Wire connection structure and method for manufacturing the same

Abstract

By reducing the magnitude of localized tensile residual stress in the conductor, it is possible to prevent the conductor from breaking, and at the same time, improve the weather resistance and durability of the conductor. [Solution] A wire connection structure comprising a resin base material 3, a heater wire 5 which is a wire laid with a contact area fixed to the resin base material 3, and metal plates 61, 62 embedded in recesses 32, 32 formed in the resin base material 3, wherein the connection ends 51, 52 of the heater wire 5 and the power supply connection terminals are joined to the metal plates 61, 62 at a joint portion 8 so that they are electrically connected, and an intermediate joint portion 80 is provided at a position closer to the laid-out side of the heater wire 5 on the resin base material 3 than the joint portion 8 to join the heater wire 5 and the metal plates 61, 62.

Description

Technical Field

[0001] The present invention relates to a conductive wire connection structure for connecting a conductive wire wired on a resin base material to a power supply connection terminal and a manufacturing method thereof.

Background Art

[0002] Conventionally, as a structure for connecting a conductive wire wired on a resin base material to a power supply connection terminal, there is a connection structure of Patent Document 1. In the connection structure of Patent Document 1, a first metal plate and a second metal plate are respectively fitted and arranged in a first recess and a second recess formed separately on a resin base material, and a heater wire is wired along a groove so that a part thereof protrudes from the groove formed in the resin base material. One connection portion of the heater wire placed on the first metal plate and one wire harness connection terminal are connected by a conductive bonding material such as solder or brazing material, and the other connection portion of the heater wire placed on the second metal plate and the other wire harness connection terminal are connected by a conductive bonding material.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in a structure in which a heater wire is wired on a resin base material and the connection portion of the heater wire and the wire harness connection terminal are connected via a metal material such as a metal plate and a conductive bonding material, for example, when using welding that melts the resin base material by ultrasonic vibration and wiring the heater wire so as to fix the contact area to the resin base material while melting the resin base material, since the contact area of the heater wire cannot be fixed to the metal material by welding, the heater wire is wired in a state of floating from the resin base material and the metal plate from a position in front of the metal material, and the connection portion of the heater wire floating from the metal material and the wire harness connection terminal are connected by a conductive bonding material to construct a connection structure.

[0005] However, when the contact area is welded to the resin substrate up to the point in front of the metal material, and the heater wire, which is floating above the point in front of the metal material, is connected with a conductive bonding material such as solder or brazing material, a large localized tensile residual stress is generated in the floating portion of the heater wire between the fixed end of the heater wire in the contact area and the conductive bonding material. As a result, the heater wire is more prone to breakage in the portion of the heater wire where this large tensile residual stress is generated, leading to a problem of reduced weather resistance and durability of the heater wire. A similar problem also occurs when conductors other than the heater wire are laid with their contact areas fixed to the resin substrate, a metal material is fitted into a recess formed in the resin substrate, and the connection point of the conductor, which is floating above the point in front of the metal material, is connected to the power supply connection terminal with a conductive bonding material.

[0006] In view of the above problems, the present invention is proposed to provide a wire connection structure and a method for manufacturing the same, which, in a structure in which the connection end of a wire having a contact area fixed to a resin substrate and a power supply connection terminal are connected to a metal material and a joint, can reduce the magnitude of locally generated tensile residual stress in the wire, thereby preventing wire breakage, and can also improve the weather resistance and durability of the wire. [Means for solving the problem]

[0007] The wire connection structure of the present invention comprises a resin substrate, a wire laid with a contact area fixed to the resin substrate, and a metal material embedded in a recess formed in the resin substrate, wherein the connection end of the wire and the power supply connection terminal are joined to the metal material at a joint so as to be electrically conductive, and an intermediate joint is provided that joins the wire and the metal material at a position closer to the wire laid on the resin substrate than the joint. According to this, instead of a joint where the connection end of the conductor and the power supply connection terminal are joined to the metal material so that they are electrically connected, an intermediate joint is provided where the conductor and the metal material are joined at the position of the conductor on the side of the conductor that is laid on the resin substrate. By dividing the continuity of the wiring state of the conductor at the intermediate joint, the maximum value of the tensile residual stress that occurs locally in the conductor can be reduced. Therefore, in a structure in which the connection end of a conductor, whose contact area is fixed to the resin substrate, and the power supply connection terminal are connected to the metal material via a joint, the magnitude of the tensile residual stress that occurs locally in the conductor can be reduced, preventing the conductor from breaking, and the weather resistance and durability of the conductor can be improved. In addition, the heat generated when the connection end of the conductor and the power supply connection terminal are joined to the metal material at the joint, and the heat generated when the conductor and the metal material are joined at the intermediate joint, can be suppressed by the metal material from being conducted to the resin substrate, preventing the resin substrate from melting and being damaged.

[0008] The wire connection structure of the present invention is characterized in that a curved portion is provided in the portion of the wire between the joint and the intermediate joint. According to this design, the curved section provided in the conductor between the joint and the intermediate joint disperses and reduces the thermal stress repeatedly applied to the conductor between the joint and the intermediate joint. Therefore, it is possible to more reliably prevent the conductor from breaking, and to further improve the weather resistance and durability of the conductor.

[0009] The wire connection structure of the present invention is characterized in that a redundant wiring portion is locally provided in the portion of the wire that is located on the side of the wire that is laid on the resin substrate rather than the intermediate joint portion, and the redundant wiring portion is fixed to the resin substrate in the contact area and laid. According to this, redundant wiring sections are locally provided in the portion of the conductor located on the side of the conductor that is laid on the resin substrate rather than at the intermediate joint. This allows for the dispersion and reduction of thermal stress repeatedly applied to the portion of the conductor that is laid on the resin substrate near the metal material. Consequently, the occurrence of conductor breakage can be prevented more reliably, and the weather resistance and durability of the conductor can be further enhanced.

[0010] The wire connection structure of the present invention is characterized in that another intermediate joint is provided in the portion of the wire between the joint and the intermediate joint for joining the wire and the metal material. According to this method, by providing another intermediate joint between the joint and the intermediate joint, the maximum value of the tensile residual stress locally generated in the conductor can be further reduced. Therefore, by further reducing the magnitude of the tensile residual stress locally generated in the conductor, it is possible to more reliably prevent the conductor from breaking, and the weather resistance and durability of the conductor can be further improved.

[0011] The wire connection structure of the present invention is characterized in that the wire is embedded between the resin substrate and another resin substrate. According to this, by embedding the conductor between one resin substrate and another resin substrate, the weather resistance and durability of the conductor can be significantly improved. Furthermore, the conductor connection structure of the present invention can be applied to various components such as snow-melting radomes, where the conductor is used as a heater wire and the heater wire is embedded between two resin substrates.

