a composite material structure capable of preventing a decrease in strength while interposing an insulating resin portion between a conductive reinforced resin and a conductor. Another object of the present invention is to provide a method for manufacturing a composite material structure to form the composite material structure. Solution to the problem

[0011] To achieve the above-described object, the present invention provides a composite material structure according to claims 1 and 2.

[0012] In order to achieve the above-described object, the present invention further provides a method for producing a composite material structure according to claims 6 and 7. Advantageous effect of the invention

[0013] According to the composite material structure and the method for manufacturing the composite material structure described above, the conductor and the conductive reinforced resin are electrically insulated by inserting the insulating resin portions between the conductor embedded in the conductive resin portion and the conductive fibers contained in the conductive reinforced resin constituting the conductive resin portion. Furthermore, since the insulating resin portions are the resin portions in which the insulating fibers are contained in the insulating base materials, fiber tangles are likely to form between the conductive fibers contained in the conductive reinforced resin and the insulating fibers of the insulating resin portions. This fiber tangle increases the strength of the mechanical connection between the conductive reinforced resin and the insulating resin portions.That is, according to the composite material structure and the method for manufacturing the composite material structure described above, a decrease in strength can be prevented while the insulating resin portions are arranged between the conductive reinforced resin and the conductor. Short description of the drawings Fig. 1 is a schematic perspective view showing a composite material structure according to a first embodiment not forming part of the invention; Fig. 2 is a schematic diagram showing an internal configuration of the Fig. 1 shows the composite material structure; Fig. 3 is a schematic perspective view showing a composite material structure according to a second embodiment not forming part of the invention; Fig. 4 is a schematic perspective view showing a first connection example with respect to a connecting portion of a conductor of the first embodiment; Fig. 5 is a schematic perspective view showing a second connection example with respect to a connecting portion of a conductor of the first embodiment; Fig. 6 is a schematic cross-sectional view showing a composite material structure according to a third embodiment not forming part of the invention; Fig. 7 is a schematic perspective view showing a composite material structure according to a fourth embodiment of the present invention; Fig. 8 is a schematic cross-sectional view showing a first connection example with respect to a connecting portion of a conductor of the fourth embodiment; Fig. 9 is a schematic cross-sectional view showing a second connection example with respect to a connecting portion of a conductor of the fourth embodiment; Fig. 10 is a schematic perspective view showing a composite material structure according to a fifth embodiment not forming part of the invention; Fig. 11 is a schematic cross-sectional view taken along the line V51-V51 in Fig. 10 and shows an internal configuration of the Fig. 10 shown composite material structure; Fig. 12 is a schematic cross-sectional view showing a first connection example with respect to a connecting portion of a conductor of the fifth embodiment; Fig. 13 is a schematic cross-sectional view showing a second connection example with respect to a connecting portion of a conductor of the fifth embodiment; Fig. 14 is a schematic perspective view showing a composite material structure according to a sixth embodiment not forming part of the invention; Fig. 15 is a schematic cross-sectional view taken along the line V61-V61 in Fig. 14 and shows an internal configuration of the Fig. 14 shown composite material structure; Fig. 16 is a schematic perspective view showing a first connection example with respect to a connecting portion of a conductor of the sixth embodiment; Fig. 17 is a schematic cross-sectional view showing a second connection example with respect to a connecting portion of a conductor of the sixth embodiment; Fig. Fig. 18 is a schematic diagram not forming part of the invention showing the flow of a method for manufacturing a composite material structure for obtaining the composite material structure of the first embodiment; and Fig. 19 is a schematic diagram according to the present invention showing the operation of a modified example of the Fig. 18 shows the process for producing composite material structures. Detailed description of the exemplary embodiments

[0014] An embodiment of a composite material structure and a method for manufacturing a composite material structure according to the present invention will be described. First, a first embodiment, which is not part of the invention, of a composite material structure will be described with reference to Fig. 1 and Fig. 2 described.

[0015] Fig. 1 is a schematic perspective view showing a composite material structure of the first embodiment, and Fig. 2 is a schematic view showing an internal configuration of the Fig. 1 shows the composite material structure. Fig. 2 shows a schematic perspective exploded view of a Fig. 1 shown composite material structure 1 and a schematic cross-sectional view along the line V1-V1 in Fig. 1.

[0016] The composite material structure 1 according to this embodiment is a structure in which a conductor 12 is embedded in a conductive resin portion 11, and a part of the conductor 12 is exposed as a connecting portion 12b-1 for electrical connection to another component. The composite material structure 1 includes the conductive resin portion 11, the conductor 12, and insulating resin portions 13.

[0017] As in Fig. As shown in Figure 2, the conductive resin portion 11 is a portion formed of an electrically conductive reinforced resin in which conductive fibers 11a are contained in an insulating base material 11b. Although the conductive resin portion 11 is illustrated in a flat rectangular parallelepiped shape as an example in this embodiment, its shape is not limited to this and may have any shape according to actual applications.

[0018] An example of the conductive fibers 11a is reinforcing fibers with electrical conductivity, such as carbon fibers. Other examples of reinforcing fibers include aluminum fibers, copper fibers, stainless steel fibers, and the like.

[0019] The insulating base material 11b is an insulating resin, and examples include thermosetting resins such as epoxy, phenol, unsaturated polyester, vinyl ester, cyanate ester, polyimide, and the like. Examples of the insulating resin also include thermoplastic resins such as polyamide, polycarbonate, polyphenylene sulfide, polyetheretherketone, and the like.

[0020] In this embodiment, as in Fig. As shown in Figure 2, to incorporate the conductive fibers 11a into the insulating base material 11b, a stack of the conductive fiber layers 11a-1 formed from the conductive fibers 11a is impregnated with the molten insulating base material 11b. However, the method for incorporating the conductive fibers 11a into the insulating base material 11b is not limited thereto, and, for example, fiber pieces obtained by crushing the conductive fibers 11a may also be kneaded into the molten insulating base material 11b.

[0021] The conductor 12 is a portion formed of an electrically conductive material and embedded in the conductive resin portion 11, with a portion of the conductor 12 exposed as a connecting portion 12b-1 for electrical connection with another component. In this embodiment, the conductor 12 includes a first conductor 12a that is entirely embedded in the conductive resin portion 11, and a second conductor 12b that is connected to the first conductor 12a within the conductive resin portion 11, a portion of which forms the connecting portion 12b-1. The second conductor 12b is an electrode to which another component, such as an electric wire, is connected, as described later.

[0022] In this embodiment, the first conductor 12a and the second conductor 12b of the conductor 12 are illustrated in a rectangular flat plate shape as an example. However, the shape thereof is not limited to the rectangular flat plate shape, and the first and second conductors may each have any shape. In this embodiment, the first conductor 12a to be embedded in the conductive resin portion 11 is illustrated as a rectangular flat plate along the shape of the conductive resin portion 11, as shown in the perspective view of Fig. 1 and the perspective exploded view of Fig. 2. On the other hand, the cross-sectional view of Fig. 2 shows the first conductor 12a in the corrugated form to show that the first conductor 12a can have any shape even within the conductive resin portion 11, regardless of the shape of the conductive resin portion 11. Furthermore, the second conductor 12b, a part of which is the connecting portion 12b-1 for connection to another component, can have any shape that enables connection to another component, such as an electric wire.

[0023] Examples of the material of the first conductor 12a include carbon fiber and the following metal materials that are generally used as materials for conductive components. That is, examples of the metal material include aluminum, copper, gold, other metals and their alloys, and the like. The shape of the first conductor 12a can be any shape as described above, and may be, for example, a plate shape, a foil shape, a metal fiber woven sheet shape, a metal wire mesh shape, a linear shape, a rod shape, a tube shape, and the like.

