Snow-melting radome and manufacturing method therefor

Abstract

Provided is a snow-melting radome 1, wherein: a first resin base material 3 and a second resin base material 4 are laminated and arranged to constitute an electromagnetic wave transmissive base body 2; a heater wire 5 wired in the surface direction of the base body 2 is embedded between the first resin base material 3 and the second resin base material 4; one connection part 51 of the heater wire 5 and one wire harness connection terminal 71 are conductively connected, the other connection part 52 of the heater wire 5 and the other wire harness connection terminal 72 are conductively connected, a first redundant wiring part 53 is locally provided in a portion of the heater wire 5 that is further to the electromagnetic wave transmission region R side than is the one connection part 51, and a second redundant wiring part 54 is locally provided in a portion of the heater wire 5 that is further to the electromagnetic wave transmission region R side than is the other connection part 52. Disconnection of the heater wire is prevented, and durability against repeated use can be improved.

Description

Snow-melting radome and its manufacturing method

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

[0002] A conventional radome for an automotive radar device having a snow-melting function is disclosed in Patent Document 1. In the radome of Patent Document 1, a heater wire is embedded between a first resin substrate and a second resin substrate, the heater wire being routed along a groove. A first metal plate and a second metal plate are embedded between the first resin substrate and the second resin substrate in an area other than the electromagnetic wave transmitting area 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 another wire harness connection terminal are placed and fixed on the mounting surface of the second metal plate. The first metal plate and the second metal plate prevent the resin substrate from being melted by heat generated when the end of the heater wire routed in the resin substrate is electrically connected to the wire harness connection terminal.

[0003] Patent No. 7158818

[0004] In the radome of Patent Document 1, a portion of the heater wire closer to the electromagnetic wave transmitting region than one end of the heater wire and a portion of the heater wire closer to the electromagnetic wave transmitting region than the other end of the heater wire are wired in a straight line. In this configuration, the heater wire repeatedly expands when heat is generated and contracts when heat generation stops, causing repeated tensile stresses to be applied to the straight line portions, making the straight line portions more susceptible to breakage. Therefore, there is a demand for a radome that can prevent breakage of the heater wire and improve the durability of the heater wire against repeated use.

[0005] The present invention has been 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.

[0006] The snow-melting radome of the present invention is characterized in that it comprises an electromagnetic wave-transmitting base formed by laminating a first resin base material and a second resin base material, a heater wire wired in a surface direction of the base and embedded between the first resin base material and the second resin base material, one connection portion of the heater wire is electrically connected to one wire harness connection terminal and the other connection portion of the heater wire is electrically connected to another wire harness connection terminal, a first redundant wiring portion is locally provided in a portion of the heater wire closer to the electromagnetic wave-transmitting region than the one connection portion of the heater wire, and a second redundant wiring portion is locally provided in a portion of the heater wire closer to the electromagnetic wave-transmitting region than the other connection portion of the heater wire. According to this, the first redundant wiring portion locally provided closer to the electromagnetic wave-transmitting region than the one connection portion of the heater wire can distribute and reduce thermal stress repeatedly applied to the portion of the heater wire near one connection portion, and the second redundant wiring portion locally provided closer to the electromagnetic wave-transmitting region than the other connection portion of the heater wire can distribute and reduce thermal stress repeatedly applied to the portion of the heater wire near the other connection portion. Therefore, breakage of the heater wire can be prevented, and durability of the heater wire against repeated use can be improved.

[0007] The snow-melting radome of the present invention is characterized in that a first metal material and a second metal material are embedded between the first resin base material and the second resin base material in an area other than the electromagnetic wave transmitting area of ​​the base so as to be isolated from each other, one connection portion of the heater wire and one wire harness connection terminal are placed on a mounting surface of the first metal material so as to be fixed to the first metal material, thereby electrically connecting the one connection portion of the heater wire and the one wire harness connection terminal, and the other connection portion of the heater wire and the other wire harness connection terminal are placed on a mounting surface of the second metal material so as to be fixed to the second metal material so as to electrically connect the other connection portion of the heater wire and the other wire harness connection terminal. According to this, by providing the first metal material and the second metal material, it is possible to prevent the heat generated when electrically connecting the connection portion of the heater wire wired in the resin base material to the wire harness connection terminal from melting and damaging the resin base material.

[0008] The snow-melting radome of the present invention is characterized in that the first redundant wiring section is formed in a serpentine shape, and the second redundant wiring section is also formed in a serpentine shape. This allows the redundant length of the serpentine path to more reliably distribute and reduce thermal stress repeatedly applied to the heater wire, and more reliably reduce the effects of expansion and contraction due to thermal stress on the heater wire. Furthermore, the serpentine path allows the length of the redundant path to be extended while ensuring the required wire width of the heater wire 5 required for snow melting.

[0009] The snow melting radome of the present invention is characterized in that the number of meandering repetitions in each of the first redundant wiring section and the second redundant wiring section is one or more, and the meandering variation range is five times or more the heater wire width, thereby further improving the dispersibility of thermal stress.

[0010] The snow melting radome of the present invention is characterized in that a first tip redundant wiring portion connected to one of the heater wire connection portions is locally provided further forward than the one connection portion, and a second tip redundant wiring portion connected to the other of the heater wire connection portions is locally provided further forward than the other connection portion. This configuration makes it possible to disperse and reduce thermal stresses repeatedly applied to the heater wire portion near one of the connection portions by the first tip redundant wiring portion, and also to disperse and reduce thermal stresses repeatedly applied to the heater wire portion near the other connection portion by the second tip redundant wiring portion. This makes it possible to more reliably prevent breakage of the heater wire and further improve the durability of the heater wire against repeated use.

[0011] The snow-melting radome of the present invention is characterized in that the first tip redundant wiring portion and the second tip redundant wiring portion are formed in a serpentine shape. According to this, the redundant length of the serpentine paths of the first tip redundant wiring portion and the second tip redundant wiring portion can more reliably distribute and reduce thermal stress repeatedly applied to the heater wire portion, and can more reliably reduce the effects of expansion and contraction of the heater wire due to thermal stress. Furthermore, the serpentine path can extend the length of the redundant path while ensuring the required wire width of the heater wire 5 required for snow melting.