[0012] The wire connection structure of the present invention has a protective plate embedded in another recess formed in the other resin substrate formed by injection molding, wherein the protective plate is provided protruding from the metal material so as to cover the region of the wire near the metal material that is drawn out from the metal material on the wire laying side of the wire to the resin substrate from the opposite side of the metal material, and is fixed to the metal material in the region that overlaps with the metal material. According to this method, when forming another resin substrate by injection molding and fixing it to the resin substrate, the conductor can be protected from the flowing resin during injection molding by a protective plate, and the amount of flowing resin between the metal material and the conductor at the intermediate joint can be significantly reduced, thereby protecting the conductor. Therefore, the occurrence of conductor breakage can be prevented more reliably.

[0013] The present invention provides a method for manufacturing a wire connection structure, comprising: a first step of forming an intermediate product in which a metal material is embedded in a recess formed in a resin substrate, laying a wire with its contact area fixed to the resin substrate, and placing the connection end of the wire on the metal material without fixing it; a second step of arranging a power supply connection terminal close to the connection end of the wire; and a third step of joining the connection end of the wire and the power supply connection terminal to the metal material at a joint so that they are electrically connected, and providing an intermediate joint that joins the wire and the metal material at a position closer to the wire being laid on the resin substrate than the joint. According to this, instead of a joint where the connection end of the conductor and the power supply connection terminal are joined to the metal material so that they are electrically connected, an intermediate joint is provided where the conductor and the metal material are joined at the position on the side of the conductor that is laid on the resin substrate. By dividing the continuity of the wiring state of the conductor at the intermediate joint, the maximum value of the tensile residual stress that occurs locally in the conductor can be reduced. Therefore, in a structure in which the connection end of a conductor, whose contact area is fixed to the resin substrate, and the power supply connection terminal are connected to the metal material via a joint, the magnitude of the tensile residual stress that occurs locally in the conductor can be reduced, preventing the conductor from breaking, and the weather resistance and durability of the conductor can be improved. Furthermore, in the manufactured conductor connection structure, the heat generated when the connection end of the conductor and the power supply connection terminal are joined to the metal material at the joint, and the heat generated when the conductor and the metal material are joined at the intermediate joint, can be suppressed by the metal material from being conducted to the resin substrate, preventing the resin substrate from melting and being damaged.

[0014] The present invention provides a method for manufacturing a wire connection structure characterized by providing a curved portion in the portion of the wire that will be positioned between the joint and the intermediate joint. According to this design, the curved section positioned in the conductor portion between the joint and the intermediate joint can disperse and reduce the thermal stress repeatedly applied to the conductor portion between the joint and the intermediate joint. Therefore, it is possible to more reliably prevent the conductor from breaking, and to further improve the weather resistance and durability of the conductor.

[0015] The present invention provides a method for manufacturing a wire connection structure, characterized in that, in the third step, a protective plate is provided on the resin substrate so as to protrude from the metal material and cover the region of the wire near the metal material that is drawn out from the metal material on the side of the wire being laid on the resin substrate, from the side opposite to the metal material, and the protective plate is fixed to the metal material in the region that overlaps with the metal material, and in the fourth step, another resin substrate is formed by injection molding so as to be fixed to the resin substrate and the protective plate, and the wire is embedded between the resin substrate and the other resin substrate. According to this method, when forming another resin substrate by injection molding and fixing it to the resin substrate, the conductor can be protected from the flowing resin during injection molding by a protective plate, and the amount of flowing resin between the metal material and the conductor at the intermediate joint can be significantly reduced, thereby protecting the conductor. Therefore, the occurrence of conductor breakage can be prevented more reliably. [Effects of the Invention]

[0016] According to the present invention, in a structure in which the connection end of a conductor, whose contact area is fixed to a resin substrate, and a power supply connection terminal are connected to a metal material via a joint, the magnitude of locally generated tensile residual stress in the conductor can be reduced, thereby preventing the conductor from breaking, and the weather resistance and durability of the conductor can be improved. [Brief explanation of the drawing]

[0017] [Figure 1] (a) is a front view of a snow melting radome equipped with a wire connection structure according to the first embodiment of the present invention, and (b) is a partially enlarged front view of the same figure (a). [Figure 2] A partial longitudinal cross-sectional view of a snow melting radome equipped with a wire connection structure according to the first embodiment. [Figure 3] (a) to (d) are process diagrams illustrating the manufacturing process of the wire connection structure of the first embodiment. [Figure 4] This is an explanatory diagram showing the state in which the resin base material, metal material, heater wire, and wire harness connection terminals are arranged inside the mold in a snow melting radome equipped with the wire connection structure of the first embodiment. [Figure 5]Partial enlarged front view showing a modified example of the wire connection structure of the first embodiment. [Figure 6] (a) to (c) are process explanatory diagrams for explaining a modified example of the manufacturing process of the wire connection structure of the first embodiment. [Figure 7] Partial enlarged front view of a snow melting dome having the wire connection structure of the second embodiment according to the present invention. [Figure 8] Partial longitudinal sectional view of a snow melting dome having the wire connection structure of the second embodiment. [Figure 9] Partial enlarged front view of a snow melting dome having the wire connection structure of the third embodiment according to the present invention. [Figure 10] Partial longitudinal sectional view of a snow melting dome having the wire connection structure of the third embodiment. [Figure 11] Partial enlarged front view of a snow melting dome having the wire connection structure of the fourth embodiment according to the present invention. [Figure 12] Partial longitudinal sectional view of a snow melting dome having the wire connection structure of the fourth embodiment. [Figure 13] (a) to (c) are process explanatory diagrams for explaining the manufacturing process of the wire connection structure of the fourth embodiment. [Figure 14] (a) is a partial longitudinal sectional view showing a first modified example of the wire connection structure of the fourth embodiment, and (b) is a partial longitudinal sectional view showing a second modified example of the wire connection structure of the fourth embodiment.

Mode for Carrying Out the Invention

[0018] [Wire Connection Structure of the First Embodiment] The wire connection structure of the first embodiment according to the present invention is installed in a snow melting dome 1 such as a bumper cover attached to a bumper of a vehicle. As shown in FIGS. 1 and 2, the snow melting dome 1 includes an electromagnetic wave transmissive substrate 2. The substrate 2 is composed of, for example, a resin base material 3 disposed on the side opposite to the visual recognition side, which is the visual recognition side of the snow melting dome 1, and another resin base material 4 disposed on the visual recognition side, which is the front side of the resin base material 3. The resin base material 3 and the other resin base material 4 are laminated and fixed. Incidentally, if necessary, another resin base material 4 may be disposed on the side opposite to the visual recognition side, and the resin base material 3 may be disposed on the visual recognition side.