[0024] Examples of the material of the second conductor 12b used as an electrode include metal materials such as aluminum, copper, gold, other metals and their alloys, and the like. In this embodiment, the second conductor 12b is shown in a rectangular flat plate shape, as shown in Fig. 1 and Fig. 2. However, the shape of the second conductor is not limited to that described above, and may be another shape, such as a round terminal shape and the like, as long as it allows connection to another component, such as an electrical wire.

[0025] In this embodiment, the first conductor 12a and the second conductor 12b, as described above, are connected within the conductive resin portion 11 with their ends in surface contact with each other to form the conductor 12. A method of connecting may include general joining methods such as fusion bonding, solid-phase bonding, brazing, adhesive bonding, and mechanical joining such as crimping, riveting, screwing, and the like.

[0026] As in Fig. 2, the insulating resin portions 13 are layered resin portions each including the insulating base material 13b with insulating fibers 13a. In this embodiment, two layers of the insulating resin portions 13 are embedded in the conductive resin portion 11 so as to enclose a part of the conductor 12 and are interposed between the conductive fibers 11a and the conductor 12. Further, in this embodiment, the insulating resin portions 13 are exemplified in a rectangular parallelepiped shape formed of two layers combined with each other. However, the shape of the insulating resin portions 13 is not limited to this and can be any shape as long as it is in a layered form that can be interposed between the conductive reinforced resin constituting the conductive resin portion 11 and the conductor 12.

[0027] Examples of the insulating fibers 13a include fibers with insulating properties, such as glass fibers and the like. Other examples of the insulating fibers 13a include boron fibers, silicon carbide fibers, boron carbide fibers, phenolic resin fibers, aramid fibers, and the like. Further examples of the insulating fibers 13a are polyarylate fibers, PBO (polyparaphenylene benzobisoxazole) fibers, high-strength polyethylene fibers, and the like.

[0028] As the insulating base material 13b of the insulating resin portion 13, the thermosetting resins and thermoplastic resins exemplified above can be used for the insulating base material 11b of the conductive resin portion 11. In this embodiment, the same resin as that used for the insulating base material 11b of the conductive resin portion 11 is used for the insulating base material 13b of the insulating resin portion 13. However, a different resin than that used for the insulating base material 11b of the conductive resin portion 11 can be used for the insulating base material 13b of the insulating resin portion 13.

[0029] In this embodiment, as in Fig. As shown in Figure 2, to incorporate the insulating fibers 13a into the insulating base material 13b, a stack of insulating fiber sheets 13a-1 formed from the insulating fibers 13a is impregnated with the molten insulating base material 13b. However, the method for incorporating the insulating fibers 13a into the insulating base material 13b is not limited thereto, and, for example, fiber pieces obtained by crushing the insulating fibers 13a may also be kneaded into the molten insulating base material 13b.

[0030] In this embodiment, the conductive resin portion 11, the conductor 12, and the previously described insulating resin portions 13 are combined in the manner described below to form the composite material structure 1. First, the conductor 12b includes an extended conductor portion 12b-2 extending to the outside of the conductive resin portion 11, a portion of which is exposed at its distal end as a connecting portion 12b-1 for electrical connection with another component. The extended conductor portion 12b-2 protrudes from one end surface of the rectangular parallelepiped-shaped conductive resin portion 11 and is exposed at its distal end to form the connecting portion 12b-1.The insulating resin portions 13 are arranged to be interposed between the conductive fibers 11a and the extended conductor portion 12b-2 to prevent the exposed connecting portion 12b-1 of the extended conductor portion 12b-2 from contacting the conductive fibers 11a. That is, the two layers of the insulating resin portions 13 each include insulating extended portions 13c extending from one end surface of the conductive resin portion 11a together with the extended conductor portion 12b-2 to accommodate a non-exposed portion 12b-3 located on a base side of the extended conductor portion 12b-2, except for the connecting portion 12b-1, between the insulating resin portions 13.

[0031] In an alternative embodiment, the insulating resin portions 13 may be configured so that they do not protrude from the one end surface of the conductive resin portion 11, but have exposed surfaces flush with this one end surface. In this case, the connecting portion 12b-1 of the conductor 12 protrudes from the exposed surfaces of the insulating resin portions 13, which are flush with the one end surface of the conductive resin portion 11.

[0032] Next, a composite material structure according to a second embodiment not forming part of the invention will be described with reference to Fig. 3 described.

[0033] Fig. 3 is a schematic perspective view showing the composite material structure of the second embodiment. In Fig. 3 are the components similar to those of the first embodiment in Fig. 1 and Fig. 2, with the same reference numerals as in Fig. 1 and Fig. 2, and repeated explanations of the equivalent components are omitted below.

[0034] In a composite material structure 2 of this embodiment, a conductor 22 is a single component, unlike the conductor 12 of the previously described first embodiment, which consists of two interconnected components. In this embodiment, the conductor 22, which is a rectangular flat plate deeply embedded in the conductive resin portion 11, extends as it is to the outside of the conductive resin portion 11 and is exposed to form a connecting portion 22b-1, with a part of the conductor 22 protruding between the two layers of the insulating resin portions 13.In this embodiment, the conductor 22 has a thickness and strength sufficient to be used as an electrode including the connecting portion 22b-1 for connection to another component, and thus a part of the conductor 22 is used as an electrode as it is, eliminating the need to provide a separate electrode as in the first embodiment.

[0035] Next, two connection examples for connecting another component to the connection portion 12b-1, 22b-1 of the conductor 12, 22 of the first and second embodiments described above will be described. These connection examples are equally applicable to the first and second embodiments; therefore, the following explanation will be made with reference to the composite material structure 1 according to the first embodiment as an illustrative example.

[0036] Fig. 4 is a schematic perspective view showing a first connection example with respect to the connecting portion of the conductor of the first embodiment.

[0037] In the first connection example, a through-hole 12b-4 for connection is provided at the connecting portion 12b-1 of the conductor 12 of the composite material structure 1. Another component is to be fastened and connected to the connecting portion 12b-1 by a screw B1 inserted through the through-hole 12b-4 and a nut N1 screwed onto the screw B1. Examples of the other component in this example include a bus bar formed from a metal plate, an electric wire having a connecting portion such as a terminal at its end that can be fastened using the screw B1 and the nut N1, and the like.

[0038] As a modified example of this first connection example, instead of the through hole 12b-4, a screw hole into which the screw B1 can be screwed may be provided, or the nut N1 may be welded and fixed to the connecting portion 12b-1. As another example, the screw B1 may be welded and fixed to the connecting portion 12b-1 with the screw portion passing through the through hole 12b-4 protruding therefrom.

[0039] Fig. 5 is a schematic perspective view showing a second connection example with respect to the connecting portion of the conductor according to the first embodiment.

[0040] In the second connection example, an exposed core wire W11 is soldered and fixed to one end of an electrical wire with terminal W1 as another component to the connecting portion 12b-1 of the conductor 12 of the composite material structure 1. A circular terminal W12 for connecting to an electrical / electronic device is crimped to the other end of the electrical wire with terminal W1.

[0041] As a modified example of this second connection example, instead of the electric wire having terminal W1, one end of a connector terminal of a connector may be soldered and fixed, for example. Furthermore, as an example of the connection method for the connection with respect to the connecting portion 12b-1, ultrasonic welding, crimping, or the like may be used instead of soldering.

[0042] According to the composite material structures 1, 2 according to the first and second embodiments described above, the following advantageous effect can be achieved. That is, according to the composite material structures 1, 2 described above, the insulating resin portions 13 are arranged between the conductive fibers 11a contained in the conductive reinforced resin constituting the conductive resin portion 11 and the conductor 12, 22 embedded in the conductive resin portion 11. With the insulating resin portions 13 thus inserted, the conductive reinforced resin and the conductor 12, 22 are electrically insulated. In addition, since the insulating resin portions 13 are resin portions in which the insulating fibers 13a are contained in the insulating base materials 13b, fiber entanglement is likely to form between the conductive fibers 11a contained in the conductive reinforced resin and the insulating fibers 13a of the insulating resin portions 13.This entanglement of the fibers increases the strength of the mechanical connection between the conductive reinforced resin and the insulating resin portions 13. That is, according to the previously described composite material structures 1, 2, a decrease in strength can be prevented while the insulating resin portions 13 are arranged between the conductive reinforced resin and the conductor 12, 22.