[0012] The method for manufacturing a snow melting radome of the present invention includes a first step of fitting and arranging a first metal material and a second metal material in a first recess and a second recess formed so as to be isolated from each other on one surface of an electromagnetic wave permeable first resin base material, respectively; a second step of wiring a heater wire in a predetermined pattern on one surface of the first resin base material, placing one connection portion of the heater wire on an exposed mounting surface of the first metal material and locally forming a first redundant wiring portion in a portion of the heater wire closer to the electromagnetic wave permeable region than the one connection portion of the heater wire, and placing the other connection portion of the heater wire on an exposed mounting surface of the second metal material and locally forming a second redundant wiring portion in a portion of the heater wire closer to the electromagnetic wave permeable region than the other connection portion of the heater wire; and a second step of placing one wire harness connection terminal on the exposed mounting surface of the first metal material and locally forming a second redundant wiring portion in a portion of the heater wire closer to the electromagnetic wave permeable region than the other connection portion of the heater wire. a third step of fixing a terminal to the first metal material to electrically connect one connection portion of the heater wire and the one wire harness connection terminal, placing another wire harness connection terminal on the exposed mounting surface of the second metal material and fixing the other connection portion of the heater wire and the other wire harness connection terminal to the second metal material to electrically connect the other connection portion of the heater wire and the other wire harness connection terminal; and a fourth step of forming an electromagnetic wave transparent second resin base material by injection molding on the mounting surface of the first metal material and the side of the mounting surface of the second metal material, fixing the second resin base material to the first resin base material, and embedding the heater wire, the first metal material, the one wire harness connection terminal, the second metal material, and the other wire harness connection terminal between the first resin base material and the second resin base material. According to this, the first redundant wiring part, which is locally provided closer to the electromagnetic wave transmitting area than one connection part of the heater wire, can disperse and reduce the thermal stress repeatedly applied to the heater wire part near one connection part, and the second redundant wiring part, which is locally provided closer to the electromagnetic wave transmitting area than the other connection part of the heater wire, can disperse and reduce the thermal stress repeatedly applied to the heater wire part near the other connection part. Therefore, in the manufactured snow melting radome, it is possible to prevent breakage of the heater wire and improve the durability of the heater wire against repeated use.Furthermore, by providing the first metal material and the second metal material, it is possible to prevent the resin base material from being melted and damaged by heat generated when the connection portion of the heater wire wired in the resin base material is electrically connected to the wiring harness connection terminal. Furthermore, by wiring the heater wire in the first resin base material, it is possible to wire the heater wire in a first resin base material of an appropriate shape, which increases the degree of freedom in the shape of the first resin base material and the snow-melting radome, as well as the degree of freedom in the wiring pattern and wiring density of the heater wire.

[0013] The method for manufacturing a snow melting radome of the present invention is characterized in that, in the second step, a first tip redundant wiring portion connected to one connection portion of the heater wire is locally formed further forward than the one connection portion, and a second tip redundant wiring portion connected to the other connection portion is locally formed further forward than the other connection portion of the heater wire. This makes it possible to provide a snow melting radome that can distribute and reduce thermal stress repeatedly applied to the heater wire portion near one connection portion by the first tip redundant wiring portion and can also distribute and reduce thermal stress repeatedly applied to the heater wire portion near the other connection portion by the second tip redundant wiring portion, and thus makes it possible to obtain a snow melting radome that can more reliably prevent breakage of the heater wire and further improve the durability of the heater wire against repeated use.

[0014] According to the present invention, a snow melting radome can be obtained that can prevent breakage of the heater wire and improve the durability of the heater wire against repeated use.

[0015] 1A is a front view of a snow melting radome according to a first embodiment of the present invention, and FIG. 1B is a partially enlarged front view of FIG. 1A. A schematic vertical cross-sectional view of the snow melting radome according to the first embodiment. 1A to 1D are process explanatory diagrams of a manufacturing process for the snow melting radome according to the first embodiment. 1D is an explanatory diagram showing a state in which the first resin base material, metal plate, heater wire, and wire harness connection terminal for the snow melting radome according to the first embodiment are arranged inside a mold. 1E is a partially enlarged front view of a first modified example of the snow melting radome according to the first embodiment. 1F is a partially enlarged front view of a second modified example of the snow melting radome according to the first embodiment. 1G is a partially enlarged front view of a third modified example of the snow melting radome according to the first embodiment. 1G is a partially enlarged front view of a fourth modified example of the snow melting radome according to the first embodiment. 1G is a schematic vertical cross-sectional view of the snow melting radome according to the second embodiment before the second resin base material is formed. 1G is a schematic vertical cross-sectional view of the snow melting radome according to the third embodiment before the second resin base material is formed. 1G is a schematic vertical cross-sectional view of the snow melting radome according to the fourth embodiment before the second resin base material is formed.

[0016] [Snow Melting Radome of First Embodiment] A snow melting radome 1 of a first embodiment according to the present invention is used, for example, as a radome for an on-board radar device, such as a bumper cover attached to the bumper of a vehicle, and includes an electromagnetic wave-transmitting base 2, as shown in Figures 1 and 2. The base 2 is composed of a first resin base material 3 arranged on the side opposite to the viewing side, i.e., the radar device side, such as the on-board radar device, and a second resin base material 4 arranged on the viewing side, i.e., in front of the first resin base material 3. The first resin base material 3 and the second resin base material 4 are laminated, and in the first embodiment, the first resin base material 3 and the second resin base material 4 are laminated and fixed to each other. If necessary, the second resin base material 4 may be arranged on the side opposite to the viewing side, and the first resin base material 3 may be arranged on the viewing side.

[0017] The first resin film 3 and the second resin film 4 are each formed of an insulating, electromagnetically transmissive synthetic resin. The first resin film 3 and the second resin film 4 can be formed into any suitable shape within the applicable range, such as a flat or curved plate. The first resin film 3 and the second resin film 4 can be made of different or the same synthetic resin. From the perspective of improving electromagnetic wave transmission performance, it is preferable to form the first resin film 3 and the second resin film 4 from materials whose refractive indices n, defined based on the complex dielectric constant, match each other, or whose refractive indices n are approximately the same or close to each other. The numerical range of the refractive indices of the first resin film 3 and the second resin film 4 that are close to each other is preferably a difference of 0 to 10%.

[0018] Here, the refractive index n is a quantity defined by the real part εr' of the relative dielectric constant and the imaginary part εr" as in Equation 1. From the viewpoint of transparency, it is preferable that the magnitude of the dielectric loss tangent tanδ, defined by Equation 2 from the ratio of the imaginary part to the real part at the applicable frequency, be 0.1 or less. It is also preferable that the magnitude of the real part of the relative dielectric constant be 3 or less. By setting the magnitudes of the dielectric loss tangent and the real part of the relative dielectric constant to be equal to or less than these numerical values, it is possible to ensure the reduction of the reflectance and internal loss required for the radome.