[0019] The resin substrate 3 and the other resin substrate 4 are each formed from an insulating and electromagnetic wave-transmitting synthetic resin. Furthermore, the resin substrates 3 and 4 can be made into appropriate shapes within an applicable range, such as flat plates or curved plates. Different or the same type of synthetic resin can be used for the resin substrate 3 and the other resin substrate 4. It is preferable from the viewpoint of improving electromagnetic wave transmission performance to form the resin substrate 3 and the other resin substrate 4 with materials whose refractive indices n, defined based on the complex dielectric constant, are mutually matched, or whose refractive indices n are approximately the same or close in value. As for the numerical range of close refractive indices of the resin substrate 3 and the other resin substrate 4, it is good if the difference in refractive indices between the resin substrate 3 and the other resin substrate 4 is within the range of 0 to 10%.

[0020] 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.

[0021]

number

[0022]

number

[0023] The synthetic resin of the resin base material 3 and the synthetic resin of the other resin base material 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 resin substrate 3 and the other resin substrate 4 in the electromagnetic wave transmission direction, the ratio of the thickness of the resin substrate 3 to the thickness of the other resin substrate 4, the thickness of the base resin 3, the thickness of the other resin substrate 4, and the total thickness of the base body 2 composed of the resin substrate 3 and the other resin substrate 4 are appropriate within a range that ensures the required electromagnetic wave transmission as a snow melting radome 1.

[0024] A heater wire 5, corresponding to the conductor in this embodiment, is wired in the planar direction of the electromagnetic wave-transparent substrate 2 within the snow-melting radome 1. The conductive material constituting the heater wire 3 can be any conductive material within the scope of the present invention; for example, 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 are suitable. Furthermore, the heater wire 5 can be laid in a linear shape by fixing its contact area to the resin substrate 3; its form before laying is not limited, and for example, wire material, conductive ink, conductive filler, etc., can be used.

[0025] In the illustrated example, the heater wire 5 is formed by meandering and folding along the direction in which the plate-shaped base 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 2 in the electromagnetic wave irradiation area R of the base 2 by radar devices such as on-board radar devices and outside of that area, 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.

[0026] The heater wire 5, which corresponds to a conductor, has its contact area fixed to the resin substrate 3 and is laid out, and also has its contact area fixed to another resin substrate 4 and is laid out, and is embedded between the resin substrate 3 and the other resin substrate 4. The heater wire 5 is then sandwiched between the resin substrate 3 and the other resin substrate 4 and is installed and sealed inside the base body 2 which is composed of the resin substrate 3 and the other resin substrate 4.

[0027] In the illustrated example, a groove 31 is formed on the side of the resin substrate 3 that is fixed to another resin substrate 4, and another groove 41 is formed on the side of the other resin substrate 4 that is fixed to the resin substrate 3, opposite to the groove 31. The heater wire 5 is partially embedded and fixed to the resin substrate 3 in the groove 31 and laid out, and partially embedded and fixed to the other resin substrate 4 in the groove 41 and laid out. In other words, the heater wire 5 is fixed so as to fit into the groove 31 of the resin substrate 3 and the other groove 41 of the other resin substrate 4 and is wired along the grooves 31 and 41 (see Figure 2). It is also possible to configure the heater wire 5 to be laid out by fixing the contact area to the resin substrate 3 without forming either or both of the grooves 31 of the resin substrate 3 and the other groove 41 of the other resin substrate 4.

[0028] In the region of the substrate 2 other than the electromagnetic wave transmission region R, in this embodiment, the region of the tab 21 which is formed to protrude laterally, a first recess 32 and a second recess 33 corresponding to recesses are formed on the fixing surface side of the resin substrate 3, separated from each other. A first metal plate 61 and a second metal plate 62, which are conductive plates corresponding to metal materials, are fitted and embedded in the first recess 32 and the second recess 33, respectively, and the first metal plate 61 and the second metal plate 62 are provided in an insulated state from each other.

[0029] One connection end 51 of the heater wire 5 and one wire harness connection terminal 71, which corresponds to a power supply connection terminal, are placed on the mounting surface 611 of the first metal plate 61. In the illustrated example, one connection end 51 of the heater wire 5 and one wire harness connection terminal 71 are arranged to be in contact with each other. The first metal plate 61 and one connection end 51 of the heater wire 5 are joined at a joint 8, and the first metal plate 61 and one wire harness connection terminal 71 are also joined at a joint 8, so that electrical conductivity is maintained between the one connection end 51 of the heater wire 5 and the one wire harness connection terminal 71, at least through the first metal plate 61. In the first embodiment, the one connection end 51 of the heater wire 5, one wire harness connection terminal 71, and the first metal plate 61 are joined together by a joint 8 made of a conductive joining material with added solder, brazing material, etc.

[0030] The other connection end 52 of the heater wire 5 and another wire harness connection terminal 72 corresponding to the power supply connection terminal are placed on the mounting surface 621 of the second metal plate 62, and in the illustrated example, the other connection end 52 of the heater wire 5 and the other wire harness connection terminal 72 are arranged to be in contact with each other. The second metal plate 62 and the other connection end 52 of the heater wire 5 are joined at the joint 8, and the second metal plate 62 and the other wire harness connection terminal 72 are also joined at the joint 8, so that electrical conductivity is maintained between the other connection end 52 of the heater wire 5 and the other wire harness connection terminal 72, at least through the second metal plate 62. In the first embodiment, the other connection end 52 of the heater wire 5, the other wire harness connection terminal 72 and the second metal plate 62 are joined together by the joint 8, which is made of a conductive joining material with added solder, brazing material, etc.

[0031] In the first embodiment, the heater wire 5 is routed along the bonding surfaces of the resin substrate 3 and another resin substrate 4, and one connection end 51 of the heater wire 5, which is not bent in the lamination direction of the resin substrate 3 and the other resin substrate 4, is electrically connected to a wire harness connection terminal 71 that is positioned to overlap and contact the one connection end 51 of the heater wire 5. In addition, the other connection end 52 of the heater wire 5, which is not bent in the lamination direction of the resin substrate 3 and the other resin substrate 4, is electrically connected to another wire harness connection terminal 72 that is positioned to overlap and contact the other connection end 52 of the heater wire 5.

[0032] Furthermore, in the first metal plate 61, which corresponds to the metal material, an intermediate joint portion 80 is provided at a position closer to the laying side of the heater wire 5 on the resin substrate 3 than the joint portion 8, for joining the heater wire 5 and the first metal plate 61. Similarly, in the first metal plate 62, which corresponds to the metal material, an intermediate joint portion 80 is provided at a position closer to the laying side of the heater wire 5 on the resin substrate 3 than the joint portion 8, for joining the heater wire 5 and the second metal plate 62. The intermediate joint portion 80 is made of a conductive joining material with added solder, brazing material, etc., and the intermediate joint portion 80 can be the same type of joint portion as the joint portion 8 or a different type of joint portion.