[0043] In the first and second embodiments, the conductive resin portion 11 is configured such that the plurality of conductive fiber layers 11a-1 are contained in the insulating base material 11b in a stacked state. Further, the conductor 12, 22 is configured such that a part of it is embedded in the conductive resin portion 11, so that it is sandwiched between the conductive fiber layers 11a-1 from the outside of the insulating resin portions 13. According to this configuration, the conductive resin portion 11 can be obtained by arranging the plurality of conductive fiber layers 11a-1 in a stack while sandwiching the conductor 12, 22 and the insulating resin portions 13 between the conductive fiber layers 11a-1, and then impregnating the stack with the insulating base material 11b. This method is preferred because it ensures good processability.

[0044] Furthermore, in the first and second embodiments, the insulating resin portions 13 are configured such that the insulating fiber layers 13a-1 formed from the insulating fibers 13a are contained in the insulating base materials 13b to be disposed between the conductive fibers 11a and the conductor 12, 22. There is no particular limitation on the size ratio between the insulating fiber layer 13a-1 and the conductive fiber layer 11a-1 formed from the conductive fibers 11a, and the insulating fiber layer 13a-1 and the conductive fiber layer 11a-1 can be provided in any arrangement and size ratio as long as the electrical insulation between the conductor 12, 22 and the conductive fiber layer 11a-1 is securely ensured. However, it is desirable that the insulating fiber layer 13a-1 has a minimum size covering the circumference of the conductor 12, 22.According to this configuration, the insulating resin portions 13 can be obtained by arranging the plurality of insulating fiber layers 13a-1 in a stack while sandwiching the conductor 12, 22 therebetween, and then impregnating the stack with the insulating base material 13b, and this method is preferred because it ensures good processability.

[0045] The first and second embodiments show examples in which the two layers of the insulating resin portions 13 are provided to sandwich a conductor 12, 22 therebetween. However, the number of layers of the insulating resin portions 13 is not limited to two, and the insulating resin portions may be provided in more than two layers. In this case, the conductors 12, 22 may be individually disposed at the respective interlayer portions between the layers of the insulating resin portions 13, or the conductors 12, 22 may be individually disposed at one interlayer portion or at more than one interlayer portion.

[0046] Furthermore, the conductor 12, 22 according to the first and second embodiments includes the extended conductor portion 12b-2 extending to the outside of the conductive resin portion 11, at least a portion of which is exposed as a connecting portion 12b-1, 22b-1. The insulating resin portions 13 are provided so as to be interposed between the conductive fibers 11a and the conductive extended portion 12b-2. According to this configuration, the conductor 12, 22 within the composite material structure 1, 2 can be connected to another external component via the exposed connecting portion 12b-1, 22b-1. If the exposed connecting portion 12b-1, 22b-1 is in contact with the conductive fibers 11a of the conductive reinforced resin and water or the like comes into contact with this contact portion, so-called galvanic corrosion may occur at this portion.However, according to the above configuration, the contact between the exposed connection portion 12b-1, 22b-1 and the conductive fibers 11a can be prevented by the insulating resin portions 13, thereby avoiding galvanic corrosion.

[0047] In the first and second embodiments, the insulating resin portions 13 include insulating extension portions 13c sandwiching at least a part of a non-exposed portion 12b-3 located at a base side of the conductive extension portion 12b-2. According to this configuration, the base side of the projecting and exposed connecting portion 12b-1, 22b-1 is further separated from the conductive fibers 11a of the conductive resin portion 11 by the insulating extension portions 13c of the insulating resin portions 13. This separation can improve the reliability of preventing contact between the base side of the connecting portion 12b-1, 22b-1 and the conductive fibers 11a, thereby further preventing galvanic corrosion.

[0048] Furthermore, the conductor 12, 22 according to the first and second embodiments includes the first conductor 12a completely embedded in the conductive resin portion 11 and the second conductor 12b connected to the first conductor 12a. The insulating resin portions 13 are embedded so as to be located between the first conductor 12a and the embedded portion of the second conductor 12b. According to these configurations, the conductor 12, 22 is divided into the first conductor 12a and the second conductor 12b, with the first conductor 12a being completely embedded in the conductive resin portion 11 to be used as a package ground and the like, and the second conductor 12b being connected to this first conductor 12a. Since the conductor is divided in this way, the respective portions of the conductor 12, 22 can be formed of conductive materials suitable for the intended use.

[0049] Next, a composite material structure according to a third embodiment not forming part of the invention will be described with reference to Fig. 6 described.

[0050] Fig. 6 is a schematic perspective view showing the composite material structure of the third embodiment. In Fig. 6 are also the components that are similar to those of the first embodiment in Fig. 1 and Fig. 2, with the same reference numerals as in Fig. 1 and Fig. 2, and repeated explanations of the equivalent components are omitted below.

[0051] In the composite material structure 3 of this embodiment, a second conductor 32b of a conductor 32, which is connected to the first conductor 12a and a part of which is exposed as a connecting portion 12b-1, is provided with a protrusion 32c arranged to be in close contact with the insulating resin portions 13 within the conductive resin portion 11. The protrusion 32c is in the shape of a rectangular parallelepiped and arranged transversely to the center of the strip-shaped second conductor 32b, and a side surface of the protrusion 32c along its longitudinal direction is in close contact with the insulating resin portion 13.

[0052] Also in the composite material structure 3 of the above-described third embodiment, a decrease in strength can be prevented by interposing the insulating resin portions 13 between the conductive reinforced resin and the conductor 32 as in the above-described first embodiment.

[0053] Furthermore, according to this embodiment, the conductor 32 is provided with the protrusion 32c arranged to be in close contact with the insulating resin portion 13 within the conductive resin portion 11, thereby enhancing the contact between the conductor 32 and the insulating resin portion 13. Furthermore, since the protrusion 32c serves as a stopper against an external force applied to the connecting portion 12b-1 in the direction of pulling out the conductor 32 from the insulating resin portions 13, the strength of the composite material structure 3 against such an external force can be improved.

[0054] As a modified example of the third embodiment, the shape of the protrusion 32c of the conductor 32 may be changed from a rectangular parallelepiped to a shape other than a rectangular parallelepiped, such as a polygonal cylinder, a circular cylinder, and the like. In another modified example, the portion of the conductor 32 embedded in the insulating resin portion 13 may have a concave-convex shape in which protrusions and depressions are alternately arranged along the direction of the external force with respect to a direction intersecting the direction of the external force described above, as a configuration that enhances the contact between the conductor 32 and the insulating resin portion 13 and serves as a stopper.In another example, the portion of the conductor 32 embedded in the insulating resin portions 13 may be provided with a through-hole, and the inside of the through-hole may be filled with the insulating base material 13b constituting the insulating resin portion 13.

[0055] Next, a composite material structure according to a fourth embodiment will be described with reference to Fig. 7 described.

[0056] Fig. Fig. 7 is a schematic perspective view showing the composite material structure of the fourth embodiment. In Fig. 7 are also the components that Fig. 1 and Fig. 2 shown components of the first embodiment, with the same reference numerals as in Fig. 1 and Fig. 2, and repeated explanations of the equivalent components are omitted below.

[0057] In the composite material structure 4 according to this embodiment, a conductive resin portion 41 includes a step-shaped portion including a first plane 41a, a second plane 41b located one step lower than the first plane 41a, and a standing plane 41c connecting the first and second planes.