[0019]

[0020]

[0021] Any suitable synthetic resin can be used within the spirit and scope of the present invention for the synthetic resin of the first resin substrate 3 and the synthetic resin of the second resin substrate 4. For example, acrylic resins such as polymethyl methacrylate (PMMA), polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylate copolymer (ASA), acrylonitrile-ethylene propyl rubber-styrene copolymer (AES), polypropylene (PP), polyphenylene ether (PPE), modified polyphenylene ether (m-PPE), polystyrene (PS), etc. can be used alone or in combination of two or more, and additives may also be added. Foams may also be used for these synthetic resins. Furthermore, with regard to the thicknesses of the first resin base material 3 and the second resin base material 4 in the electromagnetic wave transmission direction, the ratio of the thickness of the first resin base material 3 to the thickness of the second resin base material 4, the thickness of the first base resin 3, the thickness of the second resin base material 4, and the total thickness of the base 2 composed of the first resin base material 3 and the second resin base material 4 are appropriate within a range that can ensure the required electromagnetic wave transmission properties of the snow-melting radome 1.

[0022] In the snow-melting radome 1, heater wires 5 are wired in a predetermined pattern in the surface direction of the electromagnetic wave-transmitting substrate 2 so as to exert a snow-melting function in the electromagnetic wave-transmitting region R. Any appropriate conductive material can be used for the heater wire 5 within the spirit and scope of the present invention, and preferred examples include copper, silver, silver-plated copper, copper-silver alloy, copper-nickel alloy, nickel-chromium alloy, iron-chromium alloy, transparent conductive film such as ITO film, and carbon fiber. Furthermore, the heater wire may take any form, and wire rod, conductive ink, conductive filler-added material, etc. can be used.

[0023] The heater wire 5 in the illustrated example is formed as a continuous wire that meanders and folds back along the direction in which the plate-like base 2 expands, and the straight portions of the heater wire 5 are arranged side by side at intervals along the surface direction of the base 2 in and outside the electromagnetic wave irradiation region R of the base 2 by the radar device, and the directions of currents flowing in the straight portions of adjacent heater wires 5 are set to be approximately anti-parallel or anti-parallel to each other.

[0024] The heater wire 5 is embedded between the first resin film 3 and the second resin film 4, and is sandwiched between the first resin film 3 and the second resin film 4, and is disposed within and sealed in the base 2 formed of the first resin film 3 and the second resin film 4. In the first embodiment, the heater wire 5 is routed along a groove 31 formed on the surface of the first resin film 3 that is fixed to the second resin film 4, and another groove 41 formed on the surface of the second resin film 4 that is fixed to the first resin film 3 so as to face the groove 31, and the heater wire 5 is fixed to the first resin film 3 and the second resin film 4, respectively.

[0025] In a region other than the electromagnetic wave transmission region R of the base 2, i.e., in the region of the tab 21 that protrudes laterally in the first embodiment, a first recess 32 and a second recess 33 are formed on the fixing surface side of the first resin base material 3 so as to be isolated from each other. A first metal plate 61 corresponding to a first metal material having electrical conductivity and a second metal plate 62 corresponding to a 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 base material 3 and the second resin base material 4 so as to be isolated 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] One connection portion 51 of the heater wire 5 and one wire harness connection terminal 71 are placed on the mounting surface 611 of the first metal plate 61, and are arranged so as to be in contact with one connection portion 51 of the heater wire 5 and one wire harness connection terminal 71 (see FIGS. 2 and 3 ). One connection portion 51 of the heater wire 5 and one wire harness connection terminal 71 are fixed to the first metal plate 61, and are electrically connected to one connection portion 51 of the heater wire 5 and one wire harness connection terminal 71. In the first embodiment, one connection portion 51 of the heater wire 5, one wire harness connection terminal 71, and the first metal plate 61 are joined together integrally, by a joint 8 made of a joining material such as solder or brazing filler metal, or a joint 8 made of a welded part such as laser welding (see FIGS. 2 , 3(d) and 4 ).

[0027] The other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72 are placed on the mounting surface 621 of the second metal plate 62, and are arranged so as to be in contact with each other (see FIGS. 2 and 3 ). The other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72 are fixed to the second metal plate 62, thereby electrically connecting the other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72. In the first embodiment, the other connection portion 52 of the heater wire 5, the other wire harness connection terminal 72, and the second metal plate 62 are joined together integrally, by a joint 8 made of a joining material such as solder or brazing filler metal, or a joint 8 made of a welded part such as laser welding (see FIGS. 2 , 3(d) and 4 ).

[0028] Furthermore, in the first embodiment, the heater wire 5 is wired along the fixing surface of the first resin base material 3 and the second resin base material 4, and one connection portion 51 of the heater wire 5 that is not bent in the stacking direction of the first resin base material 3 and the second resin base material 4 is electrically connected to one wire harness connection terminal 71 that is arranged so as to overlap and contact the one connection portion 51 of the heater wire 5. Also, the other connection portion 52 of the heater wire 5 that is not bent in the stacking direction of the first resin base material 3 and the second resin base material 4 is electrically connected to another wire harness connection terminal 72 that is arranged so as to overlap and contact the other connection portion 52 of the heater wire 5 (see FIGS. 2 and 3(d)).

[0029] A first redundant wiring portion 53 is locally provided in a portion of the heater wire 5 closer to the electromagnetic wave transmission region R than one connection portion 51 of the heater wire 5. The first redundant wiring portion 53 is redundantly wired as part of the heater wire 5 in a position near one connection portion 51 between the electromagnetic wave transmission region R and the one connection portion 51, and is fixed to the first resin base material 3 and the second resin base material 4. A second redundant wiring portion 54 is locally provided in a portion of the heater wire 5 closer to the electromagnetic wave transmission region R than the other connection portion 52 of the heater wire 5. The second redundant wiring portion 54 is redundantly wired as part of the heater wire 5 in a position near the other connection portion 52 between the electromagnetic wave transmission region R and the other connection portion 52, and is fixed to the first resin base material 3 and the second resin base material 4.

[0030] The first redundant wiring portion 53 is formed to meander in a direction perpendicular to the extension direction of one wire harness connection terminal 71, and in the first embodiment, is formed to meander in a rectangular wave shape bending at right angles or approximately right angles. The second redundant wiring portion 54 is formed to meander in a direction perpendicular to the extension direction of the other wire harness connection terminal 72, and in the first embodiment, is formed to meander in a rectangular wave shape bending at right angles or approximately right angles. The number of meander repetitions corresponding to one period of the rectangular wave in the first redundant wiring portion 53 and the second redundant wiring portion 54 is preferably one or more times, but is more preferably two or more times from the viewpoint of improving the dispersibility of thermal stress. Furthermore, the meandering fluctuation width W1, which corresponds to the fluctuation width of the rectangular wave in the first redundant wiring portion 53 and the second redundant wiring portion 54, is preferably set to 5 times or more, more preferably 10 times or more, the line width of the heater wire 5, from the viewpoint of improving the dispersibility of thermal stress, and is preferably set to 30 times or less the line width of the heater wire 5, from the viewpoint of reducing the installation space of the first redundant wiring portion 53 and the second redundant wiring portion 54.

