Conducting wire connection structure and method for manufacturing same

Abstract

This conducting wire connection structure includes a conducting wire having a contacting region that is fixed and wired to a resin base material 3, metal material 61, 62 fitted to and embedded in recessed portions 32, 33 formed in the resin base material 3, and wiring resin layers 71, 72 stacked on the metal material 61, 62 so as to cover a wiring region to which the conducting wire is wired, wherein: the conducting wire is wired by affixing the contacting region to the wiring resin layer 71, 72; electrically conductive bonding material 91, 92 is provided so as to come into contact with the metal material 61, 62; and a connecting portion of the conducting wire and a power supply connection terminal are connected together by the electrically conductive bonding material 91, 92. This prevents the occurrence of large localized residual tensile stress in parts of the conducting wire, thereby improving the weather resistance and durability of the conducting wire.

Description

Conductor connection structure and manufacturing method thereof

[0001] The present invention relates to a conductor connection structure for connecting a conductor wire laid on a resin base material to a power supply connection terminal, and a method for manufacturing the same.

[0002] A conventional structure for connecting a conductor wire laid on a resin base material to a power supply connection terminal is the connection structure disclosed in Patent Document 1. The connection structure of Patent Document 1 includes a first metal plate and a second metal plate fitted into a first recess and a second recess formed separately in the resin base material, respectively, a heater wire is laid along a groove formed in the resin base material so that a portion of the heater wire protrudes from the groove, one end of the heater wire placed on the first metal plate is connected to one wire harness connection terminal with a conductive bonding material such as solder or brazing material, and the other end of the heater wire placed on the second metal plate is connected to another wire harness connection terminal with a conductive bonding material.

[0003] Patent No. 7158818

[0004] Incidentally, in the connection structure of Patent Document 1, when the heater wire is laid out using, for example, welding that melts the resin base material using ultrasonic vibrations, so that the contact area of ​​the heater wire is fixed to the resin base material while melting the resin base material, it is not possible to fix the contact area of ​​the heater wire to the metal plate. Therefore, it is necessary to lay out the heater wire in a state where it is floating above the resin base material and the metal plate from a position in front of the metal plate, and to connect the end of the heater wire floating above the metal plate to a wire harness connection terminal with a conductive bonding material to construct the connection structure.

[0005] However, when the contact area is fixed up to a position in front of the metal plate and the heater wire floating above the position in front of the metal plate is connected with a conductive bonding material such as solder or brazing material, a large tensile residual stress is locally generated in the portion of the heater wire between the fixed end of the heater wire at the fixed contact area and the conductive bonding material. As a result, the portion of the heater wire where this large tensile residual stress is generated is prone to breakage, resulting in a problem of reduced weather resistance and durability of the heater wire. The same problem also occurs when a conductor other than the heater wire is laid on a resin substrate with its contact area fixed, a metal material is fitted into a recess formed in the resin substrate, and the connection portion of the conductor floating above the position in front of the metal material is connected to a power supply connection terminal with a conductive bonding material.

[0006] The present invention has been proposed in consideration of the above-mentioned problems, and aims to provide a conductor connection structure and a manufacturing method thereof that can prevent the occurrence of large localized tensile residual stress in part of the conductor and improve the weather resistance and durability of the conductor in a structure in which the connection portion of a conductor whose contact area is fixed to a resin base material is connected to a power supply connection terminal via a metal material and a conductive bonding material.

[0007] The conductor connection structure of the present invention includes a resin base material, a conductor wire having a contact area fixed to the resin base material and wired therein, a metal material fitted into a recess formed in the resin base material and embedded therein, and a wiring resin layer laminated on the metal material so as to cover the wiring area where the conductor wire is wired. The conductor wire is wired by having the contact area fixed to the wiring resin layer, and a conductive adhesive material is provided in contact with the metal material, and the connection portion of the conductor wire and the power supply connection terminal are connected by the conductive adhesive. This structure prevents the conductor wire from being wired in a floating state above the metal material by providing the conductive adhesive material so as to penetrate the wiring resin layer and contact the metal material, and connecting the connection portion of the conductor wire that is not floating to the power supply connection terminal with the conductive adhesive, thereby preventing large localized tensile residual stress from occurring in a portion of the conductor wire. Therefore, in a structure in which the connection portion of a conductor having a contact area fixed to a resin base material is connected to a power supply connection terminal via a metal material and a conductive adhesive, the weather resistance and durability of the conductor can be improved. Also, the metal material suppresses the heat generated when connecting the connection portion of the conductor to the power supply connection terminal with the conductive adhesive, thereby preventing the resin base material from being melted and damaged.