[0058] In this embodiment, a conductor 42 is embedded in the conductive resin portion 41, a part of a second conductor 42b is exposed as a connecting portion 42b-1 at a second portion 41b-1 of the conductive resin portion 41 including the second plane 41b, and a remaining part of the second conductor 42b is embedded in the second portion 41b-1. Insulating resin portions 43 are provided to sandwich the conductor 42 including the first conductor 12a at a first portion 41a-1 of the conductive resin portion 41 including the first plane 41a. On the other hand, the insulating resin portion 43 at the second portion 41b-1 is embedded in the conductive resin portion 41 on the side opposite to the exposed side of the connecting portion 42b-1 of the second conductor 42b.

[0059] Further, the insulating resin portion 43 is shaped so that the part thereof is exposed flush with the second plane 41b of the conductive resin portion 41. Further, the second conductor 42b constituting the conductor 42 includes the connecting portion 42b-1, which is the part further exposed in such a manner as to be flush with the surface of the part of the insulating resin portion 43 exposed from the second plane 41b of the conductive resin portion 41. That is, in this embodiment, the second plane 41b of the conductive resin portion 41, the exposed surface of the insulating resin portion 43 exposed from the second plane 41b, and the surface of the connecting portion 42b-1 are flush with each other.

[0060] Next, two connection examples for connecting another component to the connecting portion 42b-1 of the conductor 42 according to the fourth embodiment described above will be explained.

[0061] Fig. 8 is a schematic cross-sectional view showing a first connection example with respect to the connecting portion of the conductor of the fourth embodiment.

[0062] In the first connection example, a part of the composite material structure 4 including the connecting portion 42b-1 of the second conductor 42b, which together with the first conductor 12a forms the conductor 42, is provided with a through-hole 4a for connection. This through-hole 4a is provided to penetrate the connecting portion 42b-1, the insulating resin portion 43 located thereunder and containing an insulating fiber layer 43a-1 formed of insulating fibers 43a-1, and the conductive resin portion 41 located further thereunder and containing the conductive fiber layer 11a-1. Another component is fixed and connected to the connecting portion 42b-1 by a screw B4 penetrating the through-hole 4a, a nut N4 screwed to the screw B4, and an insulating washer WS4 arranged between the nut N4 and the conductive resin portion 11a-1.Examples of the other component in this example are a bus bar formed of a metal plate, an electric wire including at its end a connecting portion such as a round terminal that can be fastened by means of the screw B4, the nut N4 and the insulating washer WS4, and the like.

[0063] Further, as a modified example of the first connection example, for example, instead of the through hole 4a, a screw hole into which the screw B4 can be screwed may be provided, or a connector terminal having a terminal shape that allows attachment and detachment of the other component to the connecting portion 42b-1 may be provided.

[0064] Fig. 9 is a schematic cross-sectional view showing a second connection example with respect to the connecting portion of the conductor according to the fourth embodiment.

[0065] In the second connection example, an exposed core wire W41 is soldered and fixed to one end of an electrical wire with terminal W4 as another component to the connecting portion 42b-1 of the second conductor 42b of the composite material structure 4, which, together with the first conductor 12a, forms the conductor 42. A circular terminal W42 for connecting to an electrical / electronic device is crimped to the other end of the electrical wire with terminal W4.

[0066] As a modified example of the second connection example, instead of the electric wire having terminal W4, one end of a terminal of a connector may be soldered and fixed, for example. In another example, ultrasonic welding, crimping, or the like may be used as the connection method for connecting the connecting portion 42b-1 instead of soldering.

[0067] In the composite material structure 4 of the fourth embodiment described above, a decrease in strength can also be prevented by interposing the insulating resin portion 43 between the conductive reinforced resin and the conductor 42 as in the first embodiment and as described above.

[0068] Furthermore, according to this embodiment, the connecting portion 42b-1 is exposed at the second portion 41b-1, which includes the second level 41b of the step shape of the conductive resin portion 41, which is one step lower and forms an easily accessible part. And at this part, the insulating resin portion 43 is disposed between the connecting portion 42b-1 and the conductive fibers 11a on the side opposite to the exposed side of the conductor 42 to insulate them. With the connecting portion 42b-1 provided at the second portion 41b-1, while the insulation from the conductive fibers 11a is secured by the insulating resin portion 43, for example, the attachment of an electric wire and the like to the connecting portion 42b-1 can be easily performed.

[0069] Furthermore, in this embodiment, the insulating resin portion 43 is formed so that a portion thereof is exposed flush with the surface such as the second plane 41b and the standing plane 41c of the conductive resin portion 41. Furthermore, the conductor 42 includes the connecting portion 42b-1, which is the portion exposed from the part of the insulating resin portion 43 exposed from the second plane 41b. According to this configuration, since the insulating resin portion 43 does not protrude beyond the surface of the conductive resin portion 41 and is flush with it, it is possible to reduce the size of the composite structure 4 by this amount.

[0070] Furthermore, in this embodiment, the conductor 42 includes the connecting portion 42b-1, which is the part flush with the surface of the part of the insulating resin portion 43 exposed from the second plane 41b of the conductive resin portion 41. According to this configuration, since the connecting portion 42b-1 does not protrude from the surface of the insulating resin portion 43 and is flush with it, it is possible to reduce the size of the composite material structure 4 by this amount. Furthermore, since the insulating resin portion 43, including the surface flush with the connecting portion 42b-1, can support the entire connecting portion 42b-1, it is possible to improve the mechanical strength of the connecting portion 42b-1 against an external force.It is also possible to reduce the thickness of the connecting portion 42b-1 of the conductor 42 in view of improving the mechanical strength thereof, and it is also possible to use a conductive material having excellent electrical properties but slightly lower mechanical strength as the material for forming the connecting portion 42b-1 of the conductor 42.

[0071] Next, a composite material structure according to a fifth embodiment not forming part of the invention will be described with reference to Fig. 10 and Fig. 11 described.

[0072] Fig. 10 is a schematic perspective view showing a composite material structure of the fifth embodiment, and Fig. 11 is a schematic cross-sectional view taken along the line V51-V51 in Fig. 10, which shows the internal configuration of the Fig. 10 shows the composite material structure. In Fig. 10 and Fig. 11 are also the components that are similar to those of the first embodiment in Fig. 1 and Fig. 2, with the same reference numerals as in Fig. 1 and Fig. 2, and repeated explanations of the equivalent components are omitted below.

[0073] In a composite material structure 5 according to this embodiment, a quadrangular cylindrical recess 51b is provided on a wide surface 51a of a conductive resin portion 51 formed in a flat rectangular parallelepiped. Similar to the previously described first embodiment, the conductive resin portion 51 is formed of the conductive reinforced resin in which the stack of the conductive fiber layers 11a-1 formed of the conductive fibers 11a is impregnated with the molten insulating base material 11b. The recess 51b is formed by a part of the conductive fiber layer 11a-1. The shape of the recess 51b is not limited to a quadrangular cylinder-like shape, and it may be a polygonal cylinder-like shape other than a quadrangular cylinder-like shape, or it may be a circular cylinder-like shape as long as it is a cylinder-like shape.

[0074] The conductor 52 of the composite material structure 5 includes a first conductor 52a and a second conductor 52b. The first conductor 52a is completely embedded in the conductive resin portion 51 so that it is sandwiched between the conductive fiber layers 11a-1 of the stack of conductive fiber layers 11a-1. The second conductor 52b has a square plate shape and is arranged near the center of and connected to the first conductor 52a, with a part of the second conductor 52b exposed as a connecting portion 52b-1 at a bottom of the recess 51b in the conductive resin portion 51. Thus, the conductor 52 is embedded in the conductive resin portion 51 so that a part of the second conductor 52b is exposed as a connecting portion 52b-1 to form the bottom of the recess 51b. The shape of the second conductor 52b of the conductor 52 is not limited to a square plate shape. The shape of the second conductor 52b may have another shape, such asThe conductor 52 may be a circular plate shape, as long as a part of the second conductor 52b can form the bottom of the recess 51b in the conductive resin portion 51. Alternatively, the conductor 52 may consist only of the first conductor 52a without providing the second conductor 52b.