[0033] The joint portion 8 and the intermediate joint portion 80 are each formed as points and are spaced apart from each other, and the portion of the heater wire 5 that is positioned between the joint portion 8 and the intermediate joint portion 80 in the first embodiment is in a straight line. The intermediate joint portion 80 is preferably located near the opposite edge of the wire harness connection terminals 71 and 72 of the first metal plate 61 and the second metal plate 62, away from the opposite edge. Alternatively, as shown in Figure 5, it is also preferable to provide one or more other intermediate joint portions 81 scattered between the intermediate joint portion 80 and the joint portion 8, and to join the heater wire 5 to the first metal plate 61 and the heater wire 5 to the second metal plate 62 using these other intermediate joint portions 81.

[0034] When manufacturing the snow-melting radome 1 equipped with the wire connection structure of the first embodiment, an intermediate product is formed in which the first metal plate 61 and the second metal plate 62 are fitted and embedded in the first recess 32 and the second recess 33, which are formed in isolation in the resin substrate 3 in a region other than the electromagnetic wave transmission region R (see Figure 3(a)). In forming this intermediate product, for example, the non-penetrating first recess 32 and the second recess 33 are formed in isolation in a region other than the electromagnetic wave transmission region R on one side of the resin substrate 3, and the first metal plate 61 and the second metal plate 62 are fitted and embedded in the first recess 32 and the second recess 33, respectively. The first recess 32 and the second recess 33 may be formed by correspondingly shaped protrusions in the mold when the resin substrate 3 is formed by injection molding, or they may be formed on one side of the resin substrate 3 by cutting or the like.

[0035] Then, for example, by welding using ultrasonic vibration or printing, the heater wire 5, which corresponds to the conductor, is laid out in a predetermined pattern such as a meandering shape, with the contact area fixed to the resin substrate 3. One connection end 51 of the heater wire 5 is placed unglued on the exposed mounting surface 611 of the first metal plate 61, and the other connection end 52 of the heater wire 5 is placed unglued on the exposed mounting surface 621 of the second metal plate 62 (see Figure 3(b)). The method of laying out the conductor is appropriate within the applicable range.

[0036] Furthermore, as a method for manufacturing a modified version, as shown in Figures 6(a) to (c), the following steps may be used: first, lay the heater wire 5 in a predetermined pattern on one surface of the resin substrate 3 in an area that does not overlap with the first recess 32 and the second recess 33 of the resin substrate 3; then, fit and position the first metal plate 61 and the second metal plate 62 in the first recess 32 and the second recess 33, respectively; after that, lay the heater wire 5 to connect in the area that overlaps with the first recess 32 and the second recess 33; place one connecting end 51 of the heater wire 5 on the exposed mounting surface 611 of the first metal plate 61 and place the other connecting end 52 of the heater wire 5 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.

[0037] Subsequently, one wire harness connection terminal 71, corresponding to a power supply connection terminal, is positioned close to one connection end 51 of the heater wire 5 on the mounting surface 611 of the first metal plate 61, and another wire harness connection terminal 72, corresponding to a power supply connection terminal, is positioned close to the other connection end 52 of the heater wire 5 on the mounting surface 621 of the second metal plate 62 (see Figure 3(c)).

[0038] Next, as shown in Figure 3(d), the heater wire 5, which corresponds to a conductor, is joined to the first metal plate 61, which corresponds to a metal material, at the joint 8 so that one connection end 51 of the heater wire 5, which corresponds to a conductor, and one wire harness connection terminal 71, which corresponds to a power supply connection terminal, are electrically connected. An intermediate joint 80 is provided at a position closer to the resin base material 3 than the joint 8 to join the heater wire 5 and the first metal plate 61. Furthermore, the other connection end 52 of the heater wire 5, which corresponds to a conductor, is joined to the second metal plate 62, which corresponds to a metal material, at the joint 8 so that the other connection end 52 of the heater wire 5, which corresponds to a conductor, and another wire harness connection terminal 72, which corresponds to a power supply connection terminal, are electrically connected. An intermediate joint 80 is provided at a position closer to the resin base material 3 than the joint 8 to join the heater wire 5 and the second metal plate 62.

[0039] Subsequently, as shown in Figure 4, the resin substrate 3, to which the heater wire 5, the first metal plate 61 and the second metal plate 62, the joint portion 8 and the intermediate joint portion 80, 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 portion 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.

[0040] Then, molten resin MR is poured into the mold 100 from the injection port 101 to perform injection molding, and injection molding is performed on the mounting surface 611 of the first metal plate 61 and the mounting surface 621 of the second metal plate 62 to form another resin base material 4, and the other resin base material 4 is fixed to the first resin base material 3. The interface where the other resin base material 4 is laminated by injection molding is molded and welded to the resin base material 3, heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminal 72, joint 8, and intermediate joint 80, and the heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminal 72, joint 8, and intermediate joint 80 are embedded between the resin base material 3 and the other resin base material 4.

[0041] Furthermore, since the other resin base material 4 is formed to cover the portion of the heater wire 5 that protrudes outside the groove 31, the portion of the heater wire 5 that protrudes outside the groove 31 is molded and fixed to the other resin base material 4 by insert molding, and the heater wire 5 is fitted into another groove 41 of the other resin base material 4. The other resin base material 4 is preferably an injection molded material, but is not limited to a configuration formed by injection molding, and can be fixed to the resin base material 3 by adhesive or other means as needed. After the formation of the other resin base material 4, the mold 100 is demolded to obtain the snow melting radome 1 equipped with the wire connection structure of the first embodiment.

[0042] According to the first embodiment, an intermediate joint 80 is provided to join the heater wire 5 to the first metal plate 61 and the second metal plate 62 at a position on the side of the heater wire 5 that is laid on the resin base material 3, rather than the joint 8 that joins the heater wire 5 to the first metal plate 61 and the second metal plate 62 so that the connection ends 51 and 52 of the heater wire 5 and the wire harness connection terminals 71 and 72 are electrically connected. By dividing the continuity of the wiring state of the heater wire 5 at the intermediate joint 80, the maximum value of locally generated tensile residual stress in the heater wire 5 can be reduced. Therefore, in a structure in which the connection ends 51 and 52 of the heater wire 5, whose contact area is fixed to the resin base material 3, and the wire harness connection terminals 71 and 72 are connected to the first metal plate 61 and the second metal plate 62 via the joint 8, the magnitude of locally generated tensile residual stress in the heater wire 5 can be reduced, preventing the heater wire 5, which corresponds to a conductor, from breaking, and the weather resistance and durability of the heater wire 5 can be improved.

