Snow melting radome and method for manufacturing the same

Abstract

This prevents the heater wire from breaking and improves durability for repeated use. [Solution] In the snow melting radome 1, metal plates 61 and 62 are embedded between the first resin substrate 3 and the second resin substrate 4 in a region of the base body 2 other than the electromagnetic wave transmission region R, so as to be separated from each other, and the connection parts 51 and 52 of the heater wire 5 embedded in the base body 2 and the wire harness connection terminals 71 and 72 are placed on the mounting surfaces 611 and 621 of each metal plate 61 and 62 so as to be spaced apart, and the metal plates 61 and 62 and the connection parts 51 and 52 are electrically connected at the heater wire joint parts 81a and 82a, and the metal plates 61 and 62 and the wire harness connection terminals 71 and 72 are electrically connected at the connection terminal joint parts 83a and 84a which are spaced apart from the heater wire joint parts 81a and 82a, and redundant wiring parts 53 and 54 are locally provided in the portion of the heater wire 5 that is positioned on the side of the heater wire 5 that is facing the electromagnetic wave transmission region R from the connection parts 51 and 52.

Description

Technical Field

[0004] , , , , , ,

[0001] The present invention relates to a snow melting dome such as a radome for an in-vehicle radar device having a snow melting function, and a method for manufacturing the same.

Background Art

[0002] Conventionally, there is a radome of Patent Document 1 as a radome for an in-vehicle radar device having a snow melting function. In the radome of Patent Document 1, a heater wire wired along a groove is embedded between a first resin base material and a second resin base material, and a first metal plate and a second metal plate are embedded between the first resin base material and the second resin base material in a region other than the electromagnetic wave transmission region so as to be isolated from each other. One end of the heater wire and one wire harness connection terminal are placed and fixed on the mounting surface of the first metal plate, and the other end of the heater wire and the other wire harness connection terminal are placed and fixed on the mounting surface of the second metal plate. Then, the first metal plate and the second metal plate can prevent the heat generated when the end of the heater wire wired to the resin base material and the wire harness connection terminal are conductively connected from melting the resin base material.

[0003] Furthermore, Patent Document 1 discloses an example of a radome in which the degree of freedom and diversity of the joining of the metal plate and the end of the heater wire and the joining of the metal plate and the wire harness connection terminal are enhanced. One end of the heater wire and the first metal plate are joined at a first heater wire joining portion formed of a conductive joining material, and the first metal plate and one wire harness connection terminal are joined at a first connection terminal joining portion formed of a conductive joining material spaced apart from the first heater wire joining portion. The other end of the heater wire and the second metal plate are joined at a second heater wire joining portion formed of a conductive joining material, and the second metal plate and the other wire harness connection terminal are joined at a second connection terminal joining portion spaced apart from the second heater wire joining portion.

Prior Art Documents

Patent Documents

[0004] [Patent Document 1] Patent No. 7158818 [Overview of the project] [Problems that the invention aims to solve]

[0005] By the way, in the example of a radome described in Patent Document 1, in which a first metal plate fitted into a resin substrate is joined to one end of a heater wire at a first heater wire joint, the first metal plate is joined to one wire harness connection terminal at a first connection terminal joint spaced apart from the first heater wire joint, the second metal plate is joined to the other end of a heater wire at a second heater wire joint, and the second metal plate is joined to another wire harness connection terminal at a second connection terminal joint spaced apart from the second heater wire joint, the portion of the heater wire on the electromagnetic wave transmission side from one end of the heater wire and the portion of the heater wire on the electromagnetic wave transmission side from the other end of the heater wire are wired in a straight line.

[0006] Therefore, the repeated thermal expansion of the heater wire during heating and the contraction of the heater wire when heating stops repeatedly applies tensile stress to this linear wiring section, making it prone to breakage. For this reason, there is a need for a radome that can prevent breakage of the heater wire and improve its durability against repeated use.

[0007] This invention is proposed in view of the above problems, and aims to provide a snow-melting radome and a method for manufacturing the same that can prevent breakage of the heater wire and improve the durability of the heater wire against repeated use. [Means for solving the problem]

[0008] The snow-melting radome of the present invention has an electromagnetic wave-transmitting base formed by laminating a first resin substrate and a second resin substrate, a heater wire wired in the planar direction of the base embedded between the first resin substrate and the second resin substrate, a first metal material and a second metal material embedded between the first resin substrate and the second resin substrate in a region of the base other than the electromagnetic wave-transmitting region, a first metal material and a second metal material embedded so as to be separated from each other, a first metal material is placed on the mounting surface such that one connection portion of the heater wire and a wire harness connection terminal are spaced apart, the first metal material and one connection portion of the heater wire are joined so as to be electrically connected at the first heater wire joint, and the first metal material and the first wire harness connection terminal are spaced apart from the first heater wire joint, The heater wire is joined to be electrically conductive at the sub-joint, the heater wire is placed on the mounting surface of the second metal material such that the other connection part of the heater wire and the other wire harness connection terminal are spaced apart, the second metal material and the other connection part of the heater wire are joined to be electrically conductive at the second heater wire joint, and the second metal material and the other wire harness connection terminal are joined to be electrically conductive at the second connection terminal joint which is spaced apart from the second heater wire joint, a first redundant wiring section is locally provided in the portion of the heater wire that is located on the side of the heater wire that is toward the electromagnetic wave transmission region than one of the connection parts of the heater wire, and a second redundant wiring section is locally provided in the portion of the heater wire that is located on the side of the heater wire that is toward the electromagnetic wave transmission region than the other connection part of the heater wire. According to this, a first redundant wiring section, locally provided in the portion of the heater wire located on the side of the heater wire facing the electromagnetic wave transmission region from one connection point, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near one connection point. Similarly, a second redundant wiring section, locally provided in the portion of the heater wire located on the side of the heater wire facing the electromagnetic wave transmission region from the other connection point, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near the other connection point. Therefore, breakage of the heater wire can be prevented, and the durability of the heater wire against repeated use can be improved. Furthermore, by joining the connection point between the metal material and the heater wire at the heater wire joint, and separately joining the metal material and the wire harness connection terminal at a connection terminal joint spaced apart from the heater wire joint, it is possible to use an appropriate joining method according to the design conditions and manufacturing environment, such as joining the connection point between the metal material and the heater wire by soldering or brazing, and joining the metal material and the wire harness connection terminal by laser welding, thereby increasing the freedom and diversity of joining methods. Furthermore, since the heater wire connection point and the wire harness connection terminal are electrically connected via a metal material, the length and amount of heater wire used can be reduced, thereby lowering component costs and manufacturing costs.