[0008] The method for manufacturing a conductor connection structure of the present invention is characterized by comprising the steps of: a first step of forming an intermediate product in which a metal material is fitted and embedded in a recess formed in a resin base material; a second step of laminating a wiring resin layer on the metal material so as to cover a wiring area where the conductor wire is to be routed; a third step of routing the conductor wire by fixing a contact area to the resin base material and also to the wiring resin layer; a fourth step of arranging a power supply connection terminal adjacent to a connection portion of the conductor wire whose contact area is fixed to the wiring resin layer; and a fifth step of providing a conductive adhesive material in contact with the metal material and connecting the connection portion of the conductor wire to the power supply connection terminal with the conductive adhesive. This method allows the conductor wire to be routed by fixing the contact area to the wiring resin layer laminated on the metal material, thereby preventing the conductor wire from being routed in a floating state above the metal material. Furthermore, by providing a conductive adhesive material so as to penetrate the wiring resin layer and contact the metal material, and connecting the connection portion of the conductor that is not floating to the power supply connection terminal with the conductive adhesive material, it is possible to prevent the generation of large localized tensile residual stress in a portion of the conductor. Therefore, in a structure in which the connection portion of the conductor, the contact area of ​​which is fixed to the resin substrate, and the power supply connection terminal are connected via the metal material and the conductive adhesive, it is possible to improve the weather resistance and durability of the conductor. Furthermore, the metal material suppresses the thermal conduction of heat generated when connecting the connection portion of the conductor to the power supply connection terminal with the conductive adhesive, thereby preventing the resin substrate from being melted and damaged. Furthermore, when wiring the conductor using welding that melts the resin substrate with ultrasonic vibrations, for example, the conductor can be efficiently partially fixed to the resin substrate and the wiring resin layer.

[0009] The method for manufacturing a conductor connection structure of the present invention is characterized in that, in the first step, the metal material, which is thinner than the depth of the recess, is fitted so that the exposed surface of the metal material is positioned deeper than the surface of the resin base material where the recess is formed, and in the second step, the wiring resin layer is provided in an area surrounded by the peripheral wall of the recess and the exposed surface of the metal material so as to cover the entire exposed surface of the metal material. This allows the wiring resin layer to be reliably formed to cover the wiring area where the conductor wires are to be routed, and also allows the wiring resin layer to be easily formed to be laminated on the metal material so as to cover the wiring area where the conductor wires are to be routed, thereby improving manufacturing efficiency.

[0010] In the method for manufacturing a conductor connection structure according to the present invention, in the second step, the wiring resin layer is provided so as to be substantially flush with the surface of the resin base material where the recess is formed. By providing the wiring resin layer so as to be substantially flush with the surface of the resin base material where the recess is formed, wiring of the conductor in the wiring resin layer can be more reliably performed continuously from the wiring of the conductor in the resin base material.

[0011] The method for manufacturing a conductor connection structure of the present invention is characterized in that, in the fourth step, the wiring resin layer is removed while leaving a portion covering the wiring area where the conductor is to be routed, and then the power supply connection terminal is disposed adjacent to the connection portion of the conductor whose contact area is fixed to the remaining wiring resin layer. By removing the wiring resin layer while leaving only the necessary portion, the connection between the connection portion of the conductor and the power supply connection terminal is prevented from being obstructed by the wiring resin layer other than the necessary portion, and the connection portion of the conductor and the power supply connection terminal can be more reliably connected with the conductive adhesive.

[0012] a first metal material fitted and embedded in a first recess formed in the resin material in an area other than the electromagnetic wave transmitting area; a second metal material fitted and embedded in a second recess formed in the resin material in an area other than the electromagnetic wave transmitting area so as to be isolated from the first recess; a first wiring resin layer laminated on the first metal material so as to cover the wiring area where the heater wire is laid, and a second wiring resin layer laminated on the second metal material, wherein the heater wire is laid by having contact areas fixed to the first wiring resin layer and the second wiring resin layer, a first conductive adhesive material is provided in contact with the first metal material, one connection portion of the heater wire and a first power supply connection terminal are connected by the first conductive adhesive material, and a second conductive adhesive material is provided in contact with the second metal material, and the other connection portion of the heater wire and a second power supply connection terminal are connected by the second conductive adhesive material. According to this, the heater wire is laid by fixing the contact area to the wiring resin layer laminated on the metal material, preventing the heater wire from being laid in a floating state above the metal material. Furthermore, by providing a conductive adhesive material so as to penetrate the wiring resin layer or the like and contact the metal material, and connecting the non-floating heater wire connection portion and the power supply connection terminal with the conductive adhesive material, it is possible to prevent the occurrence of large localized tensile residual stress in a part of the heater wire. Therefore, in a structure in which the heater wire connection portion, whose contact area is fixed to the resin base material, and the power supply connection terminal are connected via the metal material and the conductive adhesive material, the weather resistance and durability of the heater wire can be improved. Furthermore, the metal material suppresses thermal conduction of heat generated when connecting the heater wire connection portion and the power supply connection terminal with the conductive adhesive material to the resin base material, preventing the resin base material from being melted and damaged.

[0013] The snow melting radome of the present invention is characterized in that the first wiring resin layer and the second wiring resin layer are embedded between the resin base material and another resin base material laminated on the resin base material. According to this, by embedding the first wiring resin layer and the second wiring resin layer between the resin base material and the other resin base material without removing them, the manufacturing efficiency of the snow melting radome can be improved.