[0043] Furthermore, the first metal plates 61 and 2 metal plates 62 suppress the transfer of heat to the resin substrate 3 when the connection ends 51 and 52 of the heater wire 5 and the wire harness connection terminals 71 and 72 are joined to the first metal plate 61 and 2 metal plate 62 at the joint 8, and when the heater wire 5 and the first metal plate 61 and 2 metal plate 62 are joined to the intermediate joint 80, thereby preventing the resin substrate 3 from melting and being damaged.

[0044] Furthermore, by embedding the heater wire 5 between the resin substrate 3 and another resin substrate 4, the weather resistance and durability of the heater wire 5, which corresponds to a conductor, can be significantly improved. In addition, although the first embodiment described an example of a snow-melting radome equipped with a conductor connection structure, the conductor connection structure of the first embodiment can be applied to various components in which a conductor is embedded between two resin substrates, and the conductor connection structures of the second, third, and fourth embodiments described later are similar.

[0045] Furthermore, if another intermediate joint 81 is provided in the portion of the heater wire 5 between the joint 8 and the intermediate joint 80, connecting the heater wire 5 to the first metal plate 61 or the second metal plate 62, the maximum value of the tensile residual stress locally generated in the heater wire 5, which corresponds to the conductor, can be further reduced. Therefore, by further reducing the magnitude of the tensile residual stress locally generated in the heater wire 5, which corresponds to the conductor, breakage of the heater wire 5 can be prevented more reliably, and the weather resistance and durability of the heater wire 5 can be further improved.

[0046] Furthermore, when injection molding another resin substrate 4, the intermediate joint 80 significantly reduces the amount of fluid resin flowing between the first metal plate 61 and the heater wire 5, and between the first metal plate 62 and the heater wire 5, thereby protecting the heater wire 5 which corresponds to a conductor. If another intermediate joint 81 is provided, this amount of fluid resin can be reduced even more significantly, further protecting the heater wire 5.

[0047] [Conductor connection structure of the second embodiment] The conductor connection structure of the second embodiment of the present invention is installed, for example, on a snow-melting radome 1a such as a bumper cover attached to the bumper of a vehicle. As shown in Figures 7 and 8, the snow-melting radome 1a is provided with a curved portion 53 in the portion of the heater wire 5 corresponding to the conductor between the joint portion 8 and the intermediate joint portion 80.

[0048] In the illustrated example, the curved portion 53 is formed in an arc shape and protrudes outward from the first recess 32 or the second recess 33 in a front view, in other words, it protrudes outward from the first metal plate 61 or the second metal plate 62 in a front view, and the contact area of ​​the curved portion 53 that is in contact with the resin substrate 3 is fixed to the resin substrate 3 by welding by ultrasonic vibration, printing, or adhesion of resin material. The curved portion 53 may be formed in an arc shape and protrude inward from the first recess 32 or the second recess 33 in a front view, in other words, it may protrude inward from the first metal plate 61 or the second metal plate 62 in a front view, with the arc-shaped protrusions facing each other. Furthermore, the curved portion 53 is fixed to another resin substrate 4, which is an injection molded material, by molding and fixing by insert molding.

[0049] Furthermore, the curved portion 53 can also be formed in a shape other than an arc, such as an S-shaped curve. In addition, the contact area of ​​the curved portion 53 that protrudes outward or inward from the first metal plate 61 or the second metal plate 62 in a front view and is in contact with the resin base material 3 can be configured so that it is not fixed to the resin base material 3. Also, the entire curved portion 53 can be placed on the first metal plate 61 or the second metal plate 62 and not protrude outward or inward from the first metal plate 61 or the second metal plate 62 in a front view.

[0050] The configuration of the conductor connection structure or snow melting radome 1a of the second embodiment, other than the configuration of providing the curved portion 53, is the same as that of the first embodiment. Furthermore, the snow melting radome 1a equipped with the conductor connection structure of the second embodiment is based on the manufacturing process for the snow melting radome 1 equipped with the conductor connection structure of the first embodiment, in which the first metal plate 61 and the second metal plate 62 are fitted into the first recess 32 and the second recess 33, and then the heater wire 5 corresponding to the conductor is laid in a predetermined pattern such as a meandering shape by fixing the contact area to the resin base material 3, for example by welding by ultrasonic vibration or printing, and the exposed mounting surface 611 or of the first metal plate 61 or the second metal plate 62 The product can be manufactured by adding a step of forming a curved portion 53 when placing one connection end 51 or the other connection end 52 of the heater wire 5 on the mounting surface 621 without fixing it, fixing the contact area of ​​the curved portion 53 that protrudes outward from the first metal plate 61 or the second metal plate 62 in a front view and is in contact with the resin base material 3 to the resin base material 3, and providing the joint 8 and intermediate joint 80 such that the portion of the heater wire 5 positioned between the joint 8 and the intermediate joint 80 becomes the curved portion 53.

[0051] Furthermore, as a manufacturing method for a modified example that includes the curved portion 53, it is also preferable to use a manufacturing process in which, for example, welding by ultrasonic vibration or printing, using an appropriate method within the applicable range, the heater wire 5 is laid on one surface of the resin substrate 3 in a predetermined pattern including a part of the curved portion 53 in an area that does not overlap with the first recess 32 and the second recess 33 of the resin substrate 3, the first metal plate 61 and the second metal plate 62 are fitted and placed in the first recess 32 and the second recess 33, respectively, and then the heater wire 5 including the remaining part of the curved portion 53 is laid to connect in the area that overlaps with the first recess 32 and the second recess 33, one connecting end 51 of the heater wire 5 is placed on the exposed mounting surface 611 of the first metal plate 61, and the other connecting end 52 of the heater wire 5 is placed on the exposed mounting surface 621 of the second metal plate 62. The wiring of the heater wire 5 in the region overlapping with the first recess 32 and the second recess 33 may be done using the heater wire 5 that has been pre-wired to be placed on the first metal plate 61 and the second metal plate 62 before fitting.

[0052] Furthermore, as a manufacturing method for a further modified form that includes the curved portion 53, for example, by welding using ultrasonic vibration or printing, the heater wire 5 is laid on one surface of the resin substrate 3 in a predetermined pattern excluding the curved portion 53 in an area that does not overlap with the first recess 32 and the second recess 33 of the resin substrate 3, and 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, and then a part of the curved portion 53 in the area that does not overlap with the first recess 32 and the second recess 33 ( It is also preferable to use a manufacturing process that involves laying out the heater wire 5, including the curved portion 53 that protrudes outward from the first metal plate 61 and the second metal plate 62 in a front view, and the remaining portion of the curved portion 53 in the area overlapping with the first recess 32 and the second recess 33, so as to connect it to the existing heater wire 5, and then placing one connection end 51 of the heater wire 5 on the exposed mounting surface 611 of the first metal plate 61 and the other connection end 52 of the heater wire 5 on the exposed mounting surface 621 of the second metal plate 62.