[0009] The snow-melting radome of the present invention is characterized in that the first redundant wiring section is formed in a meandering manner, and the second redundant wiring section is formed in a meandering manner. According to this, the redundant length of the meandering path allows for more reliable distribution and reduction of the thermal stress repeatedly applied to the heater wire, thereby more reliably reducing the effects of expansion and contraction on the heater wire due to thermal stress. Furthermore, the meandering path allows for extending the length of the redundant path while ensuring the required wire width necessary for snow melting on the heater wire.

[0010] The snow-melting radome of the present invention is characterized in that a first redundant wiring section is locally provided at the tip end of one of the heater wires, connected to the first connection end, and a second redundant wiring section is locally provided at the tip end of the other connection end of the heater wires, connected to the other connection end. According to this, the first redundant wiring section at the end can disperse and reduce the thermal stress repeatedly applied to the heater wire portion near one connection point, and the second redundant wiring section at the end can also disperse and reduce the thermal stress repeatedly applied to the heater wire portion near the other connection point. Therefore, the breakage of the heater wire can be prevented more reliably, and the durability of the heater wire against repeated use can be further improved.

[0011] The snow-melting radome of the present invention is characterized in that the first tip redundant wiring section is formed in a meandering manner, and the second tip redundant wiring section is formed in a meandering manner. According to this, the redundant length of the meandering paths of the first and second redundant wiring sections at the front end allows for more reliable distribution and reduction of the thermal stress repeatedly applied to the heater wire, thereby more reliably reducing the effects of expansion and contraction on the heater wire due to thermal stress. Furthermore, the meandering paths allow for extending the length of the redundant paths while ensuring the required wire width necessary for snow melting on the heater wire.

[0012] The present invention provides a method for manufacturing a snow-melting radome, comprising fitting a first metal material and a second metal material into first recesses and second recesses, respectively, formed on one surface of an electromagnetic wave-transmitting first resin substrate so as to be separated from each other, laying heater wires in a predetermined pattern on one surface of the first resin substrate, placing one connection portion of the heater wires on the exposed mounting surface of the first metal material, and locally forming a first redundant wiring portion on the portion of the heater wires that is positioned on the side of the heater wires toward the electromagnetic wave-transmitting region from the one connection portion of the heater wires, and the exposure of the second metal material The first step is to place the other connection portion of the heater wire on the mounting surface and locally form a second redundant wiring portion on the portion of the heater wire that is positioned on the side of the other connection portion of the heater wire toward the electromagnetic wave transmission region, and to place a wire harness connection terminal on the exposed mounting surface of the first metal material so as to be spaced apart from one connection portion of the heater wire, and to join the first metal material and one connection portion of the heater wire so as to be electrically connected at the first heater wire joint, and to connect the first metal material and the one wire harness connection terminal in front The first step involves joining the first heater wire joint and the first connection terminal joint, which is spaced apart from the first heater wire joint, so that they are electrically connected, and placing another wire harness connection terminal on the exposed mounting surface of the second metal material so that it is spaced apart from the other connection part of the heater wire, joining the second metal material and the other connection part of the heater wire so that they are electrically connected at the second heater wire joint, and joining the second metal material and the other wire harness connection terminal so that they are electrically connected at the second connection terminal joint, which is spaced apart from the second heater wire joint, and the first metal The present invention is characterized by comprising a third step of forming an electromagnetic wave-transmitting second resin substrate by injection molding on the mounting surface of the material and the mounting surface of the second metal material, fixing the second resin substrate to the first resin substrate, and embedding the heater wire, the first metal material, the first wire harness connection terminal, the first heater wire joint, the first connection terminal joint, the second metal material, the other wire harness connection terminal, the second heater wire joint, and the second connection terminal joint between the first resin substrate and the second resin substrate. According to this, a first redundant wiring section, locally provided in the portion of the heater wire located on the side of the heater wire facing the electromagnetic wave transmission region beyond one connection point, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near one connection point. Similarly, a second redundant wiring section, locally provided in the portion of the heater wire located on the side of the heater wire facing the electromagnetic wave transmission region beyond the other connection point, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near the other connection point. Therefore, in the manufactured snow-melting radome, breakage of the heater wire can be prevented, and the durability of the heater wire against repeated use can be improved. Furthermore, by providing the first and second metal materials, it is possible to prevent the heat generated when joining the connection point of the heater wire wired to the resin substrate to the metal material at the heater wire joint, or when joining the metal material to the wire harness connection terminal at the connection terminal joint, from melting and damaging the resin substrate. Furthermore, by laying heater wires on the first resin substrate, it becomes possible to lay heater wires on the first resin substrate of any suitable shape, thereby increasing the freedom of the shape of the first resin substrate and the snow melting radome, as well as increasing the freedom of the heater wire wiring pattern and wiring density. In addition, by joining the connection part between the metal material and the heater wire at the heater wire joint, and separately joining the metal material and the wire harness connection terminal at a connection terminal joint spaced apart from the heater wire joint, it becomes possible to join the metal material and the heater wire connection part and the metal material and the wire harness connection terminal using an appropriate joining method according to the design conditions and manufacturing environment, for example, by soldering or brazing the metal material and the heater wire connection part, and by laser welding the metal material and the wire harness connection terminal, thereby increasing the freedom and diversity of joining methods. Moreover, since the heater wire connection part and the wire harness connection terminal are electrically connected via the metal material, the length and amount of heater wire used can be reduced, thereby reducing component costs and manufacturing costs.