[0075] The insulating resin portions 53 of the composite material structure 5 are embedded in the conductive resin portion 51 so as to be disposed between the conductive reinforced resin and the second conductor 52b, with a part of the insulating resin portion 53 being exposed at the bottom, in a depth direction D51 of the recess 51b, of an inner peripheral surface of the recess 51b. At a part of the conductive resin portion 51 not located in the recess 51b, the insulating resin portions 53 are disposed between the conductive fibers 11a and the conductor 52 to accommodate the conductor 52 between the insulating resin portions 53. At a part where the recess 51b is provided, the insulating resin portion 53 is embedded in the conductive resin portion 51 so as to be disposed between the conductor 52 and the conductive fibers 11a on the side opposite to the exposed side of the conductor 52.On the inner peripheral surface of the recess 51b, the insulating resin portion 53 is disposed between the conductive reinforced resin and the second conductor 52b so as to cover an outer peripheral portion of the second conductor 52b over the entire circumference, thereby preventing the connecting portion 52b-1 of the second conductor 52b from contacting the conductive reinforced resin. Here, the insulating resin portion 53 is not limited to being configured with a part of it exposed at the bottom of the inner peripheral surface of the recess 51b; it may be exposed on the entire peripheral surface of the inner peripheral surface of the recess 51b, that is, the inner peripheral surface of the insulating resin portion 53 may form the recess 51b itself.

[0076] Next, two connection examples for connecting another component to the connecting portion 52b-1 of the conductor 52 of the fifth embodiment described above will be described.

[0077] Fig. 12 is a schematic cross-sectional view showing a first connection example with respect to the connecting portion of the conductor according to the fifth embodiment not forming part of the invention.

[0078] In the first connection example, a through-hole 5a for connection is provided at a part of the composite material structure 5 where the connecting portion 52b-1 of the second conductor 52b constituting the conductor 52 is provided. This through-hole 5a is provided to penetrate the connecting portion 52b-1, the underlying first conductor 52a, the further underlying insulating resin portion 53 including the insulating fiber layer 53a-1, and the further underlying conductive resin portion 51 including the conductive fiber layer 11a-1. Another component is fastened and connected to the connecting portion 52b-1 by a screw B5 inserted through the through-hole 5a, a nut N5 screwed onto the screw B5, and an insulating washer WS5 interposed between the nut N5 and the conductive resin portion 51.Examples of the other component in this example are a bus bar formed of a metal plate, an electric wire including at its end a connecting portion such as a round terminal that can be fastened with the screw B5, the nut N5, and the washer WS5, and the like.

[0079] As a modified example of the first connection example, a screw hole into which the screw B5 can be screwed may be provided instead of the through hole 5a, or a connector terminal having a terminal shape that allows attachment and detachment of the other component to the connecting portion 52b-1 may be provided.

[0080] Fig. 13 is a schematic cross-sectional view showing a second connection example with respect to the connecting portion of the conductor according to the fifth embodiment.

[0081] In the second connection example, an exposed core wire W51 is soldered and fixed to one end of an electric wire with terminal W5 as another component to the connecting portion 52b-1 of the second conductor 52b, which, together with the first conductor 52a, forms the conductor 52 of the composite material structure 5. A circular terminal W52 for connecting to an electrical / electronic device is crimped to the other end of the electric wire with terminal W5.

[0082] As a modified example of the second connection example, instead of the electric wire having terminal W5, one end of a plug terminal of a connector may be soldered and fixed, for example. In another example, ultrasonic welding, crimping, or the like may be used as the connection method for the connection with respect to the connecting portion 52b-1 instead of soldering.

[0083] In the composite material structure 5 of the fifth embodiment described above, a decrease in strength can also be prevented by interposing the insulating resin portions 53 between the conductive reinforced resin and the conductor 52 as in the first embodiment and as described above.

[0084] Furthermore, according to this embodiment, the inner peripheral surface of the recess 51b of the conductive resin portion 51 can support the peripheral portion of the connecting portion 52b-1, while preventing contact between the connecting portion 52b-1 exposed at the bottom of the recess 51b and the conductive fibers 11a by the insulating resin portion 53. With this peripheral portion support, it is possible to improve the mechanical strength of the connecting portion 52b-1 against an external force. It is also possible to reduce the thickness of the connecting portion 52b-1 of the conductor 52 with a view to improving the mechanical strength thereof, and it is also possible to use a conductive material having excellent electrical properties but slightly lower mechanical strength as the material for forming the connecting portion 52b-1 of the conductor 52.

[0085] Next, a composite material structure according to a sixth embodiment not forming part of the invention will be described with reference to Fig. 14 and Fig. 15 described.

[0086] Fig. 14 is a schematic perspective view showing a composite material structure of the sixth embodiment, Fig. 15 is a schematic cross-sectional view taken along the line V61-V61 in Fig. 14 and an internal configuration of the Fig. 14 shows the composite material structure. In Fig. 14 and Fig. 15 are also the components that correspond to those in Fig. 1 and Fig. 2, with the same reference numerals as in Fig. 1 and Fig. 2, and repeated explanations of the equivalent components are omitted below.

[0087] In the composite material structure 6 of this embodiment, rectangular parallelepiped-shaped insulating resin portions 63 protrude and are exposed from substantially the center of a wide surface 61a of a conductive resin portion 61 formed in a flat rectangular parallelepiped, sandwiching a second conductor 62b of a conductor 62. A square plate-shaped connecting portion 62b-1 of the second conductor 62b protrudes and is exposed from the insulating resin portions 63. Similar to the previously described first embodiment, the conductive resin portion 61 is formed of a conductive reinforced resin in which the stack of the conductive fiber layers 11a-1 formed of the conductive fibers 11a is impregnated with the molten insulating base material 11b.

[0088] The conductor 62 of the composite material structure 6 includes a first conductor 62a and a second conductor 62b. The first conductor 62a is completely embedded in the conductive resin portion 61. The second conductor 62b has a shape in which a square plate-shaped metal plate is bent to have an L-shaped cross section, and a part of the second conductor 62b corresponding to a cross beam of the L-shape is arranged near the center of the first conductor 62a and connected to it. A part of the second conductor 62b corresponding to a vertical beam of the L-shape protrudes and is exposed between the two layers of the insulating resin portions 63 as a square plate-shaped connecting portion 62b-1. Here, the shape of the second conductor 62b of the conductor 62 is not limited to the shape with the L-shaped cross section.The shape of the second conductor 62b is not limited to any particular shape as long as it can be placed on and connected to the first conductor 62a and a part of the second conductor 62b can protrude from the insulating resin portions 63, and the shape may be, for example, a shape having a Z-shaped, T-shaped, or C-shaped cross section.

[0089] The insulating resin portions 63 are formed in two layers so that the connecting portion 62b-1 of the second conductor 62b protrudes as described above and a remaining part of the conductor 62 is accommodated between the layers, and are embedded in the conductive resin portion 61 so as to be arranged between the conductive reinforced resin and the conductor 62.

[0090] Next, two connection examples for connecting another component to the connecting portion 62b-1 of the conductor 62 of the sixth embodiment described above will be described.

[0091] Fig. 16 is a schematic perspective view showing a first connection example with respect to the connecting portion of the conductor of the sixth embodiment.

[0092] In the first connection example, a through-hole 62b-2 for connection is provided through the connecting portion 62b-1 of the second conductor 62b constituting the conductor 62 of the composite material structure 6. Another component is to be fastened and connected to the connecting portion 62b-1 by a screw B6 inserted through the through-hole 62b-2 and a nut N6 screwed onto the screw B6. Examples of the other component in this example include a bus bar formed from a metal plate, an electric wire having a terminal part such as a round terminal at its end that can be fastened with the screw B6 and the nut N6, and the like.