[0053] According to the second embodiment, the curved portion 53 provided on the heater wire 5 corresponding to the conductor between the joint 8 and the intermediate joint 80 can disperse and reduce the thermal stress repeatedly applied to the heater wire 5 between the joint 8 and the intermediate joint 80. Therefore, the occurrence of breakage of the heater wire 5 can be prevented more reliably, and the weather resistance and durability of the heater wire 5 can be further improved. Furthermore, the second embodiment can obtain the same effects as the first embodiment from the same configuration.

[0054] [Wire connection structure of the third embodiment] The conductor connection structure of the third embodiment of the present invention is installed in a snow-melting radome 1b, such as a bumper cover attached to the bumper of a vehicle. As shown in Figures 9 and 10, the snow-melting radome 1b is provided with a curved portion 53 in the portion of the heater wire 5 corresponding to the conductor between the joint portion 8 and the intermediate joint portion 80, similar to the second embodiment. Furthermore, in the conductor connection structure or snow-melting radome 1b of the third embodiment, a redundant wiring portion 54 is locally provided in the portion of the heater wire 5 that is located on the side of the heater wire 5 corresponding to the conductor that is laid to the resin base material 3, rather than the intermediate joint portion 80, and the redundant wiring portion 54 is fixed to the resin base material 3 in the contact area and laid.

[0055] The redundant wiring section 54 is redundantly wired as part of the heater wire 5 near the first metal plate 61 or the second metal plate 62 and is fixed to the resin substrate 3 and another resin substrate 4. In the illustrated example, the redundant wiring section 54 is formed to meander in a direction perpendicular to the extension direction of one wire harness connection terminal 71 or the other wire harness connection terminal, and is formed to meander in a rectangular wave shape that bends at a right angle or approximately a right angle. The number of meanders corresponding to one period of the rectangular wave in the redundant wiring section 54 is preferably one or more, but two or more is more preferable from the viewpoint of improving the dispersion of thermal stress. Furthermore, the meandering fluctuation width corresponding to the fluctuation width of the rectangular wave in the redundant wiring section 54 is preferably five times or more the wire width of the heater wire 5 from the viewpoint of improving the dispersion of thermal stress, and more preferably ten times or more. Also, from the viewpoint of minimizing the installation space of the redundant wiring section 54, it is preferable to have a meandering width of 30 times or less the wire width of the heater wire 5.

[0056] The wiring shape of the redundant wiring section 54 is not limited to the illustrated example. For example, it may be formed in a meandering manner in a direction perpendicular to the extension direction of one wire harness connection terminal 71 or another wire harness connection terminal, and may be formed in a curved, S-shaped meandering manner. In the case of an S-shaped shape, it is preferable that the number of meandering repetitions and the variation in meandering width be the same as in the case of a rectangular wave shape.

[0057] Furthermore, the wiring shape of the redundant wiring section 54 may be formed to meander in the extension direction of one wire harness connection terminal 71 or another wire harness connection terminal, and may also be formed to meander in a rectangular wave shape that bends at a right angle or approximately at a right angle. When meandering in the extension direction, the number of repetitions of the meander and the variation in the meander are preferably the same as when meandering in a direction perpendicular to the extension direction. In addition, the wiring shape of the redundant wiring section 54 may be formed in a spiral shape that folds back in the middle. Furthermore, the redundant wiring section 54 may be formed to meander in a predetermined periodic pattern other than the above example.

[0058] The configuration of the conductor connection structure or snow melting radome 1b of the third embodiment, other than the configuration that provides the redundant wiring section 54, is the same as that of the second embodiment. Furthermore, the snow melting radome 1b equipped with the conductor connection structure of the third embodiment can be manufactured by using the manufacturing process for the snow melting radome 1 equipped with the conductor connection structure of the second embodiment as a basis, and laying the heater wire 5, which corresponds to the conductor, in a predetermined pattern such as a meandering shape by fixing the contact area to the resin substrate 3, for example by welding with ultrasonic vibration or printing. The redundant wiring section 54 of the heater wire 5 is then laid so that it is fixed to the resin substrate 3 in the contact area.

[0059] In the third embodiment, a curved portion 53 is provided on the heater wire 5 in addition to the redundant wiring portion 54. However, it is also preferable to provide only the redundant wiring portion 54 on the heater wire 5 without the curved portion 53, as in the configuration in the first embodiment in which the redundant wiring portion 54 is added.

[0060] According to the third embodiment, the 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 that is laid on the resin substrate 3 rather than the intermediate joint 80, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire 5 that is laid on the resin substrate 3 near the first metal plate 61 or the second metal plate 62. Therefore, the occurrence of breakage of the heater wire 5 can be prevented more reliably, and the weather resistance and durability of the heater wire 5 can be further improved. Furthermore, the third embodiment exhibits the same effects as the first and second embodiments due to its corresponding configuration.

[0061] [Conductor connection structure of the fourth embodiment] The conductor connection structure of the fourth embodiment of the present invention is installed in a snow-melting radome 1c such as a bumper cover attached to the bumper of a vehicle. The snow-melting radome 1c has a configuration similar to the first embodiment, as shown in Figures 11 and 12, in which a heater wire 5 corresponding to a conductor is laid in a straight line between the joint 8 and the intermediate joint 80. As a modification of the fourth embodiment, a configuration with a curved portion 53 as in the second embodiment, or a configuration with a curved portion 53 and a redundant wiring portion 54 as in the third embodiment, or a configuration with only a redundant wiring portion 54 without a curved portion 53 is also suitable.

[0062] In the fourth embodiment of the wire connection structure or snow melting radome 1c, a first recess 42 and a second recess 43 are formed as separate recesses in another resin substrate 4 formed by injection molding, and the first recess 42 and the second recess 43 are formed to be separated from each other. A first protective plate 91 and a second protective plate 92, which correspond to protective plates, are embedded in the first recess 42 and the second recess 43, respectively, so as to fit into them.

[0063] The first protective plate 91 is provided so as to protrude from the first metal plate 61, which is the metal material, that it covers the area of ​​the heater wire 5 near the metal material that is drawn out from the first metal plate 61 on the side of the heater wire 5 that is laid out on the resin substrate 3, in the thickness direction of the base 2, from the side opposite to the first metal plate 61, and is fixed to the first metal plate 61 in the area that overlaps with the first metal plate 61. In the illustrated example, the first protective plate 91 is provided so as to cover both the joint 8 and the intermediate joint 80, but it is also acceptable to have a configuration that covers only the intermediate joint 80 without covering the joint 8, or it is also possible to have a configuration that does not cover either the joint 8 or the intermediate joint 80.