[0013] The present invention provides a method for manufacturing a snow-melting radome, characterized in that, in the first step, a first redundant wiring section is locally formed at the tip of one of the heater wires, connected to the first connection, and a second redundant wiring section is locally formed at the tip of the other connection of the heater wire, connected to the other connection. According to this, the first redundant wiring section at the front end can disperse and reduce the thermal stress repeatedly applied to the heater wire portion near one connection point, and the second redundant wiring section at the front end can also disperse and reduce the thermal stress repeatedly applied to the heater wire portion near the other connection point. This makes it possible to obtain a snow melting radome that more reliably prevents breakage of the heater wire and further improves the durability of the heater wire against repeated use. [Effects of the Invention]

[0014] According to the present invention, a snow-melting radome can be obtained that prevents breakage of the heater wire and improves the durability of the heater wire against repeated use. [Brief explanation of the drawing]

[0015] [Figure 1] (a) is a front view of a snow-melting radome according to an embodiment of the present invention, and (b) is a partially enlarged front view of the same figure (a). [Figure 2] A schematic longitudinal section of the snow-melting radome according to the embodiment. [Figure 3] (a) to (d) are process diagrams illustrating the manufacturing process of the snow melting radome according to the embodiment. [Figure 4] This is an explanatory diagram showing the state in which the first resin substrate, metal plate, heater wire, and wire harness connection terminals of the snow melting radome of the embodiment are arranged inside the mold. [Figure 5] A partially enlarged front view of the first modified snow-melting radome of the embodiment. [Figure 6] A partially enlarged front view of a second modified example of the snow-melting radome of the embodiment. [Figure 7] A partially enlarged front view of a third modified example of the snow-melting radome of the embodiment. [Figure 8]Partial enlarged front view of the fourth modification of the snow-melting dome according to the embodiment. [Figure 9] (a) to (c) are process explanatory diagrams for explaining a modification of the manufacturing process of the snow-melting dome according to the embodiment.

Mode for Carrying Out the Invention

[0016] 〔Snow-melting dome according to the embodiment〕 The snow-melting dome 1 according to the embodiment of the present invention is used as, for example, a dome for an in-vehicle radar device such as a bumper cover attached to a bumper of a vehicle. As shown in FIGS. 1 and 2, it includes an electromagnetic wave-transmissive substrate 2. The substrate 2 is composed of, for example, a first resin base material 3 disposed on the side opposite to the visual recognition side, which is the radar device side such as an in-vehicle radar device, and a second resin base material 4 disposed on the visual recognition side, which is the front side of the first resin base material 3. The first resin base material 3 and the second resin base material 4 are laminated and arranged, and in this embodiment, the first resin base material 3 and the second resin base material 4 are laminated and fixed to each other. Incidentally, if necessary, the second resin base material 4 may be disposed on the side opposite to the visual recognition side, and the first resin base material 3 may be disposed on the visual recognition side.

[0017] The first resin base material 3 and the second resin base material 4 are each formed of an insulating and electromagnetic wave-transmissive synthetic resin, and the first resin base material 3 and the second resin base material 4 can have an appropriate shape within an applicable range such as a flat plate shape or a curved plate shape, for example. Different synthetic resins or the same synthetic resin can be used for the first resin base material 3 and the second resin base material 4. When the refractive index n defined based on the complex dielectric constant matches each other, or when the first resin base material 3 and the second resin base material 4 are formed of materials having substantially the same or close refractive index n, it is preferable from the viewpoint of improving the transmission performance of electromagnetic waves. As the numerical range of the refractive indices of the first resin base material 3 and the second resin base material 4 that are close to each other, it is good if the difference in the refractive indices of the first resin base material 3 and the second resin base material 4 is within the range of 0 to 10%.

[0018] Here, the refractive index n is a quantity defined by Equation 1, which is derived from the real part εr' and the imaginary part εr'' of the relative permittivity. From the viewpoint of transmittance, it is preferable that the magnitude of the dielectric loss tangent tanδ, defined by Equation 2 from the ratio of the imaginary and real parts at the applicable frequency, be 0.1 or less. It is also preferable that the magnitude of the real part of the relative permittivity be 3 or less. By keeping the magnitudes of the dielectric loss tangent and the real part of the non-dielectric constant below these values, it is possible to reliably reduce the reflectivity and internal loss required for the radome.

[0019]

number

[0020]

number

[0021] The synthetic resin of the first resin substrate 3 and the synthetic resin of the second resin substrate 4 can be any synthetic resin appropriate within the scope of the present invention. For example, it is preferable to use one or more of the following: acrylic resins such as polymethyl methacrylate (PMMA), polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylate copolymer (ASA), acrylonitrile-ethylenepropyl rubber-styrene copolymer (AES), polypropylene (PP), polyphenylene ether (PPE), modified polyphenylene ether (m-PPE), polystyrene (PS), etc., either alone or in combination of two or more. Additives may also be included. Furthermore, foamed synthetic resins may be used. Furthermore, regarding the thickness of the first resin substrate 3 and the second resin substrate 4 in the electromagnetic wave transmission direction, the ratio of the thickness of the first resin substrate 3 to the thickness of the second resin substrate 4, the thickness of the first substrate resin 3, the thickness of the second resin substrate 4, and the total thickness of the base body 2 composed of the first resin substrate 3 and the second resin substrate 4 are appropriate within a range that ensures the required electromagnetic wave transmission for the snow melting radome 1.

[0022] The snow-melting radome 1 has heater wires 5 wired in a predetermined pattern in the direction of the electromagnetic wave-transmitting substrate 2 so as to exhibit snow-melting function in the electromagnetic wave-transmitting region R. The conductive material constituting the heater wires 5 can be any conductive material within the scope of the present invention, such as copper, silver, silver-plated copper, copper-silver alloy, copper-nickel alloy, nickel-chromium alloy, iron-chromium alloy, transparent conductive films such as ITO films, or carbon fibers. Furthermore, the form of the heater wire is not limited, and wire, conductive ink, conductive filler materials, etc., can be used.

[0023] In the illustrated example, the heater wire 5 is formed by meandering and folding along the direction in which the plate-shaped base body 2 expands, extending in a continuous line. The straight sections of the heater wire 5 are arranged side by side with spacing along the plane direction of the base body 2 in and outside the electromagnetic wave irradiation area R of the radar device on the base body 2, and the direction of the current flowing through the straight sections of adjacent heater wires 5 is set to be approximately antiparallel or antiparallel to each other.