[0014] The method for manufacturing the snow melting radome of the present invention is a method for manufacturing the snow melting radome of the present invention, and includes a first step of forming an intermediate product in which a first metal material and a second metal material are fitted and embedded in a first recess and a second recess formed isolated in a resin base material in an area other than an electromagnetic wave transmitting area; a second step of laminating a first wiring resin layer on the first metal material and a second wiring resin layer on the second metal material so as to cover a wiring area in which a heater wire is to be wired; a third step of wiring the heater wire by fixing a contact area to the resin base material and fixing a contact area to the first wiring resin layer and the second wiring resin layer; and a fifth step of providing a first conductive bonding material in contact with the first metal material, connecting one connection portion of the heater wire to the first power supply connection terminal with the first conductive bonding material and providing a second conductive bonding material in contact with the second metal material, and connecting the other connection portion of the heater wire to the second power supply connection terminal with the second conductive bonding material. This allows the heater wire to be efficiently partially bonded to the resin substrate and the wiring resin layer, for example, when wiring the heater wire by welding, which melts the resin substrate with ultrasonic vibrations.

[0015] According to the present invention, in a structure in which the connection portion of a conductor having a contact area fixed to a resin base material is connected to a power supply connection terminal via a metal material and a conductive bonding material, it is possible to prevent the occurrence of large localized tensile residual stress in part of the conductor, thereby improving the weather resistance and durability of the conductor.

[0016] 1 is a front view of a snow melting radome equipped with a conductor connection structure of a first embodiment according to the present invention. (a) is an enlarged front view of the peripheral portion of the conductor connection structure of FIG. 1, and (b) is an enlarged rear view of the peripheral portion of FIG. 1(a). A longitudinal sectional view of a snow melting radome equipped with the conductor connection structure of the first embodiment. (a) to (c) are process explanatory diagrams explaining the first half of the manufacturing process of the conductor connection structure of the first embodiment. (a) to (c) are process explanatory diagrams explaining the second half of the manufacturing process of the conductor connection structure of the first embodiment. An explanatory diagram showing the state in which the first resin base material, metal material, heater wire, and wire harness connection terminal are arranged inside a mold in a snow melting radome equipped with the conductor connection structure of the first embodiment. A front view of a snow melting radome equipped with a conductor connection structure of a second embodiment according to the present invention. (a) is an enlarged front view of the peripheral portion of the conductor connection structure of FIG. 7, and (b) is an enlarged rear view of the peripheral portion of FIG. 1(a). (a) to (d) are process explanatory diagrams explaining the second half of the manufacturing process of the conductor connection structure of the second embodiment.

[0017] [Wire Connection Structure of First Embodiment] The wire connection structure of the first embodiment according to the present invention is installed in a snow melting radome 1, such as a bumper cover attached to a vehicle bumper. As shown in Figures 1 to 3, the snow melting radome 1 includes an electromagnetic wave-transmitting base 2. The base 2 is made up of, for example, a resin base material 3 arranged on the side opposite to the viewing side and another resin base material 4 arranged on the viewing side, i.e., in front of the resin base material 3, and the resin base material 3 and the other resin base material 4 are laminated and fixed together. If necessary, the other resin base material 4 may be arranged on the side opposite to the viewing side, and the resin base material 3 may be arranged on the viewing side. The resin base material 3 and the other resin base material 4 are each made of an insulating, electromagnetic wave-transmitting synthetic resin.

[0018] The resin substrate 3 and the other resin substrate 4 are each formed of an insulating, electromagnetic wave-transmitting synthetic resin, and can be formed into any suitable shape within an applicable range, such as a flat plate or a curved plate. The resin substrate 3 and the other resin substrate 4 can be made of different or the same synthetic resin, and it is preferable from the perspective of improving electromagnetic wave transmission performance to form the resin substrate 3 and the other resin substrate 4 from materials whose refractive indexes n, defined based on the complex dielectric constant, match each other, or whose refractive indexes n are approximately the same or close to each other. The numerical range of the refractive indexes of the resin substrate 3 and the other resin substrate 4 that are close to each other is preferably a difference of 0 to 10%.

[0019] 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.

[0020]

[0021]

[0022] Any suitable synthetic resin can be used within the spirit and scope of the present invention for the synthetic resin of the resin substrate 3 and the synthetic resin of the other 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 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 substrate resin 3, the thickness of the other resin substrate 4, and the total thickness of the base 2 composed of the resin substrate 3 and the other resin substrate 4 are appropriate within a range that can ensure the required electromagnetic wave transmission properties for the snow-melting radome 1.

[0023] In the snow-melting radome 1, heater wires 5, which correspond to the conductors of this embodiment, are wired in the surface direction of the electromagnetic wave-transmitting substrate 2. Any appropriate conductive material can be used for the heater wire 3 within the spirit and scope of the present invention, and preferable 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 5 may be in any form before wiring, as long as it can be wired in a linear manner with its contact area fixed to the resin substrate 3, and may be made of, for example, wire material, conductive ink, conductive filler, etc.

[0024] 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 a radar device such as an on-vehicle 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.

[0025] The heater wire 5 is laid out with its contact region fixed to the resin base material 3, and is also laid out with its contact region fixed to another resin base material 4, and is buried between the resin base material 3 and another resin base material 4. The heater wire 5 is sandwiched between the resin base material 3 and another resin base material 4, and is provided and sealed within the base 2 formed by the resin base material 3 and another resin base material 4.