[0064] The second protective plate 92 is provided so as to protrude from the second metal plate 62, which is the metal material, that it covers the area of ​​the heater wire 5 near the metal material of the heater wire 5 that is drawn out from the second metal plate 62 on the side of the heater wire 5 that is laid out on the resin substrate 3, in the thickness direction of the base 2, from the side opposite to the second metal plate 62, and is fixed to the second metal plate 62 in the area that overlaps with the second metal plate 62. In the illustrated example, the second protective plate 92 is provided so as to cover both the joint 8 and the intermediate joint 80, but it is also acceptable to have a configuration that covers the intermediate joint 80 but not the joint 8, or it is also possible to have a configuration in which it does not cover either the joint 8 or the intermediate joint 80.

[0065] The first protective plate 91 and the second protective plate 92 are formed from synthetic resins such as ultraviolet-curing resins, and are fixed to the first metal plate 61 and the second metal plate 62 in contact areas by adhesive bonding, heat compression bonding, or welding, respectively. Preferably, the fixing area between the first protective plate 91 and the first metal plate 61 is formed in the overlapping area of ​​the first protective plate 91 and the first metal plate 61 so as to cover the periphery of the heater wire 5 corresponding to the conductor, and the fixing area between the second protective plate 92 and the second metal plate 62 is formed in the overlapping area of ​​the second protective plate 92 and the second metal plate 62 so as to cover the periphery of the heater wire 5 corresponding to the conductor, thereby further reducing the force applied to the heater wire 5 from the flowing resin when another resin substrate 4 is formed by injection molding, more reliably preventing the heater wire 5 from breaking, and further improving the weather resistance and durability of the heater wire 5. Furthermore, preferably, the first protective plate 91 and the second protective plate 92 are fixed to the resin substrate 3 by adhesive, heat compression, or welding.

[0066] Furthermore, as shown in the first modified example in Figure 14(a), the first protective plate 91 and the second protective plate 92 may be made of metal or the like, and the first protective plate 91 and the second protective plate 92 may be fixed in a point-like manner to the first metal plate 61 and the second metal plate 62, respectively, in the overlapping region, by joints 8 or intermediate joints 80 made of solder or brazing material. Alternatively, as shown in the second modified example in Figure 14(b), the first protective plate 91 and the second protective plate 92 may each be made of reinforcing laminates, and may be composed of an inner layer plate 93 made of metal or the like fixed to the first metal plate 61 and the second metal plate 62, and an outer layer plate 94 made of synthetic resin such as ultraviolet curing resin fixed over the entire inner layer plate 93. In this case, for example, the inner layer plate 93 may be fixed in the same manner as in the first modified example, and the outer layer plate 94 may be fixed by applying a paste-like ultraviolet curing resin to the outside of the inner layer plate 94 and curing it.

[0067] Aside from the configuration in which a first protective plate 91 and a second protective plate 92 are provided to fit into the first recess 42 and the second recess 43 respectively, and the first protective plate 91 and the second protective plate 92 are fixed to the first metal plate 61 and the second metal plate 62, the configuration of the conductor connection structure or snow melting radome 1c of the fourth embodiment is the same as that of the first embodiment. Furthermore, a configuration in which part or all of the curved portion 53 in the second embodiment is covered with the first protective plate 91 and the second protective plate 92, or a configuration in which part or all of the redundant wiring portion 54 in the third embodiment is covered with the first protective plate 91 and the second protective plate 92 is also suitable.

[0068] When manufacturing the snow-melting radome 1c equipped with the conductor connection structure of the fourth embodiment, the same process as in the first embodiment is performed to join one connection end 51 of the heater wire 5, which corresponds to a conductor, to a first metal plate 61, which corresponds to a metal material, at the joint 8, so that one connection end 51 of the heater wire 5, which corresponds to a conductor, and one wire harness connection terminal 71, which corresponds to a power supply connection terminal, are electrically connected. An intermediate joint 80 is provided at a position closer to the resin base material 3 than the joint 8, to join the heater wire 5 and the first metal plate 61. In addition, the other connection end 52 of the heater wire 5, which corresponds to a conductor, and another wire harness connection terminal 72, which corresponds to a power supply connection terminal, are electrically connected to a second metal plate 62, which corresponds to a metal material, at the joint 8. An intermediate joint 80 is provided at a position closer to the resin base material 3 than the joint 8, to join the heater wire 5 and the second metal plate 62 (see Figure 13(a)).

[0069] Furthermore, as shown in Figure 13(b), the first protective plate 91 is provided on the resin substrate 3, which is provided with the joint portion 8 and the intermediate joint portion 80. This is achieved by placing, for example, a paste-like ultraviolet-curing resin that will serve as a protective plate in a predetermined area and irradiating it with ultraviolet light, thereby causing the first protective plate 91 to protrude from the first metal plate 61 so as to cover the area near the metal material of the heater wire 5 that is drawn out from the first metal plate 61 on the side of the heater wire 5 that is laid out on the resin substrate 3, from the opposite side of the first metal plate 61 in the thickness direction of the resin substrate 3, and fixing it to the first metal plate 61 in the area that overlaps with the first metal plate 61. Furthermore, the second protective plate 92 is provided on the resin substrate 3, which has a joint portion 8 and an intermediate joint portion 80, so as to protrude from the second metal plate 62 and cover the area near the metal material of the heater wire 5 that is drawn out from the second metal plate 62 on the side of the heater wire 5 that is laid out on the resin substrate 3, from the opposite side of the second metal plate 62 in the thickness direction of the resin substrate 3, and is fixed to the second metal plate 62 in the area that overlaps with the second metal plate 62.

[0070] Alternatively, instead of this process, a conductive bonding material such as solder or brazing material may be applied to predetermined locations to harden and form the joint 8 and the intermediate joint 80, the first protective plate 91 and the second protective plate 92 made of metal or the like may be placed in predetermined areas, and the bonding material 8 and the intermediate joint 80 may be melted and then hardened again to fix the first protective plate 91 to the first metal plate 61 in the area overlapping with the first metal plate 61, and the second protective plate 92 to the second metal plate 62 in the area overlapping with the second metal plate 62.

[0071] Subsequently, the resin substrate 3, to which the heater wire 5, the first metal plate 61 and the second metal plate 62, the first protective plate 91 and the second protective plate 92, the joint 8 and the intermediate joint 80, and the wire harness connection terminals 71 and 72 are attached, is placed inside a mold 100 made of a split mold, and another resin substrate 4 is formed by injection molding in the same manner as in the first embodiment (see Figures 13(c) and 4). At this time, the areas near the metal material of the heater wire 5 drawn from the first metal plate 61 and the areas near the metal material of the heater wire 5 drawn from the second metal plate 62, etc., that are covered by the first protective plate 91 and the second protective plate 92 on the side where the other resin substrate 4 is formed are protected by the first protective plate 91 and the second protective plate 92 from the force applied by the flowing resin that will become the other resin substrate 4.