[0024] Furthermore, the heater wire 5 is embedded between the first resin substrate 3 and the second resin substrate 4, and is sandwiched between the first resin substrate 3 and the second resin substrate 4, and is installed and sealed inside the base body 2 composed of the first resin substrate 3 and the second resin substrate 4. In this embodiment, the heater wire 5 is routed along a groove 31 formed on the side of the first resin substrate 3 that is fixed to the second resin substrate 4, and another groove 41 formed on the side of the second resin substrate 4 that is fixed to the first resin substrate 3, opposite to the groove 31, and the heater wire 5 is fixed to the first resin substrate 3 and the second resin substrate 4, respectively. It is also possible to configure the heater wire 5 to be routed by fixing the contact area to the first resin substrate 3 without forming either or both of the grooves 31 in the first resin substrate 3 and the other groove 41 in the second resin substrate 4.

[0025] In the region of the substrate 2 other than the electromagnetic wave transmission region R, in this embodiment, in the region of the tab 21 that protrudes laterally, a first recess 32 and a second recess 33 are formed on the fixing surface side of the first resin substrate 3, separated from each other. A first metal plate 61 corresponding to a conductive first metal material and a second metal plate 62 corresponding to a conductive second metal material are fitted into the first recess 32 and the second recess 33, respectively. That is, the first metal plate 61 and the second metal plate 62 are embedded between the first resin substrate 3 and the second resin substrate 4 so as to be separated from each other, and the first metal plate 61 and the second metal plate 62 are provided in an insulated state from each other.

[0026] The mounting surface 611 of the first metal plate 61 is placed such that one connection portion 51 of the heater wire 5 and one wire harness connection terminal 71 are spaced apart. The first metal plate 61 and one connection portion 51 of the heater wire 5 are joined together at the first heater wire joint portion 81a so that they are electrically connected, and the first metal plate 61 and one wire harness connection terminal 71 are joined together at the first connection terminal joint portion 83a, which is spaced apart from the first heater wire joint portion 81a so that they are electrically connected (see Figures 2 and 3).

[0027] The conductive connection of the first heater wire joint 81a and the conductive connection of the first connection terminal joint 83a connects one connection portion 51 of the heater wire 5 to one wire harness connection terminal 71 via the conductive first metal plate 61. The first heater wire joint 81a and the first connection terminal joint 83a can each be configured in a suitable manner to enable conductive connection. For example, they can be made of a conductive joining material with added solder or brazing material, or a welded joint such as a laser weld. Furthermore, the first heater wire joint 81a and the first connection terminal joint 83a may be made of different types of joining materials instead of the same type.

[0028] The mounting surface 621 of the second metal plate 62 is placed such that the other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72 are spaced apart, and the second metal plate 62 and the other connection portion 52 of the heater wire 5 are joined together so that they are electrically connected at the second heater wire joint portion 82a, and the second metal material 62 and the other wire harness connection terminal 72 are joined together so that they are electrically connected at the second connection terminal joint portion 84a which is spaced apart from the second heater wire joint portion 82a (see Figures 2 and 3).

[0029] The conductive connection of the second heater wire joint 82a and the conductive connection of the second connection terminal joint 84a connects the other connection part 52 of the heater wire 5 to the other wire harness connection terminal 72 via the conductive second metal plate 62. The second heater wire joint 82a and the second connection terminal joint 84a can each be configured in a suitable manner to enable conductive connection. For example, it is preferable to have a joint made of a conductive joining material with added solder or brazing material, or a joint made of a weld such as laser welding. Furthermore, the second heater wire joint 82a and the second connection terminal joint 84a may be made of different types of joints rather than the same type.

[0030] A first redundant wiring section 53 is locally provided in the portion of the heater wire 5 located on the side of one connection point 51 toward the electromagnetic wave transmission region R. The first redundant wiring section 53 is redundantly wired as part of the heater wire 5 near the connection point 51 between the electromagnetic wave transmission region R and the connection point 51, and is fixed to the first resin substrate 3 and the second resin substrate 4. A second redundant wiring section 54 is locally provided in the portion of the heater wire 5 located on the side of the other connection point 52 toward the electromagnetic wave transmission region R. The second redundant wiring section 54 is redundantly wired as part of the heater wire 5 near the other connection point 52 between the electromagnetic wave transmission region R and the other connection point 52, and is fixed to the first resin substrate 3 and the second resin substrate 4.

[0031] The first redundant wiring section 53 is formed in a meandering direction perpendicular to the extension direction of one wire harness connection terminal 71, and in this embodiment, it is formed in a meandering rectangular wave shape that bends at a right angle or approximately at a right angle. The second redundant wiring section 54 is formed in a meandering direction perpendicular to the extension direction of another wire harness connection terminal 72, and in this embodiment, it is formed in a meandering rectangular wave shape that bends at a right angle or approximately at a right angle. It is preferable that the number of meandering repetitions corresponding to one period of the rectangular wave in the first redundant wiring section 53 and the second redundant wiring section 54 be one or more, but it is more preferable to have two or more repetitions from the viewpoint of improving the dispersion of thermal stress. Furthermore, the meandering fluctuation width W1, which corresponds to the fluctuation width of the rectangular wave in the first redundant wiring section 53 and the second redundant wiring section 54, is preferably 5 times or more the line width of the heater wire 5 from the viewpoint of improving the dispersion of thermal stress, and more preferably 10 times or more. Also, from the viewpoint of minimizing the installation space of the first redundant wiring section 53 and the second redundant wiring section 54, it is preferably 30 times or less the line width of the heater wire 5.

[0032] When manufacturing the snow-melting radome 1 of this embodiment, a first recess 32 and a second recess 33 are formed on one surface of the electromagnetic wave-transmitting first resin substrate 3 so as to be isolated from each other. The first recess 32 and the second recess 33 may be formed by correspondingly shaped protrusions in the mold when the first resin substrate 3 is formed by injection molding, or they may be formed on the resin substrate by cutting or other processes. Furthermore, a first metal plate 61 and a second metal plate 62 are fitted into the first recess 32 and the second recess 33, respectively, which are formed so as to be isolated from each other in the first resin substrate 3 (see Figure 3(a)).