[0026] In the illustrated example, a groove 31 is formed on the surface of the resin substrate 3 that is fixed to the other resin substrate 4, and another groove 41 is formed on the surface of the other resin substrate 4 that is fixed to the resin substrate 3 so as to face the groove 31. The heater wire 5 is laid by being partially embedded and fixed in the resin substrate 3 at the groove 31, and is laid by being partially embedded and fixed in the other resin substrate 4 at the groove 41. 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 routed along the groove 31 and the groove 41 (see FIG. 2 ). It is also possible to adopt a configuration in which the heater wire 5 is laid by fixing a contact region to the resin substrate 3 without forming either or both of the groove 31 of the resin substrate 3 and the other groove 41 of the other resin substrate 4.

[0027] In a region other than the electromagnetic wave transmission region R of the base 2, which in this embodiment is the region of the tab 21 that is formed to protrude laterally, a first recess 32 and a second recess 33 that correspond to recesses are formed and isolated from each other on the fixing surface side of the resin substrate 3. A first metal material 61 and a second metal material 62 that are conductive and equivalent to metal materials and are plate-shaped and fitted into the first recess 32 and the second recess 33, respectively, and the first metal material 61 and the second metal material 62 are provided in a mutually insulated state.

[0028] In this embodiment, the depth of the first recess 32 and the depth of the second recess 33 are formed deeper than the thickness of the plate-shaped first metal material 61 and second metal material 62 to be embedded, respectively. The first metal material 61, which is thinner than the depth of the first recess 32, is fitted so that the exposed surface 611 of the first metal material 61 is positioned deeper than the formation surface of the first recess 32 and the second recess 33 of the resin base material 3, and the second metal material 62, which is thinner than the depth of the second recess 33, is fitted so that the exposed surface 621 of the second metal material 62 is positioned deeper than the formation surface of the first recess 32 and the second recess 33 of the resin base material 3 (see Figures 3 and 4).

[0029] A first wiring resin layer 71 corresponding to the wiring resin layer is laminated on the first metal material 61 so as to cover the wiring area where the heater wire 5 is laid, and a first wiring resin layer 72 corresponding to the wiring resin layer is laminated on the second metal material 62 so as to cover the wiring area where the heater wire 5 is laid (see FIGS. 1 to 5). Any appropriate resin material may be used for the first wiring resin layer 71 and the second wiring resin layer 72 within the scope of the present invention, and for example, the same resin material as that of the resin base material 3 may be used.

[0030] In this embodiment, a first wiring resin layer 71 is provided in an area surrounded by the peripheral wall of the first recess 32 and the exposed surface 611 of the first metal material 61 so as to cover the entire exposed surface 611 of the first metal material 611, and a second wiring resin layer 72 is provided in an area surrounded by the peripheral wall of the second recess 33 and the exposed surface 621 of the second metal material 62 so as to cover the entire exposed surface 621 of the second metal material 62. Furthermore, in this embodiment, the first wiring resin layer 71 and the second wiring resin layer 72 are provided so as to be substantially flush with the surfaces of the resin base material 3 where the first recess 32 and the second recess 32 are formed.

[0031] The heater wire 5 is laid out with its contact region fixed to the first wiring resin layer 71 and the second wiring resin layer 72, and one connection portion 51 of the heater wire 5 and its periphery are laid out with their contact region embedded and fixed in the first wiring resin layer 71, and the other connection portion 52 of the heater wire 5 and its periphery are laid out with their contact region embedded and fixed in the second wiring resin layer 72 (see FIGS. 3 and 5). That is, the heater wire 5 corresponding to a conductor is laid out with its contact region fixed to the resin base material 3 and either the first wiring resin layer 71 or the second wiring resin layer 72 over its entire length.

[0032] A first wire harness connection terminal 81 corresponding to the first power supply connection terminal of the first power supply wire extending outside the resin base material 3 is arranged on the first metal material 61 and the first wiring resin layer 71, and a first conductive adhesive material 91 is provided so as to penetrate the first wiring resin layer 71 and contact the first metal material 61, and one connection portion 51 of the heater wire 5 and the first wire harness connection terminal 81 are connected and electrically conductive by the first conductive adhesive material 91. Furthermore, a second wire harness connection terminal 82 corresponding to the second power supply connection terminal of the second power supply line extending outside the resin base material 3 is disposed in correspondence with the second metal material 62 and the second wiring resin layer 72, and a second conductive adhesive 92 is provided so as to penetrate the second wiring resin layer 72 and come into contact with the second metal material 62, and the other connection portion 52 of the heater wire 5 and the second wire harness connection terminal 82 are connected and electrically conductive by the second conductive adhesive 92 (see FIGS. 3 and 5 ).

[0033] One connection portion 51 of the heater wire 5 and the first wire harness connection terminal 81 are joined to be integrated with the first conductive bonding material 91 and the first metal material 61, and the other connection portion 52 of the heater wire 5 and the second wire harness connection terminal 82 are joined to be integrated with the second conductive bonding material 92 and the second metal material 62. Any appropriate conductive bonding material can be used for the first conductive bonding material 91 and the second conductive bonding material 92 within the scope of the present invention, and it is preferable to use, for example, solder, brazing material, or the like, which has excellent electrical conductivity and thermal conductivity.