[0093] As a modification example of the first connection example, a screw hole into which the screw B6 can be screwed may be provided instead of the through hole 62b-2, or a connector terminal having a terminal shape that allows attachment and detachment of the other component to the connecting portion 62b-1 may be provided.

[0094] Fig. 17 is a schematic cross-sectional view showing a second connection example with respect to the connecting portion of the conductor of the sixth embodiment.

[0095] In the second connection example, an exposed core wire W61 is soldered and fixed to one end of an electrical wire with terminal W6 as another component to the connecting portion 62b-1 of the second conductor 62b, which, together with the first conductor 62a, forms the conductor 62 of the composite material structure 6. A circular terminal W62 for connecting to an electrical / electronic device is crimped to the other end of the electrical wire with terminal W6.

[0096] As a modified example of the second connection example, instead of connecting the electric wire to the terminal W6, one end of a terminal of a connector may be soldered and fixed, for example. In another example, ultrasonic welding, crimping, or the like may be used as the connection method for the connection with respect to the connecting portion 62b-1 instead of soldering.

[0097] In the composite material structure 6 of the sixth embodiment described above, a decrease in strength can also be prevented by interposing the insulating resin portions 63 between the conductive reinforced resin and the conductor 62 as in the first embodiment and as described above.

[0098] Furthermore, in this embodiment, the insulating resin portions 63 partially protrude from the surface of the conductive resin portion 61, and the connecting portion 62b-1 of the conductor 62 is exposed from this protrusion portion. According to this configuration, the reliability of preventing contact between the connecting portion 62b-1 and the conductive reinforced resin can be increased, thereby further preventing galvanic corrosion.

[0099] Furthermore, in this embodiment, the part of the conductor 62 that protrudes from the exposed portions of the insulating resin portions 63 exposed from the conductive resin portion 61 is the connecting portion 62b-1. According to this configuration, since the connecting portion 62b-1 protrudes from the insulating resin portions 63, for example, the attachment of an electric wire or the like with respect to the connecting portion 62b-1 can be easily performed.

[0100] As one embodiment of a method for manufacturing composite material structures, a method for manufacturing composite material structures for obtaining the composite material structures 1, ..., and 6 of the first to sixth embodiments will be described next. The method for manufacturing composite material structures is substantially the same for the first to sixth embodiments, so the following explanation will be given with reference to a method for manufacturing composite material structures for manufacturing the composite material structure 1 of the first embodiment as an illustrative example.

[0101] Fig. 18 is a schematic diagram showing the flow of a composite material structure manufacturing method for forming the composite material structure of the first embodiment not forming part of the invention.

[0102] One in Fig. The method for manufacturing a composite material structure shown in Fig. 18 includes an insulating fiber placement step S11 and a resin portion forming step S12.

[0103] The insulating fiber placement step S11 is a step of attaching the plurality of insulating fiber sheets 13a-1 formed of the insulating fibers 13a to sandwich the entire conductor 12 including the second conductor 12b connected to the first conductor 12a.

[0104] A subsequent resin portion forming step S12 is a step for forming the conductive resin portion 11 and the insulating resin portions 13 using the conductor 12 completely enclosed between the insulating fiber layers 13a-1 to expose the connecting portion 12b-1. This resin portion forming step S12 includes a pre-exposure step S121 and an exposure step S122.

[0105] The pre-exposure step S121 is a step of forming a pre-exposure structure 1a obtained in a step S121c in which the conductor 12, including the connecting portion 12b-1, is completely in a non-exposed state. In the pre-exposure structure 1a, a part of the conductor 12, including the connecting portion 12b-1, is covered only with insulating resin Z1, which is a forming material of the insulating resin portion 13, and a remainder of the conductor 12 is covered with the insulating resin Z1 and conductive reinforced resin Z2, which is a forming material of the conductive resin portion 11. The pre-exposure step S121 further includes a conductive fiber layer placement step S121a, a base material impregnation step S121b, and the machining / polishing / cleaning step S121c.

[0106] The conductive fiber layer placement step S121a is a step of arranging the plurality of conductive fiber layers 11a-1 in a stack to sandwich a stack Z3 ​​consisting of the conductor 12 sandwiched between the plurality of insulating fiber layers 13a-1. At this time, the conductive fiber layers 11a-1 are arranged in the stack so as to be laminated to avoid the connecting portion 12b-1. The subsequent base material impregnation step S121b is a step of impregnating the conductive fiber layer 11a-1, which sandwiches the stack Z3 ​​and the insulating fiber layer 13a-1 of the stack Z3, with the molten insulating base material 11b. After subsequent curing, the conductor 12 is completely covered with the insulating resin Z1, and the entire insulating resin Z1 is further covered with the conductive reinforced resin Z2.The subsequent machining / polishing / cleaning step S121c is a step of machining / polishing the cured conductive reinforced resin Z2 formed in the base material impregnation step S121b into the conductive resin portion 11 having a desired shape, and then cleaning the polished powder. After this machining / polishing / cleaning step S121c, the pre-exposure structure 1a is completed.

[0107] The exposing step S122 following 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 insulating resin portions 13 are completed, thereby obtaining the composite material structure 1.

[0108] According to the above-described method for manufacturing the composite material structure, the composite material structure 1 in which a decrease in strength can be prevented while the insulating resin portions 13 are interposed between the conductive reinforced resin and the conductor 12 as described above can be obtained.

[0109] Furthermore, the method for producing the composite material of this embodiment is preferable because the structure of the composite material 1 can be obtained through a series of steps including arranging the conductive fiber layer 11a-1, the insulating fiber layer 13a-1 and the conductor 12 in the stack and impregnating the stack with the insulating base material 11b, thereby ensuring good processability.

[0110] Furthermore, in this embodiment, the connecting portion 12b-1 of the conductor 12 is protected because it is embedded in the pre-exposure structure 1a formed in the pre-exposure step S121 until the connecting portion 12b-1 is exposed in the exposure step S122. This protection can also prevent galvanic corrosion during manufacturing, e.g., during cleaning and the like, which are correspondingly performed during the manufacturing of the composite material structure 1.

[0111] In this embodiment, the insulating fiber layers 13a-1 and the conductive fiber layers 11a-1 are arranged in stacks in the insulating fiber placement step S11 and the conductive fiber layer placement step S121a. In the subsequent base material impregnation step S121b, the layer stacks are then impregnated with the insulating base material 11b. However, instead of the insulating fiber layer 13a-1 and the conductive fiber layer 11a-1, layered prepregs formed by previously incorporating fibers into a resin may be arranged in a stack and molded into a single part using heat bonding and the like to obtain the composite structure. In this method, the base material impregnation step S121b can be replaced by a step that performs heat bonding and the like of the stacked prepregs, thereby saving time and labor, and therefore, this method is preferable.

[0112] Next, a modified example according to the invention for the Fig. 18, the method for producing a composite material structure is explained.

[0113] Fig. 19 is a schematic diagram of the present invention showing the operation of a modified example of the Fig. 18 shown method for manufacturing a composite material structure. In Fig. 19 are the components that make up the Fig. 18 are the same, with the same reference numerals as in Fig. 18, and duplicate explanations of these same components will be omitted below.

[0114] In the method for manufacturing the composite material structure of this modified example, the insulating fiber placement step S21 and the exposure step S222 in the resin portion forming step S22 are different from that in Fig. 18 shown method for manufacturing the composite material structure.

[0115] First, in the method for manufacturing the composite material structure of this modified example, a composite material structure 1' according to a modified example is manufactured as described below. That is, the composite material structure 1' of the modified example further includes an insulator 14 formed of an insulating material to cover the non-exposed portion 12b-3 of the extended portion 12b-2 of the conductor 12 extending to the outside of the conductive resin portion 11. In the composite material structure 1' of the modified example, two layers of the insulating resin portions 13 are formed so that the extended insulating portions 13c of the respective layers extending from the conductive resin portion 11 accommodate the part of the non-exposed portion 12b-3 via a part of the insulator 14 covering the non-exposed portion 12b-3.The connecting portion 12b-1 protrudes from an end face of the insulator 14 and is exposed.