[0031] When manufacturing the snow melting radome 1 of the first embodiment, a first recess 32 and a second recess 33 are formed so as to be isolated from each other on one surface of the electromagnetically transparent first resin base material 3. The first recess 32 and the second recess 33 may be formed by convex portions of corresponding shapes in a mold when the first resin base material 3 is formed by injection molding, or may be formed by cutting the resin base material or the like. Furthermore, a first metal plate 61 and a second metal plate 62 are fitted and arranged in the first recess 32 and the second recess 33 formed so as to be isolated from each other in the first resin base material 3, respectively (see FIG. 3( a)).

[0032] Then, the heater wire 5 is laid out in a predetermined pattern on one surface of the first resin base material 3, 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 in a portion of the heater wire 5 closer to the electromagnetic wave transmission region R than the one connection portion 51 of the heater wire 5, 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 in a portion of the heater wire 5 closer to the electromagnetic wave transmission region R than the other connection portion 52 of the heater wire 5 (see FIG. 3( b)). In this example, when laying out the heater wire 5, the first resin base material 3 melts to form grooves 31 that bond the heater wire 5. When laying out the heater wire 5 in a predetermined pattern on one surface of the first resin base material 3, it is preferable to use, for example, ultrasonic vibration welding, printing, or the like.

[0033] Furthermore, one connection portion 51 of the heater wire 5 and one wire harness connection terminal 71 are placed on the exposed mounting surface 611 of the first metal plate 61, and the one connection portion 51 of the heater wire 5, the one wire harness connection terminal 71, and the first metal plate 61 that are in contact with each other are joined at a joint 8 from the exposed mounting surface 611 side to establish a conductive connection, and the one connection portion 51 of the heater wire 5, the one wire harness connection terminal 71, and the first metal plate 61 are fixed to the first metal plate 61. Similarly, the other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72 are placed on the exposed mounting surface 621 of the second metal plate 62, and the other connection portion 52 of the heater wire 5, the other wire harness connection terminal 72, and the second metal plate 62 that are in contact with each other are joined at the joint 8 from the exposed mounting surface 621 side to establish a conductive connection, and the other connection portion 52 of the heater wire 5 and the other wire harness connection terminal 72 are fixed to the second metal plate 62 (see FIGS. 3(c) and 3(d)).

[0034] 4, the first resin base material 3 to which the heater wire 5, the first metal plate 61, the second metal plate 62, and the wire harness connection terminals 71, 72 are attached is placed inside a mold 100 configured as a split mold. At this time, the wire harness connection portion 7 from which the wire harness connection terminals 71, 72 are drawn is led out of the mold 100 through a lead-out port 102 formed in a part of the mold 100.

[0035] Then, injection molding is performed by pouring molten resin MR into the interior of the mold 100 through the injection port 101 of the mold 100, 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 base material 4 laminated by injection molding is molded and welded to the first resin base material 3, the heater wire 5, the first metal plate 61, the one wire harness connection terminal 71, the second metal plate 62, and the other wire harness connection terminal 72, and the heater wire 5, the first metal plate 61, the one wire harness connection terminal 71, the second metal plate 62, the other wire harness connection terminal 72, and the joint 8 are embedded between the first resin base material 3 and the second resin base material 4.

[0036] Furthermore, since the second resin base material 4 is formed so as 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 second resin base material 4 in an insert-molded manner, and the heater wire 5 is fitted into another groove 41 of the second resin base material 4. Note that the second resin base material 4 is not limited to a configuration formed by injection molding, and may be fixed to the first resin base material 3 by adhesion or the like, as necessary. After the second resin base material 4 is formed, the mold 100 is demolded to obtain the snow melting radome 1 of the first embodiment.

[0037] According to the first embodiment, the first redundant wiring part 53, which is locally provided closer to the electromagnetic wave transmitting region R than one connection part 51 of the heater wire 5, can disperse and reduce thermal stress repeatedly applied to the heater wire part near the one connection part 51, and the second redundant wiring part 54, which is locally provided closer to the electromagnetic wave transmitting region R than the other connection part 52 of the heater wire 5, can disperse and reduce thermal stress repeatedly applied to the heater wire part near the other connection part 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.

[0038] Furthermore, by providing the first metal plate 61 and the second metal plate 62, it is possible to prevent the heat generated when electrically connecting the connection portions 51, 52 of the heater wire 5 wired to the first resin base material 3 to the wire harness connection terminal 71 from melting and damaging the first resin base material 3.

[0039] Furthermore, by forming the first redundant wiring portion 53 and the second redundant wiring portion 54 in a serpentine manner, the thermal stress repeatedly applied to the heater wire portion can be more reliably dispersed and reduced due to the redundant length of the serpentine path, and the influence of expansion and contraction due to the thermal stress on the heater wire 5 can be more reliably reduced. Furthermore, the serpentine path can extend the length of the redundant path while ensuring the required line width of the heater wire 5 necessary for snow melting.

[0040] Furthermore, by wiring the heater wire 5 in the first resin base material 3, it becomes possible to wire the heater wire 5 in a first resin base material 3 of an appropriate shape, which increases the degree of freedom in the shape of the first resin base material 3 and the snow-melting radome 1, as well as the degree of freedom in the wiring pattern and wiring density of the heater wire 5.

[0041] 5 , the snow melting radome 1p of the first modified example of the first embodiment has a first redundant wiring portion 53p formed to meander in a direction perpendicular to the extension direction of one wire harness connection terminal 71, and formed to meander in a curved sinusoidal shape, and a second redundant wiring portion 54p formed to meander in a direction perpendicular to the extension direction of the other wire harness connection terminal 72, and formed to meander in a curved sinusoidal shape. It is preferable that the number of meander repetitions corresponding to one period of the sine wave in the first redundant wiring portion 53p and the second redundant wiring portion 54p is one or more, but two or more is more preferable from the viewpoint of improving the dispersibility of thermal stress. Furthermore, the meandering fluctuation width W2, which corresponds to the fluctuation width of the sine wave in the first redundant wiring portion 53p and the second redundant wiring portion 54p, is preferably set to 5 times or more, more preferably 10 times or more, the line width of the heater wire 5 from the viewpoint of improving the dispersibility of thermal stress, and is preferably set to 30 times or less the line width of the heater wire 5 from the viewpoint of reducing the space required for installing the first redundant wiring portion 53p and the second redundant wiring portion 54p.

[0042] Other configurations of the snow melting radome 1p of the first modified example are the same as those of the snow melting radome 1 of the first embodiment. Moreover, the snow melting radome 1p of the first modified example can be manufactured by the same manufacturing process as that of the snow melting radome 1 of the first embodiment.

[0043] The snow melting radome 1p of the first modified example and its manufacturing method can exhibit the corresponding effects from the configuration corresponding to the snow melting radome 1 of the first embodiment or its manufacturing method.