[0034] One connection portion 51 of the heater wire 5, the first wire harness connection terminal 81, the first conductive bonding material 91, the first metal material 61 and the first wiring resin layer 71, and the other connection portion 52 of the heater wire 5, the second wire harness connection terminal 82, the second conductive bonding material 92, the second metal material 62 and the second wiring resin layer 72 are embedded between the resin base material 3 and another resin base material 4 laminated on the resin base material 3 to form the snow-melting radome 1.

[0035] When manufacturing the snow melting radome 1 equipped with the conductor connection structure of the first embodiment, an intermediate product is formed in which a first metal material 61 and a second metal material 62 are fitted and embedded in a first recess 32 and a second recess 33 formed in isolation in the resin substrate 3 in an area other than the electromagnetic wave transmitting area R. In forming this intermediate product, for example, the first recess 32 and the second recess 33 that do not penetrate through are formed in isolation on one side of the resin substrate 3 in an area other than the electromagnetic wave transmitting area R (see FIG. 4( a)). The first recess 32 and the second recess 33 may be formed by convex portions of corresponding shapes in a mold when the resin substrate 3 is formed by injection molding, or may be formed on one side of the resin substrate 3 by cutting work or the like.

[0036] Furthermore, a first metal material 61 and a second metal material 62 are fitted and embedded into the first recess 32 and the second recess 33 formed separately in the resin substrate 3, respectively (see FIG. 4B ). At this time, the first metal material 61, which is thinner than the depth of the first recess 32, is fitted so that an exposed surface 611 of the first metal material 61 is positioned deeper than the surface of the resin substrate 3 where the first recess 32 is formed, and the second metal material 62, which is thinner than the depth of the second recess 33, is fitted so that an exposed surface 621 of the second metal material 62 is positioned deeper than the surface of the resin substrate 3 where the second recess 33 is formed.

[0037] 4( c), a first wiring resin layer 71 is laminated on the first metal material 61 so as to cover the wiring area where the heater wire 5 is laid, and a second wiring resin layer 72 is laminated on the second metal material 62. In the illustrated example, the first wiring resin layer 71 is provided in the area surrounded by the peripheral wall of the first recess 32 and the exposed surface 611 of the first metal material 61 so as to cover the entire exposed surface 611 of the first metal material 611, and the second wiring resin layer 72 is provided in the area surrounded by the peripheral wall of the second recess 33 and the exposed surface 621 of the second metal material 62 so as to cover the entire exposed surface 621 of the second metal material 62. Furthermore, the first wiring resin layer 71 and the second wiring resin layer 72 are provided so as to be substantially flush with the surfaces of the resin base material 3 where the first recess 32 and the second recess 32 are formed.

[0038] Thereafter, using a wiring machine or the like that performs welding using ultrasonic vibrations, the heater wires 5 corresponding to the conductors are laid out in a predetermined pattern such as a serpentine pattern with their contact areas fixed to the resin base material 3, and also laid out with their contact areas fixed to the first wiring resin layer 71 and the second wiring resin layer 72 (see FIG. 5( a)). One connection portion 51 of the heater wire 5 and its periphery are laid out in the first wiring resin layer 71 so that the contact area is fixed thereto, and the other connection portion 52 of the heater wire 5 and its periphery are laid out in the second wiring resin layer 72 so that the contact area is fixed thereto.

[0039] Thereafter, a first wire harness connection terminal 81 corresponding to the first power supply connection terminal of the first power supply wire extending outside the resin base material 3 is arranged adjacent to one connection portion 51 of the heater wire 5 whose contact region is fixed to the first wiring resin layer 71, and a second wire harness connection terminal 82 corresponding to the second power supply connection terminal of the second power supply wire extending outside the resin base material 3 is arranged adjacent to the other connection portion 52 of the heater wire 5 whose contact region is fixed to the second wiring resin layer 72 (see FIG. 5(b)).

[0040] A first conductive adhesive 91 is provided so as to penetrate the first wiring resin layer 71 and come into contact with the first metal material 61, and one connection portion 51 of the heater wire 5 and the first wire harness connection terminal 81 are connected and electrically connected by the first conductive adhesive 91, and a second conductive adhesive 92 is provided so as to penetrate the second wiring resin layer 72 and come into contact with the second metal material 62, and the other connection portion 52 of the heater wire 5 and the second wire harness connection terminal 82 are connected and electrically connected by the second conductive adhesive 92 (see FIG. 5( c )).

[0041] 6 , the resin base material 3 to which the heater wire 5, the first metal material 61 and the second metal material 62, the first wiring resin layer 71 and the second wiring resin layer 72, and the first wire harness connection terminal 81 and the second wire harness connection terminal 82 are attached is placed inside a mold 100 configured as a split mold. At this time, the wire harness connection portion 8 from which the first wire harness connection terminal 81 and the second wire harness connection terminal 82 are drawn is led out of the mold 100 through a lead-out port 102 formed in a part of the mold 100.