[0033] Then, the heater wire 5 is laid on one surface of the first resin substrate 3 in a predetermined pattern, one connection portion 51 of the heater wire 5 is placed on the exposed mounting surface 611 of the first metal plate 61, and a first redundant wiring portion 53 is locally formed on the portion of the heater wire 5 that is positioned toward the electromagnetic wave transmission region R from the one connection portion 51, and the other connection portion 52 of the heater wire 5 is placed on the exposed mounting surface 621 of the second metal plate 62, and a second redundant wiring portion 54 is locally formed on the portion of the heater wire 5 that is positioned toward the electromagnetic wave transmission region R from the other connection portion 52 (see Figure 3(b)). In this example, when laying the heater wire 5, a groove 31 is formed in the first resin substrate 3 that melts and fixes to the heater wire 5. When laying the heater wire 5 on one surface of the first resin substrate 3 in a predetermined pattern, it is possible to use an appropriate laying method within the applicable range, but for example, welding by ultrasonic vibration or printing is preferred.

[0034] Furthermore, as a method for manufacturing a modified version, as shown in Figures 9(a) to (c), the heater wire 5 is laid in a predetermined pattern on one surface of the first resin substrate 3 in an area that does not overlap with the first recess 32 and the second recess 33 of the first resin substrate 3. Then, the first metal plate 61 and the second metal plate 62 are fitted into the first recess 32 and the second recess 33, respectively. After that, the heater wire 5 is laid to connect in the area that overlaps with the first recess 32 and the second recess 33. One connection portion 51 of the heater wire 5 is placed on the exposed mounting surface 611 of the first metal plate 61, and the other connection portion 52 of the heater wire 5 is placed on the exposed mounting surface 621 of the second metal plate 62. The laying of the heater wire 5 in the area that overlaps with the first recess 32 and the second recess 33 may be performed using the heater wire 5 that has been laid in advance to be placed on the first metal plate 61 and the second metal plate 62 before fitting.

[0035] Furthermore, as shown in Figures 3(c) and 3(d), one wire harness connection terminal 71 is placed on the exposed mounting surface 611 of the first metal plate 61 such that it is spaced apart from one of the connection portions 51 of the heater wire 5, and the first metal plate 61 and one of the connection portions 51 of the heater wire 5 are joined together at the first heater wire joint 81a so that they are electrically connected, and the first metal plate 61 and one wire harness connection terminal 71 are joined together at the first connection terminal joint 83a which is spaced apart from the first heater wire joint 81a so that they are electrically connected.

[0036] Furthermore, another wire harness connection terminal 72 is placed on the exposed mounting surface 621 of the second metal plate 62 such that it is spaced apart from the other connection portion 52 of the heater wire 5, and the second metal plate 62 and the other connection portion 52 of the heater wire 5 are joined together at the second heater wire joint portion 82a so that they are electrically connected, and the second metal plate 62 and the other wire harness connection terminal 72 are joined together at the second connection terminal joint portion 84a which is spaced apart from the second heater wire joint portion 82a so that they are electrically connected.

[0037] Subsequently, as shown in Figure 4, the first resin substrate 3, to which the heater wire 5, the first metal plate 61 and the second metal plate 62, and the wire harness connection terminals 71 and 72 are attached, is placed inside the mold 100, which is made up of split molds. At this time, the wire harness connection section 7, from which the wire harness connection terminals 71 and 72 are pulled out, is led out to the outside of the mold 100 through an outlet 102 formed in a part of the mold 100.

[0038] Then, molten resin MR is poured into the mold 100 from the injection port 101 to perform injection molding, and the second resin base material 4 is formed by injection molding on the mounting surface 611 of the first metal plate 61 and the mounting surface 621 of the second metal plate 62, and the second resin base material 4 is fixed to the first resin base material 3. The interface of the second resin substrate 4, which is laminated by injection molding, is molded and welded to the first resin substrate 3, heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, and other wire harness connection terminals 72, and the heater wire 5, first metal plate 61, one wire harness connection terminal 71, first heater wire joint 81a, first connection terminal joint 83a, second metal plate 62, other wire harness connection terminals 72, second heater wire joint 82a, and second connection terminal joint 84a are embedded between the first resin substrate 3 and the second resin substrate 4.

[0039] The second resin substrate 4 is formed to cover the portion of the heater wire 5 that protrudes outside the groove 31. As a result, the portion of the heater wire 5 that protrudes outside the groove 31 is molded and fixed to the second resin substrate 4 by insert molding, and the heater wire 5 is fitted into another groove 41 of the second resin substrate 4. The second resin substrate 4 is not limited to being formed by injection molding, and may be fixed to the first resin substrate 3 by adhesive or other means as needed. After the formation of the second resin substrate 4, the mold 100 is demolded to obtain the snow melting radome 1 of this embodiment.

[0040] According to this embodiment, the first redundant wiring section 53, which is locally provided on the portion of the heater wire 5 located on the side of the heater wire 5 facing the electromagnetic wave transmission region R from one connection section 51, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near the one connection section 51. Similarly, the second redundant wiring section 54, which is locally provided on the portion of the heater wire 5 located on the side of the heater wire 5 facing the electromagnetic wave transmission region R from the other connection section 52, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire near the other connection section 52. Therefore, breakage of the heater wire 5 can be prevented, and the durability of the heater wire 5 against repeated use can be improved.

[0041] Furthermore, by providing the first metal plate 61 and the second metal plate 62, it is possible to prevent the heat generated when the connection parts 51 and 52 of the heater wire 5 wired to the first resin substrate 3 and the wire harness connection terminals 71 and 72 are joined to the metal plates 61 and 62 to establish electrical connection from melting and damaging the first resin substrate 3.