[0116] The insulating material from which the insulator 14 is formed may be any material that can ensure the insulating property, and examples include resin, rubber, elastomer, ceramic, and the like. When the insulator 14 is made of resin, rubber, or elastomer, examples of the molding method may include injection molding, extrusion molding, blow molding, vacuum casting, compression molding, casting, foam molding, hot melting, potting, and the like. In the case where the insulator 14 is molded from ceramic, examples of the molding method may include machining and the like. By press-fitting the conductor 12 into the insulator 14 molded in the manner described above, the insulator 14 is connected to the conductor 12.In addition, when molding the insulator 14 with resin, rubber, or elastomer, the surface of the conductor 12 is coated with these materials to simultaneously mold the insulator 14 and fix it to the conductor 12. Although the shape of the insulator 14 is described herein as a rectangular parallelepiped shape, as shown in FIG. Fig. 19, the shape of the insulator 14 is not limited thereto and may have another shape.

[0117] In the placement step of the insulating fiber S21 according to the manufacturing method of the composite material structure of the Fig. In the modified example shown in FIG. 19, the conductor 12 is prepared, and a part thereof, including the connecting portion 12b-1, is covered with the insulating material Z21, which is the forming material of the insulator 14. Then, the insulating fiber layers 13a-1 are placed so as to enclose this conductor 12. At this time, the insulating fiber layers 13a-1 are placed so as to overlap a part of the insulating material Z21.

[0118] Then, the conductive fiber layer placement step S121a, the base material impregnation step S121b, and the machining / polishing / cleaning step S121c in the pre-exposure step S121 in the resin portion formation step S22 are performed in a state where a part of the conductor 12 is covered with the insulating material Z21. The operation in each step at this time is the same as in Fig.18 for manufacturing the composite material structure. However, in the base material impregnation step S121b, the insulating resin Z1 and the conductive reinforced resin Z2 are formed so that a part of the insulating material Z21 covering the connecting portion 12b-1 protrudes and is exposed. Furthermore, in this modified example, the conductive resin portion 11 and the insulating resin portions 13 are completed in the pre-exposure structure 1a' obtained at the end of the machining / polishing / cleaning step S121c, but the connecting portion 12b-1 is still covered with the insulating material Z21.

[0119] In the final exposure step S222, the insulating material Z21 covering the connecting portion 12b-1 of the conductor 12 is removed from the pre-exposure structure 1a, thereby exposing the connecting portion 12b-1. After the exposure step S222, the composite material structure 1' of the modified example is obtained.

[0120] According to the method for manufacturing the composite structure according to the modified example described above, the composite structure 1 in which a decrease in strength is prevented while interposing the insulating resin portion 13 between the conductive reinforced resin and the conductor 12, as in the method for manufacturing the composite structure of the embodiment described above, can also be obtained.

[0121] Further, in the method for manufacturing the composite material structure according to this modified example, the connecting portion 12b-1 is protected by the insulating material Z21 until it is exposed in the exposing step S222, thereby also preventing galvanic corrosion during cleaning and the like performed during manufacturing.

[0122] Furthermore, according to the composite structure 1' obtained by the method for manufacturing the composite structure of this modified example, the reliability of preventing contact between the base side of the connecting portion 12b-1 and the conductive fibers 11a by the insulator 14 covering the non-exposed portion 12b-3 of the extended conductor portion 12b-2 can be further improved. According to the composite structure 1' described above, this improvement in the reliability of preventing contact can further prevent galvanic corrosion. List of reference symbols 1, 1', 2, 3, 4, 5, 6 Composite material structure 1a Pre-exposure structure 11, 41, 51, 61 Conductive resin section 11a Conductive fiber 11a-1 Conductive fiber layer 11b, 13b Insulating base material 12, 22, 32, 42, 52, 62 ladder 12a, 52a, 62a First Leader 12b, 32b, 42b, 52b, 62b Second conductor 12b-1, 22b-1, 42b-1, 52b-1, 62b-1 connecting section 12b-2 Extended ladder section 12b-3 Unexposed section 12b-4, 4a, 5a, 62b-2 through hole 13, 43, 53, 63 Insulating resin section 13a, 43a insulating fiber 13a-1, 43a-1, 53a-1 Insulating fiber layer 13c Extended insulation section 14 Insulator 32c lead 41a First Level 41a-1 First Section 41b Second Level 41b-1 Second Section 41c Standing area 51a, 61a area 51b Recess B1, B4, B5, B6 screw N1, N4, N5, N6 mother W1, W4, W5, W6 power cable with connector W11, W41, W51, W61 Exposed core wire W12, W42, W52, W62 round terminal WS4, WS5 Insulating washer D51 Depth direction Z1 Insulating material Z2 Conductive reinforced resin Z3 stack Z21 Insulating material S11 Insulation fiber placement step S12, S22 Resin section forming step S121 Pre-exposure step S121a Placement step of the conductive fiber layer S121b base material impregnation step S121c Processing / polishing / cleaning step S122, S222 exposure step