[0042] 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 resin substrate 4 is injection molded onto the wiring side of the heater wire 5 of the resin substrate 3 to form another resin substrate 4, which is then fixed to the resin substrate 3. The interface of the another resin substrate 4 laminated by injection molding is molded and welded to the resin substrate 3, heater wire 5, first wire harness connection terminal 81, first conductive bonding material 91, first wiring resin layer 71, second wire harness connection terminal 82, second conductive bonding material 92, and second wiring resin layer 72, and these are embedded between the resin substrate 3 and the another resin substrate 4.

[0043] Furthermore, since the other 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 other resin base material 4 by insert molding, and the contact region of the heater wire 5 is fixed and fitted into the other groove 41 of the other resin base material 4. Note that the other resin base material 4 is not limited to a configuration formed by injection molding, and may also be fixed to the resin base material 3 by adhesion or the like as necessary. After the other resin base material 4 is formed, the mold 100 is demolded to obtain the snow melting radome 1 that is equipped with the conductor connection structure of the first embodiment.

[0044] According to the first embodiment, the heater wire 5 is laid out by fixing the contact areas to the wiring resin layers 71, 72 laminated on the metal materials 61, 62, thereby preventing the heater wire from being laid out in a floating state above the metal materials 61, 62. Then, conductive bonding materials 91, 92 are provided so as to penetrate the wiring resin layers 71, 72 and contact the metal materials 61, 62, and the connection parts 51, 52 of the heater wire 5 that are not floating are connected to the power supply connection terminals by the conductive bonding materials 91, 92, thereby preventing the generation of large localized tensile residual stress in parts of the heater wire 5. Therefore, in a structure in which the connection parts 51, 52 of the heater wire 5, the contact areas of which are fixed to the resin base material 3, are connected to the power supply connection terminals by the conductive bonding materials 91, 92, the weather resistance and durability of the heater wire 5 can be improved. In addition, the metal materials 61, 62 suppress the heat generated when connecting the connection parts 51, 52 of the heater wire 5 to the power supply connection terminals with the conductive bonding materials 91, 92 from being thermally conducted to the resin base material 3, thereby preventing the resin base material 3 from being melted and damaged.

[0045] Furthermore, by embedding the first wiring resin layer 71 and the second wiring resin layer 72 between the resin base material 3 and another resin base material 4 without removing them, it is possible to improve the manufacturing efficiency of the snow melting radome 1. Furthermore, when wiring the heater wire 5 using welding that melts the resin base material with ultrasonic vibrations, for example, the heater wire 5 can be efficiently partially fixed to the resin base material 3 and the wiring resin layers 71, 72.

[0046] Furthermore, the metal materials 61, 62 having a thickness thinner than the depth of the recesses 32, 33 are fitted together so that the exposed surfaces 611, 621 of the metal materials 61, 62 are positioned deeper than the surfaces of the resin base material 3 where the recesses 32, 33 are formed, a first wiring resin layer 71 is provided in the area surrounded by the peripheral wall of the first recess 32 and the exposed surface 611 of the first metal material 61 so as to cover the entire exposed surface 611 of the first metal material 611, and a second wiring resin layer 72 is provided in the area surrounded by the peripheral wall of the second recess 33 and the exposed surface 621 of the second metal material 62 so as to cover the entire exposed surface 621 of the second metal material 62. This makes it possible to reliably form the wiring resin layers 71, 72 to cover the wiring area where the heater wire 5 is laid, and to easily form the wiring resin layers 71, 72 laminated on the metal materials 61, 62 so as to cover the wiring area where the heater wire 5 is laid, thereby improving manufacturing efficiency.

[0047] Furthermore, by providing the first wiring resin layer 71 and the second wiring resin layer 72 so that they are approximately flush with the forming surface of the first recess 32 and the second recess 32 of the resin base material 3, the wiring of the heater wire 5 in the wiring resin layers 71, 72 can be more reliably carried out in continuity with the wiring of the heater wire 5 in the resin base material 3.

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[0049] In the first recess 32 and the second recess 33, a first conductive bonding material 91 is provided so as to penetrate the remaining first wiring resin layer 71 or to wrap around the remaining first wiring resin layer 71 and to come into contact with the first metal material 61, so that one connection portion 51 of the heater wire 5 and the first wire harness connection terminal 81 are connected and electrically connected by the first conductive bonding material 91, and a second conductive bonding material 92 is provided so as to penetrate the remaining second wiring resin layer 72 or to wrap around the remaining second wiring resin layer 72 and to come into contact with the second metal material 62, so that the other connection portion 52 of the heater wire 5 and the first wire harness connection terminal 82 are connected and electrically connected by the second conductive bonding material 91. The other configurations of the wire connection structure or snow melting radome 1a of the second embodiment are the same as those of the wire connection structure or snow melting radome 1 of the first embodiment.

[0050] When manufacturing the snow melting radome 1a having the conductor connection structure of the second embodiment, the same manufacturing steps as those for the snow melting radome 1 having the conductor connection structure of the first embodiment are carried out, and the heater wire 5 is laid out so that the contact areas are fixed to the resin base material 3, the first wiring resin layer 71a, and the second wiring resin layer 72a (see FIGS. 4 and 9(a)). Then, the first wiring resin layer 71a and the second wiring resin layer 72a are removed from the first metal material 61 and the second metal material 62, leaving portions that cover the wiring area where the heater wire 5 corresponding to the conductor is laid out (see FIG. 9(b)).