[0042] Furthermore, by joining the connection parts 51 and 52 of the metal plates 61 and 62 to the heater wires 5 at the heater wire joints 81a and 82a, and separately joining the metal plates 61 and 62 to the wire harness connection terminals 71 and 72 at the connection terminal joints 83a and 84a which are spaced apart from the heater wire joints 81a and 82a, it is possible to join the metal plates 61 and 62 to the connection parts 51 and 52 of the heater wires 5 and to the wire harness connection terminals 71 and 72 by using an appropriate joining method according to the design conditions and manufacturing environment, such as joining the metal plates 61 and 62 to the connection parts 51 and 52 of the heater wires 5 by soldering or brazing, and joining the metal plates 61 and 62 to the wire harness connection terminals 71 and 72 by laser welding, thereby increasing the freedom and diversity of joining methods. Furthermore, since the connection parts 51 and 52 of the heater wire 5 and the wire harness connection terminals 71 and 72 are electrically connected via the metal plates 61 and 62, the length and amount of heater wire 5 used can be reduced, thereby lowering component costs and manufacturing costs.

[0043] Furthermore, by forming the first redundant wiring section 53 and the second redundant wiring section 54 in a meandering manner, the redundant length of the meandering path can more reliably distribute and reduce the thermal stress repeatedly applied to the heater wire portion, thereby more reliably reducing the effects of expansion and contraction on the heater wire 5 due to thermal stress. In addition, the meandering path allows for extending the length of the redundant path while ensuring the required wire width necessary for snow melting of the heater wire 5.

[0044] Furthermore, by laying the heater wires 5 on the first resin substrate 3, it becomes possible to lay the heater wires 5 on the first resin substrate 3 of an appropriate shape, thereby increasing the degree of freedom in the shape of the first resin substrate 3 and the snow melting radome 1, as well as increasing the degree of freedom in the wiring pattern and wiring density of the heater wires 5.

[0045] [Snow-melting radome of the first modified embodiment] In the first modified snow-melting radome 1p of the above embodiment, as shown in Figure 5, the first redundant wiring section 53p, which is formed by meandering in a direction perpendicular to the extension direction of one wire harness connection terminal 71, is formed in an S-shaped wave form that curves and bends like a sinusoid, and the second redundant wiring section 54p, which is formed by meandering in a direction perpendicular to the extension direction of the other wire harness connection terminal 72, is formed in an S-shaped wave form that curves and bends like a sinusoid. It is preferable that the number of meanders corresponding to one period of the sinusoid in the first redundant wiring section 53p and the second redundant wiring section 54p be one or more, but it is more preferable to have two or more meanders from the viewpoint of improving the dispersion of thermal stress. Furthermore, the meandering fluctuation width W2, which corresponds to the fluctuation width of the sine wave in the first redundant wiring section 53p and the second redundant wiring section 54p, is preferably 5 times or more the wire width of the heater wire 5 from the viewpoint of improving the dispersion of thermal stress, and more preferably 10 times or more. Also, from the viewpoint of minimizing the installation space of the first redundant wiring section 53p and the second redundant wiring section 54p, it is preferably 30 times or less the wire width of the heater wire 5.

[0046] The other components of the snow-melting radome 1p of the first modified example are the same as those of the snow-melting radome 1 of the above embodiment. Furthermore, the snow-melting radome 1p of the first modified example can be manufactured using the same manufacturing process as the snow-melting radome 1 of the above embodiment.

[0047] The first modified snow-melting radome 1p and its manufacturing method can exhibit corresponding effects from a configuration corresponding to the snow-melting radome 1 or its manufacturing method of the above embodiment.

[0048] [Snow-melting radome of a second modified embodiment] In the second modified snow-melting radome 1q of the above embodiment, as shown in Figure 6, the first redundant wiring section 53q is formed by meandering in the direction of extension of one wire harness connection terminal 71 and meandering in a rectangular wave shape that bends at a right angle or approximately at a right angle, and the second redundant wiring section 54q is formed by meandering in the direction of extension of the other wire harness connection terminal 72 and meandering in a rectangular wave shape that bends at a right angle or approximately at a right angle. It is preferable that the number of meanders corresponding to one period of the rectangular wave in the first redundant wiring section 53q and the second redundant wiring section 54q be one or more, but it is more preferable to have two or more meanders from the viewpoint of improving the dispersion of thermal stress. Furthermore, the meandering fluctuation width W3, which corresponds to the fluctuation width of the rectangular wave in the first redundant wiring section 53q and the second redundant wiring section 54q, is preferably 5 times or more the line width of the heater wire 5 from the viewpoint of improving the dispersion of thermal stress, and more preferably 10 times or more. Also, from the viewpoint of minimizing the installation space of the first redundant wiring section 53q and the second redundant wiring section 54q, it is preferably 30 times or less the line width of the heater wire 5.

[0049] The other configurations of the snow-melting radome 1q of the second modified example are the same as those of the snow-melting radome 1 of the above embodiment. Furthermore, the snow-melting radome 1q of the second modified example can be manufactured using the same manufacturing process as the snow-melting radome 1 of the above embodiment. In addition, as a further modification of the second modified example, the first redundant wiring section 53q may be formed by meandering and curving in a sinusoidal shape in the extension direction of one wire harness connection terminal 71, and the second redundant wiring section 54q may be formed by meandering and curving in a restricted wave shape in the extension direction of the other wire harness connection terminal 72. In this case, the configuration of the first modified example can be adopted for the preferred number of meandering repetitions and the preferred meandering variation range.

[0050] A second modified snowmelt radome 1q or a further modified snowmelt radome 1q and its manufacturing method can exhibit corresponding effects from a configuration corresponding to the snowmelt radome 1 or its manufacturing method of the above embodiment.

[0051] [Snow-melting radome of a third modified embodiment] As shown in Figure 7, the third modified snow-melting radome 1r of the above embodiment has a first redundant wiring section 53r formed in a spiral shape and a second redundant wiring section 54r formed in a spiral shape. The other configurations of the third modified snow-melting radome 1r are the same as those of the snow-melting radome 1 of the above embodiment. Furthermore, the third modified snow-melting radome 1r can be manufactured using the same manufacturing process as the snow-melting radome 1 of the above embodiment.

[0052] A third modified example or a further modified example thereof of the snow melting radome 1r and its manufacturing method can exhibit corresponding effects from a configuration corresponding to the snow melting radome 1 or its manufacturing method of the above embodiment.