[0072] Another resin substrate 4 is laminated by injection molding, and its interface is molded and welded to the resin substrate 3, heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminals 72, first protective plate 91, second protective plate 92, etc., and the heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminals 72, joint 8, intermediate joint 80, first protective plate 91, second protective plate 92 are embedded between the resin substrate 3 and the other resin substrate 4. After the formation of the other resin substrate 4, the mold 100 is demolded to obtain a snow melting radome 1c equipped with the wire connection structure of the first embodiment.

[0073] According to the fourth embodiment, when another resin substrate 4 is formed by injection molding and fixed to the resin substrate 3, the first protective plate 91 and the second protective plate 92 can protect the heater wire 5, which corresponds to a conductor, from the resin that flows during injection molding. Furthermore, the amount of flowing resin that flows between the first metal plate 61 and the heater wire 5, and between the second metal plate 62 and the heater wire 5, can be significantly reduced at the intermediate joint 80, thereby protecting the heater wire 5. Therefore, the occurrence of breakage of the heater wire 5 can be prevented more reliably. In addition, the fourth embodiment exhibits the corresponding effects from the configuration corresponding to the first, second, and third embodiments.

[0074] [Scope of the invention disclosed herein] The inventions disclosed herein include, in addition to the inventions and embodiments listed herein, modifications to these to the extent applicable, or additions to these to these other disclosures, or deletions of these other disclosures to the extent that partial effects are obtained, thereby creating broader concepts. Furthermore, the inventions disclosed herein also include the modifications and additions listed below.

[0075] For example, in the above embodiment, an example was illustrated and explained in which the connection ends 51 and 52 of the heater wire 5, which correspond to the conductor, and the wire harness connection terminals 71 and 72, which correspond to the power supply connection terminals, are arranged in a straight line. However, in order to ensure electrical connectivity more reliably, it is also acceptable to arrange the connection ends 51 and 52 of the heater wire 5 so that they intersect the wire harness connection terminals 71 and 72 at an angle. Furthermore, the power supply connection terminals in the present invention include appropriate connection terminals for supplying power to the conductor, and in addition to the wire harness connection terminals of the wire harness in the above example, they also include, for example, the connection terminals of a connector.

[0076] Furthermore, the wire connection structure of the present invention includes a structure for connecting wires other than the heater wires of a snow melting radome, and also includes a wire connection structure such as a resin molded product on which wires such as MID (Molded Interconnect Device) are laid. In addition, the function of the wires in the wire connection structure of the present invention can be as appropriate, such as an antenna, wireless power supply and transmission, or an electromagnetic tag.

[0077] Furthermore, when manufacturing the snow-melting radomes 1, 1a, 1b, and 1c in the above embodiments, the step of forming an intermediate product in which the first metal plate 61 and the second metal plate 62 are fitted and embedded in the first recess 32 and the second recess 33, which are isolated and 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 plate 61 and the second metal plate 62 are fitted and embedded in the isolated first recess 32 and the second recess 33, respectively. [Industrial applicability]

[0078] This invention can be used, for example, in a connection structure for conductive wires such as heater wires in snow-melting radomes. [Explanation of Symbols]

[0079] 1, 1a, 1b, 1c…Snow melting radome 2…Base 21…Tab 3…Resin substrate 31…Groove 32…First recess 33…Second recess 4…Another resin substrate 41…Groove 42…First recess 43…Second recess 5…Heater wire 51…One connection end 52…Other connection end 53…Bent section 54…Redundant wiring section 61…First metal plate 611…Exposed surface 62…Second metal plate 621…Exposed surface 7…Wire harness connection section 71…One wire harness connection terminal 72…Other wire harness connection terminal 8…Joint 80…Intermediate joint 81…Another intermediate joint 91…First protective plate 92…Second protective plate 93…Inner layer plate 94…Outer layer plate 100…Mold 101…Injection port 102…Outlet R…Electromagnetic wave irradiation area MR... Molten resin

Claims

1. Resin substrate and A wire is laid with a contact area fixed to the resin substrate, The resin substrate comprises a metal material embedded in a recess formed in the resin substrate, The connecting end of the conductor and the power supply connection terminal are joined to a metal material at the joint so that they are electrically connected. A wire connection structure characterized in that an intermediate joint is provided for joining the wire and the metal material at a position closer to the wire being laid on the resin substrate than the aforementioned joint.

2. The wire connection structure according to claim 1, characterized in that a curved portion is provided in the portion of the wire between the joint and the intermediate joint.

3. The conductor connection structure according to claim 1, characterized in that a redundant wiring portion is locally provided in the portion of the conductor that is positioned on the side of the conductor that is laid on the resin substrate rather than the intermediate joint portion, and the redundant wiring portion is fixed to the resin substrate in a contact area and laid.

4. The wire connection structure according to claim 1, characterized in that another intermediate joint is provided in the portion of the wire between the joint and the intermediate joint for joining the wire and the metal material.

5. The wire connection structure according to any one of claims 1 to 4, characterized in that the wire is embedded between the resin substrate and another resin substrate.

6. It has a protective plate embedded in another recess formed in the other resin substrate formed by injection molding, The wire connection structure according to claim 5, characterized in that the protective plate is provided so as to protrude from the metal material that it covers the region of the wire near the metal material that is drawn out from the metal material on the wire-laying side of the wire to the resin substrate, from the side opposite to the metal material, and is fixed to the metal material in the region that overlaps with the metal material.

7. The first step involves forming an intermediate product in which a metal material is embedded in a recess formed in a resin substrate, laying a conductor wire with its contact area fixed to the resin substrate, and placing the connecting end of the conductor wire on the metal material without fixing it, A second step involves positioning the power supply connection terminal close to the connection end of the conductor, A method for manufacturing a wire connection structure, comprising a third step of joining the metal material at a joint so that the connection end of the wire and the power supply connection terminal are electrically connected, and providing an intermediate joint that joins the wire and the metal material at a position closer to the wire being laid on the resin substrate than the joint.

8. The method for manufacturing a wire connection structure according to claim 7, characterized in that, in the first step, a curved portion is provided in the portion of the wire that will be positioned between the joint and the intermediate joint.

9. In the third step, a protective plate is provided on the resin substrate so as to protrude from the metal material and cover the region of the conductor near the metal material that is drawn out from the metal material on the side of the conductor that is laid on the resin substrate, from the side opposite to the metal material, and the protective plate is fixed to the metal material in the region that overlaps with the metal material. The wire connection structure according to claim 7 or 8, characterized in that, in the fourth step, another resin substrate is formed by injection molding so as to be fixed to the resin substrate and the protective plate, and the wire is embedded between the resin substrate and the other resin substrate.

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