[0051] Thereafter, a first wire harness connection terminal 81 corresponding to the first power supply connection terminal of the first power supply wire extending outside the resin base material 3 is arranged adjacent to one connection portion 51 of the heater wire 5 whose contact region is fixed to the remaining first wiring resin layer 71, and a second wire harness connection terminal 82 corresponding to the second power supply connection terminal of the second power supply wire extending outside the resin base material 3 is arranged adjacent to the other connection portion 52 of the heater wire 5 whose contact region is fixed to the remaining second wiring resin layer 72 (see FIG. 9(c)).

[0052] Then, a first conductive bonding material 91 is provided so as to penetrate or wrap around the remaining first wiring resin layer 71a and to come into contact with the first metal material 61, and one connection portion 51 of the heater wire 5 and the first wire harness connection terminal 81 are connected and electrically connected by the first conductive bonding material 91, and a second conductive bonding material 92 is provided so as to penetrate or wrap around the remaining second wiring resin layer 72a and to come into contact with the second metal material 62, and the other connection portion 52 of the heater wire 5 and the second wire harness connection terminal 82 are connected and electrically connected by the second conductive bonding material 92 (see FIG. 9(d)). Thereafter, another resin base material 4 is formed using the same manufacturing steps as in the first embodiment, to obtain the snow melting radome 1a.

[0053] According to the second embodiment, it is possible to obtain corresponding effects from the configuration corresponding to that of the first embodiment. Furthermore, by removing the wiring resin layers 71 a, 72 a while leaving the necessary portions of the wiring resin layers 71 a, 72 a, it is possible to prevent the connection between the connection portions 51, 52 of the heater wire 5 and the power supply connection terminals from being obstructed by the wiring resin layers 71 a, 72 a other than the necessary portions, and it is possible to more reliably connect the connection portions 51, 52 of the heater wire 5 and the power supply connection terminals with the conductive bonding materials 91, 92.

[0054] [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.

[0055] For example, in the above first and second embodiments, examples have been illustrated and described in which the connection portions 51, 52 of the heater wire 5 corresponding to the conductor wire and the wire harness connection terminals 81, 82 corresponding to the power supply connection terminals are arranged in a straight line, but to ensure electrical connectivity more reliably, the connection portions 51, 52 of the heater wire 5 may be arranged so as to intersect at an angle with the wire harness connection terminals 81, 82. Furthermore, the power supply connection terminal in the present invention includes any appropriate connection terminal that supplies power to the conductor wire, and includes, in addition to the wire harness connection terminals of the wire harness in the above examples, connection terminals of connectors, for example.

[0056] Furthermore, the method of installing the first wiring resin layers 71, 71a and the second wiring resin layers 72, 72a may be appropriate within the scope of the spirit of the present invention. For example, the first wiring resin layers 71, 71a and the second wiring resin layers 72, 72a may be configured by installing resin films in the first recesses 32 and the second recesses 33, or by applying resin material to the first metal material 61 and the second metal material 62 fitted in the first recesses 32 and the second recesses 33 and drying the resin material to form the first wiring resin layers 71, 71a and the second wiring resin layers 72, 72a.

[0057] In addition, the wire connection structure or snow-melting radome of the present invention includes cases where the surface of the resin substrate where the recess is formed and the resin layer for wiring are approximately flush with each other, as well as cases where the surface of the resin layer for wiring on the wire fixing side is positioned higher than the surface of the resin substrate where the recess is formed, or where the surface of the resin layer for wiring on the wire fixing side is positioned lower than the surface of the resin substrate where the recess is formed.

[0058] The conductor connection structure of the present invention also includes a structure for connecting conductors other than the heater wire of a snow-melting radome, such as a structure for connecting heater wires other than those of a snow-melting radome, and a conductor connection structure for a resin molded product in which conductors are wired, such as an MID (Molded Interconnect Device).

[0059] Furthermore, the wiring resin layer in the present invention may be any suitable layer laminated on the metal material so as to cover the wiring area where the conductor wires are laid out. For example, it is preferable to have a configuration in which it is laminated on the metal material in an area that coincides with the wiring area where the conductor wires are laid out, or a configuration in which it is laminated on the metal material in an area that includes the wiring area where the conductor wires are laid out and is slightly wider than the wiring area, or a configuration in which it includes the wiring area where the conductor wires are laid out and is laminated over the entire metal material.

[0060] Furthermore, when manufacturing the snow-melting radomes 1, 1a in the above embodiment, the process of forming an intermediate product in which the first metal material 61 and the second metal material 62 are fitted and embedded into the first recess 32 and the second recess 33 that are formed in isolation in the resin substrate 3 in an area other than the electromagnetic wave transmission area R is not limited to the above example, and may be, for example, a process of injection molding the resin substrate 3 so that the first metal material 61 and the second metal material 62 are fitted and embedded into the first recess 32 and the second recess 33 that are formed in isolation.