[0044] 6 , the snow melting radome 1q of the second modified example of the first embodiment has a first redundant wiring portion 53q formed to meander in a rectangular wave shape that meanders in the extension direction of one wire harness connection terminal 71 and bends at right angles or approximately right angles, and a second redundant wiring portion 54q formed to meander in a rectangular wave shape that meanders in the extension direction of the other wire harness connection terminal 72 and bends at right angles or approximately right angles. The number of repetitions of meandering corresponding to one period of the rectangular wave in the first redundant wiring portion 53q and the second redundant wiring portion 54q is preferably one or more, but is more preferably two or more from the viewpoint of improving the dispersibility of thermal stress. Furthermore, the meandering fluctuation width W3, which corresponds to the fluctuation width of the rectangular wave in the first redundant wiring portion 53q and the second redundant wiring portion 54q, is preferably set to 5 times or more, more preferably 10 times or more, the line width of the heater wire 5 from the viewpoint of improving the dispersibility of thermal stress, and is preferably set to 30 times or less the line width of the heater wire 5 from the viewpoint of reducing the installation space of the first redundant wiring portion 53q and the second redundant wiring portion 54q.

[0045] 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 first embodiment. Moreover, 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 first embodiment. Moreover, as a further modified example of the second modified example, the first redundant wiring portion 53q may be formed to meander in a sinusoidal shape that meanders and curves in the extension direction of one wire harness connection terminal 71, and the second redundant wiring portion 54q may be formed to meander in a limited wave shape that meanders and curves in the extension direction of the other wire harness connection terminal 72. In this case, the suitable number of repeated meanders and the suitable range of variation of the meanders can be adopted from the configurations of the first modified example.

[0046] The snow melting radome 1q of the second modified example or a further modified example thereof and its manufacturing method can exhibit corresponding effects due to the configuration corresponding to the snow melting radome 1 of the first embodiment or its manufacturing method.

[0047] [Snow melting radome according to a third modified example of the first embodiment] In a snow melting radome 1r according to a third modified example of the first embodiment, the first redundant wiring portion 53r is formed in a spiral shape, and the second redundant wiring portion 54r is also formed in a spiral shape, as shown in Fig. 7. The other configurations of the snow melting radome 1r according to the third modified example are the same as those of the snow melting radome 1 according to the first embodiment. Moreover, the snow melting radome 1r according to the third modified example can be manufactured using the same manufacturing process as that of the snow melting radome 1 according to the first embodiment.

[0048] The snow melting radome 1r of the third modified example or a further modified example thereof and its manufacturing method can exhibit the corresponding effects from the configuration corresponding to the snow melting radome 1 of the first embodiment or its manufacturing method.

[0049] 8 , a snow melting radome 1s according to a fourth modification of the first embodiment has a first tip redundant wiring portion 55s locally provided on the tip side of one connection portion 51 of the heater wire 5 and connected to the one connection portion 51, and a second tip redundant wiring portion 56s locally provided on the tip side of the other connection portion 52 of the heater wire 5 and connected to the other connection portion 52. The first tip redundant wiring portion 55s in the fourth modification is formed to meander in the extension direction of one wire harness connection terminal 71, and the second tip redundant wiring portion 56s is formed to meander in the extension direction of the other wire harness connection terminal 72.

[0050] In the illustrated example, the first tip redundant wiring portion 55s is formed to meander in a rectangular wave shape that meanders in the extension direction of one wire harness connection terminal 71 and bends at right angles or approximately right angles, and the second tip redundant wiring portion 56s is formed to meander in a rectangular wave shape that meanders in the extension direction of the other wire harness connection terminal 72 and bends at right angles or approximately right angles. However, the first tip redundant wiring portion 55s may be formed to meander in a sinusoidal wave shape that meanders in the extension direction of one wire harness connection terminal 71 and bends in a curved manner, and the second tip redundant wiring portion 56s may be formed to meander in a sinusoidal wave shape that meanders in the extension direction of the other wire harness connection terminal 72 and bends in a curved manner.

[0051] The number of meandering repetitions and the meandering variation range when the first end redundant wiring portion 55s and the second end redundant wiring portion 56s are formed to meander in a rectangular wave shape are preferably the same as the number of meandering repetitions and the meandering variation range when the first redundant wiring portion 53 and the second redundant wiring portion 54 in the first embodiment are formed to meander in a rectangular wave shape. Also, the number of meandering repetitions and the meandering variation range when the first end redundant wiring portion 55s and the second end redundant wiring portion 56s are formed to meander in a sine wave shape are preferably the same as the number of meandering repetitions and the meandering variation range when the first redundant wiring portion 53p and the second redundant wiring portion 54p in the first modification of the first embodiment are formed to meander in a sine wave shape.

[0052] The other configurations of the snow melting radome 1 s of the fourth modified example are the same as those of the snow melting radome 1 of the first embodiment. The snow melting radome 1 s of the fourth modified example can be manufactured by basically the same manufacturing process as the snow melting radome 1 of the first embodiment, and the first tip redundant wiring portion 55 s and the second tip redundant wiring portion 56 s may be formed together when wiring the heater wire 5 in a predetermined pattern on one surface of the first resin base material 3. The first tip redundant wiring portion 55 s that is continuous with one connection portion 51 may be locally formed more distally than one connection portion 51 of the heater wire 5, and the second tip redundant wiring portion 56 s that is continuous with the other connection portion 52 may be locally formed more distally than the other connection portion 52 of the heater wire 5. The first tip redundant wiring portion 55 s and the second tip redundant wiring portion 56 s may be formed in a meandering shape in a direction perpendicular to the extension direction of the wire harness connection terminals 71, 72, or in a spiral shape.

[0053] The snow melting radome 1s of the fourth modified example or a further modified example thereof and its manufacturing method can achieve corresponding effects due to the configuration corresponding to that of the snow melting radome 1 of the first embodiment or its manufacturing method. Furthermore, in the fourth modified example, the first tip redundant wiring portion 55s can also disperse and reduce thermal stress repeatedly applied to the heater wire portion near one connection portion 51, and the second tip redundant wiring portion 56s can also disperse and reduce thermal stress repeatedly applied to the heater wire portion near the other connection portion 52. Therefore, breakage of the heater wire 5 can be more reliably prevented, and the durability of the heater wire 5 against repeated use can be further improved.

[0054] Furthermore, the redundant length of the serpentine path of the first tip redundant wiring portion 55s and the second tip redundant wiring portion 56s can more reliably distribute and reduce the thermal stress repeatedly applied to the heater wire portion, and can more reliably reduce the influence of expansion and contraction of the heater wire due to the thermal stress. Furthermore, the serpentine path can extend the length of the redundant path while ensuring the required wire width of the heater wire 5 required for snow melting.