Claims

[1] Composite material structure (1') comprising: a conductive resin portion (11) formed of an electrically conductive reinforced resin in which conductive fibers (11a) are contained in an insulating base material (11b); a conductor (12) formed of an electrically conductive material, at least a part of which is embedded in the conductive resin portion (11); and a plurality of layers of insulating resin portions (13), which are layers of resin portions each containing insulating fibers (13a) contained in an insulating base material (13b), wherein the plurality of layers of insulating resin portions (13) are embedded in the conductive resin portion (11) to accommodate the at least part of the conductor (12) therebetween and to be arranged between the conductive fibers (11a) and the conductor (12), wherein the conductor (12) has an extended conductor portion (12b-2) extending to an outside of the conductive resin portion (11) and at least a part of which is exposed as a connecting portion (12b-2) for electrical connection with another component, the insulating resin portions (13) are arranged so as to be disposed between the conductive fibers (11a) and the conductor (12) to prevent the connecting portion (12b-1) exposed at the extended conductor portion (12b-2) from contacting the conductive fibers (11a), a part of the extended conductor portion (12b-2) at a distal end thereof spaced from the conductive resin portion (11) is exposed as the connecting portion (12b-1), each of the plurality of layers of insulating resin portions (13) includes an extended insulating portion (13c) extending from the conductive resin portion (11) together with the extended conductor portion (12b-2) such that the plurality of layers of insulating resin portions (13) enclose at least a part of a non-exposed portion (12b-3) of the extended conductor portion (12b-2) therebetween, the non-exposed portion (12b-3) being located on a base side of the extended conductor portion (12b-2) and excluding the connecting portion (12b-1), wherein the composite material structure (1') further comprises an insulator (14) formed of an insulating material to cover the non-exposed portion (12b-3) of the extended conductor portion (12b-2), and the plurality of layers of insulating resin portions (13) are formed such that the extended insulating portions (13c) of the respective layers of insulating resin portions (13) sandwich a part of the non-exposed portion (12b-3) via a part of the insulator (14) covering the non-exposed portion (12b-3). [2] Composite material structure (4) comprising: a conductive resin portion (41) formed of an electrically conductive reinforced resin in which conductive fibers (11a) are contained in an insulating base material (11b); a conductor (42) formed of an electrically conductive material, at least a part of which is embedded in the conductive resin portion (41); and a plurality of layers of insulating resin portions (43), which are layers of resin portions each containing insulating fibers (43a) contained in an insulating base material (13b), wherein the plurality of layers of insulating resin portions (43) are embedded in the conductive resin portion (41) to accommodate the at least part of the conductor (42) therebetween and to be arranged between the conductive fibers (11a) and the conductor (42), wherein the conductive resin portion (41) has a step-shaped portion including a first plane (41a) and a second plane (41b) arranged one step lower from the first plane (41a), the conductor (42) is embedded in the conductive resin portion (41) such that at a second portion (41b-1) of the conductive resin portion (41) including the second plane (41b), a part of the conductor (42) is exposed as a connecting portion (42b-1) for electrical connection to another component, and the remaining conductor (42) is embedded in the second portion (41b-1), and the insulating resin portions (43) are embedded in the conductive resin portion (41) such that at a first portion (41a-1) of the conductive resin portion (41) including the first plane (41a), the insulating resin portions (43) are disposed between the conductive fibers (11a) and the conductor (42) to accommodate the conductor (42) between the insulating resin portions (43), and at the second portion (41b-1) of the conductive resin portion (41), the insulating resin portions (43) are disposed between the conductor (42) and the conductive fibers (11a) on a side opposite an exposed side of the conductor (42). [3] The composite material structure (4, 1') according to claim 1 or 2, wherein the conductive resin portion (11, 41) comprises a conductive fiber layer (11a-1) formed of the conductive fibers (11a) impregnated with the insulating base material (11b). [4] The composite material structure (4, 1') according to any one of claims 1 to 3, wherein the insulating resin portions (13, 43) comprise insulating fiber layers (13a-1, 43a-1) formed from the insulating fibers (13a, 43a) impregnated with the insulating base materials (13b). [5] Composite material structure (4, 1') according to one of claims 1-4, wherein the conductor (12, 42) comprises a first conductor (12a) and a second conductor (12b, 42b), wherein the first conductor (12a) is completely embedded in the conductive resin portion (11, 41), the second conductor (12b, 42b) is connected to the first conductor (12a) within the conductive resin portion (11, 41), and at least a part of the second conductor (12b, 42b) is embedded in the conductive resin portion (11, 41), and the insulating resin portions (13, 43) are embedded in the conductive resin portion (11, 41) to be arranged between the conductive fibers (11a) and the conductor (12, 42) to accommodate therebetween the first conductor (12a) and at least an embedded part of the second conductor (12b, 42b) embedded in the conductive resin portion (11, 41). [6] A method for producing a composite material structure (1'), comprising: an insulating fiber placement step (S11) of placing insulating fibers (13a) to accommodate at least a part of a conductor (12) formed of an electrically conductive material therebetween; and a resin portion forming step (S12) in which a conductive resin portion (11) and a plurality of layers of insulating resin portions (13) are formed using the conductor (12) accommodated between the insulating fibers (13a), wherein the conductive resin portion (11) is formed of an electrically conductive, reinforced resin in which conductive fibers (11a) are contained in an insulating base material (11b), wherein at least a portion of the conductor (12) is embedded in the conductive resin portion (11), the plurality of layers of insulating resin portions (13) are layers of resin portions each containing insulating fibers (13a) contained in an insulating base material (13b), and the plurality of layers of insulating resin portions (13) are embedded in the conductive resin portion (11) to accommodate the at least a portion of the conductor (12) therebetween and to be arranged between the conductive fibers (11a) and the conductor (12), wherein the conductor (12) has an extended conductor portion (12b-2) extending to an outside of the conductive resin portion (11) and at least a part of which is exposed as a connecting portion (12b-2) for electrical connection with another component, the insulating resin portions (13) are arranged so as to be disposed between the conductive fibers (11a) and the conductor (12) to prevent the connecting portion (12b-1) exposed at the extended conductor portion (12b-2) from contacting the conductive fibers (11a), a part of the extended conductor portion (12b-2) at a distal end thereof spaced from the conductive resin portion (11) is exposed as the connecting portion (12b-1), each of the plurality of layers of insulating resin portions (13) includes an extended insulating portion (13c) extending from the conductive resin portion (11) together with the extended conductor portion (12b-2) such that the plurality of layers of insulating resin portions (13) enclose at least a part of a non-exposed portion (12b-3) of the extended conductor portion (12b-2) therebetween, the non-exposed portion (12b-3) being located on a base side of the extended conductor portion (12b-2) and excluding the connecting portion (12b-1), wherein the composite material structure (1') further comprises an insulator (14) formed of an insulating material to cover the non-exposed portion (12b-3) of the extended conductor portion (12b-2), and the plurality of layers of insulating resin portions (13) are formed such that the extended insulating portions (13c) of the respective layers of insulating resin portions (13) sandwich a part of the non-exposed portion (12b-3) via a part of the insulator (14) covering the non-exposed portion (12b-3). [7] A method for producing a composite material structure (4), comprising: an insulating fiber placement step (S11) of placing insulating fibers (43a) to accommodate at least a part of a conductor (42) formed of an electrically conductive material therebetween; and a resin portion forming step (S12) in which a conductive resin portion (41) and a plurality of layers of insulating resin portions (43) are formed using the conductor (42) accommodated between the insulating fibers (43a), wherein the conductive resin portion (41) is formed of an electrically conductive, reinforced resin in which conductive fibers (11a) are contained in an insulating base material (11b), wherein at least a portion of the conductor (42) is embedded in the conductive resin portion (41), the plurality of layers of insulating resin portions (43) are layers of resin portions each containing insulating fibers (43a) contained in an insulating base material (11b), and the plurality of layers of insulating resin portions (43) are embedded in the conductive resin portion (41) to accommodate the at least a portion of the conductor (42) therebetween and to be arranged between the conductive fibers (11a) and the conductor (42), wherein the conductive resin portion (41) has a step-shaped portion including a first plane (41a) and a second plane (41b) arranged one step lower from the first plane (41a), the conductor (42) is embedded in the conductive resin portion (41) such that at a second portion (41b-1) of the conductive resin portion (41) including the second plane (41b), a part of the conductor (42) is exposed as a connecting portion (42b-1) for electrical connection to another component, and the remaining conductor (42) is embedded in the second portion (41b-1), and the insulating resin portions (43) are embedded in the conductive resin portion (41) such that at a first portion (41a-1) of the conductive resin portion (41) including the first plane (41a), the insulating resin portions (43) are disposed between the conductive fibers (11a) and the conductor (42) to accommodate the conductor (42) between the insulating resin portions (43), and at the second portion (41b-1) of the conductive resin portion (41), the insulating resin portions (43) are disposed between the conductor (42) and the conductive fibers (11a) on a side opposite an exposed side of the conductor (42). [8] A method for producing a composite material structure (1', 4) according to claim 6 or 7, wherein the insulating fiber placement step (S11) is a step of placing a plurality of insulating fiber layers (13a-1, 43a-1) each formed from the insulating fibers (13a, 43a) so that the at least part of the conductor (12, 42) is embedded between the plurality of insulating fiber layers (13a-1, 43a-1), and the resin section forming step (S12) comprises: a step (S121a) of placing a plurality of conductive fiber layers (11a-1) formed from the conductive fibers (11a) such that the plurality of conductive fiber layers (11a-1) accommodate a stack (Z3) therebetween in which the at least part of the conductor (12, 42) is accommodated between the plurality of insulating fiber layers (13a-1, 43a-1); and a base material impregnation step (S121b) of impregnating the conductive fiber layers (11a-1) and the insulating fiber layers (13a-1, 43a-1) with a molten insulating base material (11b). [9] Method for producing a composite material structure (1', 4) according to one of claims 6 to 8, wherein the conductor (12, 42) is designed such that a part thereof is exposed as a connecting section (12b-1, 42b-1) for electrical connection to another component, and the resin section forming step (S12) comprises: a pre-exposure step (S121) of forming a pre-exposure structure (1a) in which the conductor (12, 42) is completely in a non-exposed state, and an exposure step (S122) of exposing the connecting portion (12b-1, 42b-1) by removing a part covering the connecting portion (12b-1, 42b-1) of the conductor (12, 42) from the pre-exposure structure (1a).

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