[0053] [Snow-melting radome of the fourth modified embodiment] In the fourth modified snow-melting radome 1s of the above embodiment, as shown in Figure 8, a first redundant wiring section 55s is locally provided on the tip side of one of the connection sections 51 of the heater wire 5, connected to the one connection section 51, and a second redundant wiring section 56s is locally provided on the tip side of the other connection section 52 of the heater wire 5, connected to the other connection section 52. In the fourth modified snow-melting radome 1s, as shown in Figure 8, the first redundant wiring section 55s is formed in a meandering manner in the extension direction of one wire harness connection terminal 71, and the second redundant wiring section 56s is formed in a meandering manner in the extension direction of the other wire harness connection terminal 72.

[0054] In the illustrated example, the first redundant wiring section 55s is formed by meandering in the extension direction of one wire harness connection terminal 71 and bending at a right angle or approximately right angle in a rectangular wave shape, and the second redundant wiring section 56s is formed by meandering in the extension direction of another wire harness connection terminal 72 and bending at a right angle or approximately right angle in a rectangular wave shape. However, the first redundant wiring section 55s may be formed by meandering in the extension direction of one wire harness connection terminal 71 and bending in a curved sinusoidal wave shape, and the second redundant wiring section 56s may be formed by meandering in the extension direction of another wire harness connection terminal 72 and bending in a curved sinusoidal wave shape.

[0055] When the first redundant wiring section 55s and the second redundant wiring section 56s are formed by meandering in a rectangular wave shape, it is preferable to apply the number of meandering repetitions and the meandering variation range used when the first redundant wiring section 53 and the second redundant wiring section 54 are formed by meandering in a rectangular wave shape in the above embodiment. Furthermore, when the first redundant wiring section 55s and the second redundant wiring section 56s are formed by meandering in a sinusoidal wave shape, it is preferable to apply the number of meandering repetitions and the meandering variation range used when the first redundant wiring section 53p and the second redundant wiring section 54p are formed by meandering in a sinusoidal wave shape in the first modified example of the above embodiment.

[0056] The other configurations of the snow-melting radome 1s of the fourth modified example are the same as those of the snow-melting radome 1 of the above embodiment. Furthermore, the snow-melting radome 1s of the fourth modified example can be manufactured using basically the same manufacturing process as the snow-melting radome 1 of the above embodiment. When laying the heater wire 5 in a predetermined pattern on one surface of the first resin substrate 3, the first redundant wiring portion 55s and the second redundant wiring portion 56s can be formed together. The first redundant wiring portion 55s can be locally formed on the tip side of one of the connection portions 51 of the heater wire 5, connected to one of the connection portions 51, and the second redundant wiring portion 56s can be locally formed on the tip side of the other connection portion 52 of the heater wire 5, connected to the other connection portion 52. It is also possible to form the first redundant wiring portion 55s and the second redundant wiring portion 56s in a meandering manner in a direction perpendicular to the extension direction of the wire harness connection terminals 71 and 72, or in a spiral shape.

[0057] The fourth modified snow melting radome 1s and its manufacturing method, or any further modified snow melting radome 1 or its manufacturing method of the above embodiment, can exhibit corresponding effects due to their corresponding configurations. Furthermore, in the fourth modified snow melting radome, the first redundant wiring section 55s can also disperse and reduce the thermal stress repeatedly applied to the heater wire portion near one connection 51, and the second redundant wiring section 56s can also disperse and reduce the thermal stress repeatedly applied to the heater wire portion near the other connection 52. Therefore, the breakage of the heater wire 5 can be prevented more reliably, and the durability of the heater wire 5 against repeated use can be further improved.

[0058] Furthermore, the redundant length of the meandering paths of the first and second redundant wiring sections 55s and 56s allows for a more reliable distribution and reduction of the thermal stress repeatedly applied to the heater wire, thereby further reducing the effects of expansion and contraction on the heater wire due to thermal stress. In addition, the meandering paths allow for an extended redundant path length while ensuring the required wire width necessary for snow melting of the heater wire 5.

[0059] [Scope of the invention disclosed herein] The inventions disclosed herein include, in addition to the inventions and embodiments listed herein, those specified by modifying some of these to the extent applicable, or by adding other to these, or by deleting some of these to the extent that some effects are obtained and defining them as broader concepts. Furthermore, the inventions disclosed herein also include the modifications and additions listed below.

[0060] For example, in the above embodiments and their modified forms, the area of ​​the tab 21 that protrudes laterally when viewed from the front of the radome is provided with a first recess 32 and a second recess 33, etc., and a first metal plate 61 and a second metal plate 62, etc. that are fitted into it, and the connection between the heater wire 5 connection parts 51, 52, etc. and the wire harness connection terminals 71, 72 is made within the front view area of ​​the first metal plate 61 and the second metal plate 62, etc. However, in the case of a radome without a tab 21, for example, this configuration can be installed in an appropriate area other than the area of ​​the tab 21, or in an appropriate area other than the electromagnetic wave transmission area R. Furthermore, the first metal material and the second metal material in the present invention are not limited to plate-shaped first metal plate and second metal plate, but can be any appropriate metal material, for example, a metal part.

[0061] Furthermore, the redundant configurations of the first redundant wiring section, the second redundant wiring section, the first tip redundant wiring section, and the second tip redundant wiring section in the present invention can be configured in ways other than those described above, within the scope of applicability. For example, the first redundant wiring section, the second redundant wiring section, the first tip redundant wiring section, and the second tip redundant wiring section may be formed in an arc shape, a substantially L-shape, or a meandering shape with a predetermined periodic pattern other than those described above. In addition, the portion of the heater wire located on the side of the first redundant wiring section toward the electromagnetic wave transmission region, and the portion of the heater wire located on the side of the second redundant wiring section toward the electromagnetic wave transmission region, can be configured such that they are not exposed to the first resin substrate or the second resin substrate, but are covered with a different synthetic resin, or bonded to a different synthetic resin.

[0062] Furthermore, when manufacturing the snow-melting radomes 1, 1p, 1q, 1r, and 1s in the above embodiment, the step of forming an intermediate product in which the first metal material 61 and the second metal material 62 are fitted and embedded in the first recess 32 and the second recess 33, which are isolatedly formed in the resin substrate 3 in a region other than the electromagnetic wave transmission region R, is not limited to the above example. For example, the resin substrate 3 may be injection molded so that the first metal material 61 and the second metal material 62 are fitted and embedded in the isolated first recess 32 and the second recess 33, respectively.