[0055] [Snow-melting radome of second embodiment] As shown in Fig. 9, a snow-melting radome 1a of a second embodiment according to the present invention comprises an electromagnetic wave-transmitting base 2a formed by stacking a first resin base material 3a and a second resin base material 4a, and similarly to the first embodiment, a heater wire 5a is embedded between the first resin base material 3a and the second resin base material 4a and is wired in a predetermined pattern in the surface direction of the base 2a so as to exhibit a snow-melting function in the electromagnetic wave-transmitting region R. The heater wire 5a is laid on the surface of the first resin base material 3a facing the second resin base material 4a by electroless plating or printing using MID technology. The first resin base material 3a, the second resin base material 4a, and the heater wire 5a may be the same as the first resin base material 3, the second resin base material 4, and the heater wire 5 in the first embodiment.

[0056] In the snow melting radome 1a, as in the first embodiment, a first redundant wiring portion 53a is locally provided in a portion of the heater wire 5a closer to the electromagnetic wave transmission region R than one connection portion 51a of the heater wire 5a, and a second redundant wiring portion 54a is locally provided in a portion of the heater wire 5a closer to the electromagnetic wave transmission region R than the other connection portion 52a of the heater wire 5a (see FIGS. 9 and 1). The first redundant wiring portion 53a and the second redundant wiring portion 54a can be configured similarly to the first redundant wiring portion 53 and the second redundant wiring portion 54 in the first embodiment or their modifications, and it is also preferable to provide portions corresponding to the first tip redundant wiring portion 55s and the second tip redundant wiring portion 56s in the fourth modification.

[0057] One connection portion 51a of the heater wire 5a and one wire harness connection terminal 71a are fixed at a joint 8a, thereby electrically connecting the one connection portion 51a of the heater wire 5a and one wire harness connection terminal 71a. The other connection portion 52a of the heater wire 5a and another wire harness connection terminal 72a are also fixed at a joint 8a, thereby electrically connecting the other connection portion 52a of the heater wire 5a and another wire harness connection terminal 72a. The same configuration as the joint 8 in the first embodiment can be applied to the joint 8a.

[0058] In the snow melting radome 1a, the heater wire 5a, one wire harness connection terminal 71a, another wire harness connection terminal 72a, and the joint 8a are embedded between the first resin base material 3a and the second resin base material 4a.

[0059] When manufacturing the snow melting radome 1a of the second embodiment, the heater wire 5a is laid in a predetermined pattern on one surface of the electromagnetic wave-transmitting first resin base material 3a by electroless plating, printing, or the like, and a first redundant wiring portion 53a is locally formed in a portion of the heater wire 5a that is closer to the electromagnetic wave-transmitting region R than one connection portion 51a of the heater wire 5a, and a second redundant wiring portion 54a is locally formed in a portion of the heater wire 5a that is closer to the electromagnetic wave-transmitting region R than the other connection portion 52a of the heater wire 5a.

[0060] Furthermore, one connection portion 51a of the heater wire 5a is brought into contact with one wire harness connection terminal 71a and joined at a joint 8a for conductive connection, and one connection portion 51a of the heater wire 5a is fixed to one wire harness connection terminal 71a. Similarly, the other connection portion 52a of the heater wire 5a is brought into contact with another wire harness connection terminal 72a and joined at a joint 8a for conductive connection, and the other connection portion 52a of the heater wire 5a is fixed to another wire harness connection terminal 72a.

[0061] Thereafter, the second resin base material 4a is formed by a process such as injection molding or bonding similar to that for the second resin base material 4 in the first embodiment, and is fixed to the first resin base material 3a (see Figures 9 and 4), and the heater wire 5a, one wire harness connection terminal 71a, the other wire harness connection terminal 72a, and the joint 8a are embedded between the first resin base material 3a and the second resin base material 4a, thereby obtaining the snow melting radome 1a of the second embodiment.

[0062] According to the snow melting radome 1a of the second embodiment or the manufacturing method thereof, it is possible to obtain the corresponding effects from the configuration corresponding to the first embodiment.

[0063] [Snow-melting radome of the third embodiment] As shown in Figure 10, a snow-melting radome 1b of the third embodiment according to the present invention has an electromagnetic wave-transmitting base 2b formed by stacking a first resin base material 3b and a second resin base material 4b, and similarly to the first embodiment, heater wires 5b are buried between the first resin base material 3b and the second resin base material 4b. The heater wires 5b are wired in a predetermined pattern in the surface direction of the base 2b so as to exhibit a snow-melting function in the electromagnetic wave-transmitting region R.

[0064] The heater wire 5b is wired by fixing a heat generating sheet 501b, in which the main portion of the heater wire 5b is embedded or fixed in an electromagnetic wave transparent resin film 502b, to the surface of the first resin base material 3b facing the second resin base material 4b with a fixing layer 503b such as double-sided tape or an adhesive layer. At least the areas of one connection portion 51b and the other connection portion 52b of the heater wire 5b facing the second resin base material 4b are exposed from the resin film 502b. The first resin base material 3b, the second resin base material 4b, and the heater wire 5b can be the same as the first resin base material 3, the second resin base material 4, and the heater wire 5 in the first embodiment.

[0065] In the snow melting radome 1b, as in the first embodiment, a first redundant wiring portion 53b is locally provided in a portion of the heater wire 5b closer to the electromagnetic wave transmission region R than one connection portion 51b of the heater wire 5b, and a second redundant wiring portion 54b is locally provided in a portion of the heater wire 5b closer to the electromagnetic wave transmission region R than the other connection portion 52b of the heater wire 5b (see FIGS. 10 and 1). In the example of FIG. 10, the first redundant wiring portion 53b and the second redundant wiring portion 54b are embedded in a resin film 502b. The first redundant wiring portion 53b and the second redundant wiring portion 54b can have the same configuration as the first redundant wiring portion 53 and the second redundant wiring portion 54 in the first embodiment or their modifications, and it is also preferable to provide portions corresponding to the first end redundant wiring portion 55s and the second end redundant wiring portion 56s in the fourth modification.

[0066] One connection portion 51b of the heater wire 5b and one wire harness connection terminal 71b are fixed at a joint 8b, thereby electrically connecting the one connection portion 51b of the heater wire 5b and one wire harness connection terminal 71b. The other connection portion 52b of the heater wire 5b and another wire harness connection terminal 72b are also fixed at a joint 8b, thereby electrically connecting the other connection portion 52b of the heater wire 5b and another wire harness connection terminal 72b. The same configuration as the joint 8 in the first embodiment can be applied to the joint 8b.

[0067] In the snow melting radome 1b, the heater wire 5b, one wire harness connection terminal 71b, another wire harness connection terminal 72b, and the joint 8b are embedded between the first resin base material 3b and the second resin base material 4b.