[0061] The present invention can be used in a connection structure for conductors such as heater wires for snow-melting radomes.

[0062] REFERENCE SIGNS LIST 1, 1a...snow-melting radome 2...base 21...tab 3...resin substrate 31...groove 32...first recess 33...second recess 4...another resin substrate 41...groove 5...heater wire 51...one connection portion 52...other connection portion 61...first metal material 611...exposed surface 62...second metal material 621...exposed surface 71, 71a...first wiring resin layer 72, 72a...second wiring resin layer 8...wire harness connection portion 81...first wire harness connection terminal 82...second wire harness connection terminal 91...first conductive bonding material 92...second conductive bonding material 100...mold 101...injection port 102...outlet R...electromagnetic wave irradiation area MR...molten resin

Claims

1. A conductor connection structure comprising: a resin base material; a conductor wire whose contact area is fixed to the resin base material and wired; a metal material fitted into and embedded in a recess formed in the resin base material; and a wiring resin layer laminated on the metal material so as to cover the wiring area where the conductor wire is wired, wherein the conductor wire is wired with its contact area fixed to the wiring resin layer, and a conductive adhesive material is provided so as to be in contact with the metal material, and the connection portion of the conductor wire and a power supply connection terminal are connected by the conductive adhesive material.

2. A method for manufacturing a conductor connection structure, comprising: a first step of forming an intermediate product in which a metal material is fitted and embedded in a recess formed in a resin base material; a second step of laminating a wiring resin layer on the metal material so as to cover a wiring area where the conductor wire will be wired; a third step of wiring the conductor wire by fixing a contact area to the resin base material and also by fixing a contact area to the wiring resin layer; a fourth step of arranging a power supply connection terminal in proximity to the connection portion of the conductor wire whose contact area is fixed to the wiring resin layer; and a fifth step of providing a conductive bonding material so as to be in contact with the metal material, and connecting the connection portion of the conductor wire and the power supply connection terminal with the conductive bonding material.

3. A method for manufacturing a wire connection structure as described in claim 2, characterized in that in the first step, the metal material, which is thinner than the depth of the recess, is fitted so that the exposed surface of the metal material is positioned deeper than the surface of the resin base material where the recess is formed, and in the second step, the wiring resin layer is provided in the area surrounded by the peripheral wall of the recess and the exposed surface of the metal material so as to cover the entire exposed surface of the metal material.

4. A method for manufacturing a conductor connection structure according to claim 3, wherein in the second step, the wiring resin layer is provided so as to be substantially flush with the surface of the resin base material on which the recess is formed.

5. A method for manufacturing a conductor connection structure as described in claim 2 or 3, characterized in that in the fourth step, after removing the wiring resin layer leaving a portion covering the wiring area where the conductor is wired, a power supply connection terminal is positioned adjacent to the connection portion of the conductor whose contact area is fixed to the remaining wiring resin layer.

6. A heater wire having a contact area fixed to the resin base material and laid out; a first metal material fitted and embedded in a first recess formed in the resin base material in an area other than the electromagnetic wave transmitting area; a second metal material fitted and embedded in a second recess formed in the resin base material in an area other than the electromagnetic wave transmitting area and isolated from the first recess; a first wiring resin layer laminated on the first metal material so as to cover the wiring area where the heater wire is laid out, and a second wiring resin layer laminated on the second metal material; wherein the heater wire is laid out by having contact areas fixed to the first wiring resin layer and the second wiring resin layer, and a first conductive adhesive material is provided so as to be in contact with the first metal material; one connection portion of the heater wire and a first power supply connection terminal are connected by the first conductive adhesive material; and a second conductive adhesive material is provided so as to be in contact with the second metal material. The snow melting radome is characterized in that the other connection portion of the heater wire and a second power supply connection terminal are connected by the second conductive bonding material.

7. A snow-melting radome as described in claim 6, characterized in that the first wiring resin layer and the second wiring resin layer are embedded between the resin base material and another resin base material laminated on the resin base material.

8. A method for manufacturing a snow melting radome as set forth in claim 6 or 7, comprising: a first step of forming an intermediate product in which a first metal material and a second metal material are fitted and embedded in a first recess and a second recess formed in isolation in a resin base material in an area other than the electromagnetic wave transmitting area; a second step of laminating a first wiring resin layer on the first metal material and a second wiring resin layer on the second metal material so as to cover the wiring area where the heater wire is to be laid; a third step of laying the heater wire by fixing a contact area to the resin base material and fixing a contact area to the first wiring resin layer and the second wiring resin layer; and a fourth step of arranging a first power supply connection terminal adjacent to one connection part of the heater wire whose contact area is fixed to the first wiring resin layer and a second power supply connection terminal adjacent to the other connection part of the heater wire whose contact area is fixed to the second wiring resin layer. a fifth step of providing a first conductive bonding material so as to be in contact with the first metal material, connecting one connection portion of the heater wire and the first power supply connection terminal with the first conductive bonding material and providing a second conductive bonding material so as to be in contact with the second metal material, and connecting the other connection portion of the heater wire and the second power supply connection terminal with the second conductive bonding material.

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