[0063] Furthermore, from the viewpoint of preventing damage to the resin substrate, such as the first resin substrate, it is preferable that the shortest distance between the periphery of the first metal material and the periphery of the first heater wire joint, and the shortest distance between the periphery of the second metal material and the periphery of the second heater wire joint, be 1.0 m or more, and that the shortest distance between the periphery of the first metal material and the periphery of the first connection terminal joint, and the shortest distance between the periphery of the second metal material and the periphery of the second connection terminal joint, be 0.5 mm or more.

[0064] Furthermore, the snow-melting radome of the present invention may also be configured as a radome other than a radome for an on-board radar device, which is installed on the electromagnetic wave irradiation side of the on-board radar device. [Industrial applicability]

[0065] This invention can be used, for example, in snow-melting radomes such as those for on-board radar systems. [Explanation of Symbols]

[0066] 1, 1p, 1q, 1r, 1s…Snow melting radome 2…Base 21…Tab 3…First resin substrate 31…Groove 32…First recess 33…Second recess 4…Second resin substrate 41…Groove 5…Heater wire 51…One connection part 52…Other connection part 53, 53p, 53q, 53r…First redundant wiring part 54, 54p, 54q, 54r…Second redundant wiring part 55s…First tip redundant wiring part 56s…Second tip redundant wiring part 61…First metal plate 611…Mounting surface 62…Second metal plate 621…Mounting surface 7…Wire harness connection part 71…One wire harness connection terminal 72…Other wire harness connection terminal 81a…First heater wire joint part 82a…Second heater wire joint part 83a…First connection terminal joint part 84a...Second connection terminal joint 100...Mold 101...Injection port 102...Outlet R...Electromagnetic wave transmission area W1, W2, W3...Variation range of meandering MR...Molten resin

Claims

1. An electromagnetic wave-transmitting substrate is formed by laminating a first resin substrate and a second resin substrate, and a heater wire, which is wired in the planar direction of the substrate, is embedded between the first resin substrate and the second resin substrate. The first metal material and the second metal material are embedded between the first resin substrate and the second resin substrate in a region of the substrate other than the electromagnetic wave transmission region, so as to be separated from each other. The first metal material is placed on the mounting surface such that one connection portion of the heater wire and one wire harness connection terminal are spaced apart, and the first metal material and one connection portion of the heater wire are joined so that they are electrically connected at the first heater wire joint, and the first metal material and the one wire harness connection terminal are joined so that they are electrically connected at the first connection terminal joint which is spaced apart from the first heater wire joint. The second metal material is placed on the mounting surface such that the other connection portion of the heater wire and the other wire harness connection terminal are spaced apart, and the second metal material and the other connection portion of the heater wire are joined so that they are electrically connected at the second heater wire joint, and the second metal material and the other wire harness connection terminal are joined so that they are electrically connected at the second connection terminal joint which is spaced apart from the second heater wire joint. A snow melting radome characterized in that a first redundant wiring section is locally provided in the portion of the heater wire located on the side of one connection point toward the electromagnetic wave transmission region, and a second redundant wiring section is locally provided in the portion of the heater wire located on the side of the other connection point toward the electromagnetic wave transmission region.

2. The first redundant wiring section is formed in a meandering manner, The snow-melting radome according to claim 1, characterized in that the second redundant wiring section is formed in a meandering manner.

3. A first redundant wiring section is locally provided on the tip side of one of the connection points of the heater wire, connected to the one connection point. The snow melting radome according to claim 1 or 2, characterized in that a second redundant wiring section is locally provided at the tip end of the heater wire, connected to the other connection section, on the tip end side of the other connection section.

4. The first tip redundant wiring section is formed in a meandering manner, The snow-melting radome according to claim 3, characterized in that the second tip redundant wiring portion is formed in a meandering manner.

5. The first step involves fitting a first metal material and a second metal material into first recesses and second recesses, respectively, which are formed on one surface of a first electromagnetic wave permeable resin substrate so as to be separated from each other, laying a heater wire in a predetermined pattern on one surface of the first resin substrate, placing one connection portion of the heater wire on the exposed mounting surface of the first metal material and locally forming a first redundant wiring portion in the portion of the heater wire that is positioned on the side of the heater wire that is toward the electromagnetic wave permeable region from the one connection portion, and placing the other connection portion of the heater wire on the exposed mounting surface of the second metal material and locally forming a second redundant wiring portion in the portion of the heater wire that is positioned on the side of the heater wire that is toward the electromagnetic wave permeable region from the other connection portion, A second step is to place one wire harness connection terminal on the exposed mounting surface of the first metal material so as to be spaced apart from one of the connection portions of the heater wire, to join the first metal material and one of the connection portions of the heater wire so as to be electrically connected at the first heater wire joint, and to join the first metal material and the one wire harness connection terminal so as to be electrically connected at the first connection terminal joint which is spaced apart from the first heater wire joint, and to place another wire harness connection terminal on the exposed mounting surface of the second metal material so as to be spaced apart from the other connection portion of the heater wire, to join the second metal material and the other connection portion of the heater wire so as to be electrically connected at the second heater wire joint, and to join the second metal material and the other wire harness connection terminal so as to be electrically connected at the second connection terminal joint which is spaced apart from the second heater wire joint, A method for manufacturing a snow melting radome, comprising a third step of injection molding a second electromagnetic wave permeable resin substrate to the mounting surface of the first metal material and the mounting surface of the second metal material, fixing the second resin substrate to the first resin substrate, and embedding the heater wire, the first metal material, the first wire harness connection terminal, the first heater wire joint, the first connection terminal joint, the second metal material, the other wire harness connection terminal, the second heater wire joint, and the second connection terminal joint between the first and second resin substrates.

6. The method for manufacturing a snow-melting radome according to claim 5, characterized in that, in the first step, a first redundant wiring portion is locally formed at the tip of one of the connection portions of the heater wire, connected to the one connection portion, and a second redundant wiring portion is locally formed at the tip of the other connection portion of the heater wire, connected to the other connection portion.

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