[0068] When manufacturing the snow-melting radome 1b of the third embodiment, a heat-generating sheet 501b is used in which the first redundant wiring portion 53b and the second redundant wiring portion 54b are formed in advance and one connection portion 51b and the other connection portion 52b of the heater wire 5b are exposed, and the resin film 502b of the heat-generating sheet 501b is fixed to one surface of the electromagnetic wave-transparent first resin base material 3b with an adhesive layer 503b.

[0069] Furthermore, one connection portion 51b of the heater wire 5b is brought into contact with one wire harness connection terminal 71b and joined at a joint 8b for conductive connection, and one connection portion 51b of the heater wire 5b is fixed to one wire harness connection terminal 71b. Similarly, the other connection portion 52b of the heater wire 5b is brought into contact with another wire harness connection terminal 72b and joined at a joint 8b for conductive connection, and the other connection portion 52b of the heater wire 5b is fixed to another wire harness connection terminal 72b.

[0070] Thereafter, the second resin base material 4b is formed by a process such as injection molding or bonding similar to that for the second resin base material 4 in the first embodiment, and is fixed to the first resin base material 3b via a heat-generating sheet 501b or a resin film 502b (see Figures 10 and 4), and the heater wire 5b, one wire harness connection terminal 71b, the other wire harness connection terminal 72b, and the joint 8b are embedded between the first resin base material 3b and the second resin base material 4b, thereby obtaining the snow-melting radome 1b of the third embodiment.

[0071] According to the snow melting radome 1b of the third embodiment or the manufacturing method thereof, the corresponding effects can be obtained from the configuration corresponding to that of the first embodiment.

[0072] [Snow-melting radome of the fourth embodiment] As shown in Figure 11, a snow-melting radome 1c of the fourth embodiment according to the present invention has an electromagnetic wave-transmitting base 2c formed by stacking a first resin base material 3c and a second resin base material 4c, and similarly to the first embodiment, heater wires 5c are buried between the first resin base material 3c and the second resin base material 4c. The heater wires 5c are wired in a predetermined pattern in the surface direction of the base 2c so as to exhibit a snow-melting function in the electromagnetic wave-transmitting region R.

[0073] The heater wire 5c is wired by fixing an FPC heater 511c, on which the heater wire 5c is wired in a predetermined pattern, to the surface of the first resin base material 3c facing the second resin base material 4c with a fixing layer 514c such as double-sided tape or an adhesive layer. The FPC heater 511c is configured by wiring the heater wire 5c in a predetermined pattern on one surface of a flexible base material 512c such as a polyimide film, and sealing the main part of the heater wire 5c except for one connection portion 51c and the other connection portion 52c with a sealing portion 513c such as polyimide, with the one connection portion 51c and the other connection portion 52c exposed from the sealing portion 513c. The first resin base material 3c, second resin base material 4c, and heater wire 5c can be similar to the first resin base material 3, second resin base material 4, and heater wire 5 in the first embodiment.

[0074] In the snow melting radome 1c, as in the first embodiment, a first redundant wiring portion 53c is locally provided in a portion of the heater wire 5c closer to the electromagnetic wave transmission region R than one connection portion 51c of the heater wire 5c, and a second redundant wiring portion 54c is locally provided in a portion of the heater wire 5c closer to the electromagnetic wave transmission region R than the other connection portion 52c of the heater wire 5c (see FIGS. 11 and 1). In the example of FIG. 11, the first redundant wiring portion 53c and the second redundant wiring portion 54c are embedded and sealed in a sealing portion 513c. The first redundant wiring portion 53c and the second redundant wiring portion 54c can have the same configuration as the first redundant wiring portion 53 and the second redundant wiring portion 54 in the first embodiment or their modifications, and it is also preferable to provide portions corresponding to the first end redundant wiring portion 55s and the second end redundant wiring portion 56s in the fourth modification.

[0075] One connection portion 51c of the heater wire 5c and one wire harness connection terminal 71c are fixed at a joint 8c, thereby electrically connecting the one connection portion 51c of the heater wire 5c and one wire harness connection terminal 71c. The other connection portion 52c of the heater wire 5c and another wire harness connection terminal 72c are also fixed at a joint 8c, thereby electrically connecting the other connection portion 52c of the heater wire 5c and another wire harness connection terminal 72c. The same configuration as the joint 8 in the first embodiment can be applied to the joint 8c.

[0076] In the snow melting radome 1c, the heater wire 5c, one wire harness connection terminal 71c, another wire harness connection terminal 72c, and the joint 8c are embedded between the first resin base material 3c and the second resin base material 4c.

[0077] When manufacturing the snow-melting radome 1c of the fourth embodiment, an FPC heater 511c is used in which the first redundant wiring portion 53c and the second redundant wiring portion 54c are formed in advance and one connection portion 51c and the other connection portion 52c of the heater wire 5c are exposed, and the flexible base material 512c of the FPC heater 511c is fixed to one surface of the electromagnetic wave-transparent first resin base material 3c with a fixing layer 514c.

[0078] Furthermore, one connection portion 51c of the heater wire 5c is brought into contact with one wire harness connection terminal 71c and joined at a joint 8c for conductive connection, and one connection portion 51c of the heater wire 5c is fixed to one wire harness connection terminal 71c. Similarly, the other connection portion 52c of the heater wire 5c is brought into contact with another wire harness connection terminal 72c and joined at a joint 8c for conductive connection, and the other connection portion 52c of the heater wire 5c is fixed to another wire harness connection terminal 72c.

[0079] Thereafter, the second resin base material 4c is formed by a process such as injection molding or bonding similar to that for the second resin base material 4 in the first embodiment, and is fixed to the first resin base material 3c via an FPC heater 511c or a flexible base material 512c (see Figures 11 and 4), and the heater wire 5c, one wire harness connection terminal 71c, the other wire harness connection terminal 72c, and the joint 8c are embedded between the first resin base material 3c and the second resin base material 4c, thereby obtaining the snow melting radome 1c of the fourth embodiment.

[0080] According to the snow melting radome 1c of the fourth embodiment or the manufacturing method thereof, it is possible to obtain the corresponding effects from the configuration corresponding to the first embodiment.

[0081] [Scope of the invention disclosed herein] The invention disclosed herein includes, in addition to the individual inventions and embodiments listed as inventions, those specified by modifying partial contents of these with other contents disclosed in the present specification, those specified by adding other contents disclosed in the present specification to these contents, or those specified by deleting partial contents of these to the extent that partial effects are obtained and creating a generic concept. The invention disclosed herein also includes the following modifications and additions.

[0082] For example, in the first embodiment and its modified examples, the first recess 32, the second recess 33, etc., and the fitted first metal plate 61, the second metal plate 62, etc. are provided in the region of the tab 21 that is formed to protrude laterally when the radome is viewed from the front, and the connecting portions 51, 52, etc. of the heater wire 5 and the wire harness connecting terminals 71, 72 are electrically connected within the region of the first metal plate 61, the second metal plate 62, etc. when viewed from the front. However, for example, in the case of a radome that does not have the tab 21, this configuration can be provided in an appropriate region other than the region of the tab 21, outside the electromagnetic wave transmitting region R. Similarly, the locations where the connecting portions 51a, 52a, 51b, 52b, 51c, 52c, etc. of the heater wires 5a, 5b, 5c and the wire harness connecting terminals 71a, 72a, 71b, 72b, 71c, 72c are electrically connected can also be provided in an appropriate region other than the electromagnetic wave transmitting region R in the second to fourth embodiments. Furthermore, the first metal material and the second metal material in the present invention are not limited to the plate-shaped first metal plate and the plate-shaped second metal plate, but may be any appropriate metal material, and may be, for example, a metal part.

[0083] Furthermore, the redundancy aspects of the first redundant wiring portion, second redundant wiring portion, first tip redundant wiring portion, and second tip redundant wiring portion in the present invention can be aspects other than the above examples within the applicable range, and for example, the first redundant wiring portion, second redundant wiring portion, first tip redundant wiring portion, and second tip redundant wiring portion may be formed in an arc shape or an approximately L-shape, etc.

[0084] The snow melting radome of the present invention may also be suitably configured as a radome other than a radome for an on-vehicle radar device that is installed on the electromagnetic wave irradiation side of the on-vehicle radar device.

[0085] The present invention can be used in a snow-melting radome such as a radome for an on-vehicle radar device.

[0086] DESCRIPTION OF SYMBOLS 1, 1p, 1q, 1r, 1s, 1a, 1b, 1c... Snow melting radome 2, 2a, 2b, 2c... Base 21... Tab 3, 3a, 3b, 3c... First resin base material 31... Groove 32... First recess 33... Second recess 4, 4a, 4b, 4c... Second resin base material 41... Groove 5, 5a, 5b, 5c... Heater wire 51, 51a, 51b, 51c... One connection portion 52, 52a, 52b, 52c... Other connection portion 53, 53p, 53q, 53r, 53a, 53b, 53c... First redundant wiring portion 54, 54p, 54q, 54r, 54a, 54b, 54c... Second redundant wiring portion 55s... First tip redundant wiring portion 56s... Second tip redundant wiring portion 501b...heat generating sheet 502b...resin film 503b...fixing layer 511c...FPC heater 512c...flexible base material 513c...sealing portion 514c...fixing layer 61...first metal plate 611...mounting surface 62...second metal plate 621...mounting surface 71, 71a, 71b, 71c...one wire harness connection terminal 72, 72a, 72b, 72c...other wire harness connection terminal 8, 8a, 8b, 8c...joint portion 100...mold 101...inlet 102...outlet R...electromagnetic wave transmission area W1, W2, W3...variation width of meandering MR...molten resin

Claims

1. A snow-melting radome comprising: an electromagnetic wave-transmitting base body formed by stacking a first resin base material and a second resin base material; a heater wire wired in the surface direction of the base body is embedded between the first resin base material and the second resin base material; one connection part of the heater wire is electrically connected to one wire harness connection terminal; the other connection part of the heater wire is electrically connected to another wire harness connection terminal; a first redundant wiring part is locally provided in a part of the heater wire closer to the electromagnetic wave-transmitting region than the one connection part of the heater wire; and a second redundant wiring part is locally provided in a part of the heater wire closer to the electromagnetic wave-transmitting region than the other connection part of the heater wire.

2. The snow melting radome according to claim 1, characterized in that a first metal material and a second metal material are embedded between the first resin base material and the second resin base material in an area other than the electromagnetic wave transmitting area of the base so as to be isolated from each other, one connection portion of the heater wire and one wire harness connection terminal are placed on the mounting surface of the first metal material so as to be fixed to the first metal material, thereby electrically connecting the one connection portion of the heater wire and the one wire harness connection terminal, and the other connection portion of the heater wire and another wire harness connection terminal are placed on the mounting surface of the second metal material so as to be fixed to the second metal material so as to electrically connect the other connection portion of the heater wire and the other wire harness connection terminal.

3. A snow melting radome as claimed in claim 1 or 2, characterized in that the first redundant wiring section is formed in a serpentine shape, and the second redundant wiring section is also formed in a serpentine shape.

4. A snow melting radome as described in claim 3, characterized in that the meandering of each of the first redundant wiring section and the second redundant wiring section is repeated once or more and the fluctuation range of the meandering is five times or more the line width of the heater wire.

5. A snow melting radome as claimed in claim 1 or 2, characterized in that a first tip redundant wiring section connected to one of the connection sections of the heater wire is locally provided on the tip side of the one connection section, and a second tip redundant wiring section connected to the other connection section is locally provided on the tip side of the other connection section of the heater wire.

6. The snow melting radome according to claim 5, wherein the first tip redundant wiring portion is formed in a serpentine shape, and the second tip redundant wiring portion is also formed in a serpentine shape.

7. A first step of fitting and arranging a first metal material and a second metal material into a first recess and a second recess formed so as to be isolated from each other on one surface of an electromagnetic wave-transmitting first resin base material, respectively; a second step of wiring a heater wire in a predetermined pattern on one surface of the first resin base material, 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 a portion of the heater wire closer to the electromagnetic wave-transmitting region than the one connection portion of the heater wire, 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 a portion of the heater wire closer to the electromagnetic wave-transmitting region than the other connection portion of the heater wire; a third step of placing one wire harness connection terminal on an exposed mounting surface of the first metal material, and fixing one connection portion of the heater wire and the one wire harness connection terminal to the first metal material, thereby electrically connecting the one connection portion of the heater wire and the one wire harness connection terminal, and placing another wire harness connection terminal on an exposed mounting surface of the second metal material, and fixing the other connection portion of the heater wire and the other wire harness connection terminal to the second metal material, thereby electrically connecting the other connection portion of the heater wire and the other wire harness connection terminal; a fourth step of forming an electromagnetic wave transparent second resin base material by injection molding on the side of the mounting surface of the first metal material and the side of the mounting surface of the second metal material, fixing the second resin base material to the first resin base material, and burying the heater wire, the first metal material, the one wire harness connection terminal, the second metal material, and the other wire harness connection terminal between the first resin base material and the second resin base material.

8. A method for manufacturing a snow-melting radome as described in claim 8, characterized in that in the second step, a first tip redundant wiring portion connected to one connection portion of the heater wire is locally formed on the tip side of the one connection portion, and a second tip redundant wiring portion connected to the other connection portion of the heater wire is locally formed on the tip side of the other connection portion of the heater wire.

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