Conductor wire connection structure and method for producing same

Abstract

Provided is a conductor wire connection structure, in which: a heater wire 5 of a conductor wire routed onto a resin substrate 3 is embedded between the resin substrate 3 and another resin substrate 4; metal plates 61, 62 are embedded in recesses 32, 33 of the resin substrate 3; connecting ends 51, 52 of the heater 5 and connection terminals 71, 72 are joined to the metal plates 61, 62 so as to achieve conduction; protective plates 91, 92 are provided protruding out of the metal plates 61, 62 so as to cover, from the inverse side from the metal plates 61, 62, a metal material proximal region of the heater wire 5 drawn out from the metal plates 61, 62 to the side of routing of the heating wire 5 onto the resin substrate 3, and are fixed to the metal plates 61, 62 at a region overlapping with the metal plates 61, 62; and the protective plates 91, 92 are embedded into other recesses 42, 43 formed in the another resin substrate 4 which is an injection molded material. This invention makes it possible to greatly reduce the force applied from a flowing resin to a conductor wire when the another resin substrate is formed by injection molding, prevent breakage of the conductor wire, and enhance the weather resistance and durability of the conductor wire.

Description

Conductor connection structure and method for manufacturing the same

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

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

[0003] Japanese Patent No. 7158818

[0004] By the way, in a structure where a heater wire is wired on a resin base material, the connection end of the heater wire and the wire harness connection terminal are joined to a metal material such as a metal plate to make them conductive, and the heater wire is embedded between the resin base material and another resin base material formed by injection molding. When forming another resin base material by injection molding, a large force is applied by the flowing resin to the part of the heater wire that is placed in a floating state without being fixed to the metal material and the part of the vicinity of the metal material of the heater wire drawn out from the metal material on the wiring side of the heater wire to the resin base material.

[0005] This large force applied to the heater wire from the flowing resin easily causes the disconnection of the heater wire and reduces the weather resistance and durability of the heater wire. Also, the same problem occurs in a structure where the connection end of a conductor other than the heater wire and the power supply connection terminal are joined to a metal material such as a metal plate to make them conductive, and the conductor is embedded between the resin base material and another resin base material formed by injection molding.

[0006] The present invention is proposed in view of the above problems, and aims to provide a wire connection structure and a method for manufacturing the same, in which the connection end of a wire and a power supply connection terminal are joined to a metal material to make electrical conductivity, and the wire is embedded between a resin substrate and another resin substrate formed by injection molding, thereby significantly reducing the force applied to the wire by the flowing resin when the other resin substrate is formed by injection molding, preventing wire breakage, and improving the weather resistance and durability of the wire.

[0007] The wire connection structure of the present invention is characterized in that a wire laid in a resin substrate is embedded between the resin substrate and another resin substrate, a metal material is embedded in a recess formed in the resin substrate, the connection end of the wire and the power supply connection terminal are joined to the metal material so as to be electrically conductive, and a protective plate is provided protruding from the metal material so as to cover the region of the wire near the metal material that is drawn out from the metal material on the side of the wire laid in the resin substrate, from the opposite side of the metal material, and is fixed to the metal material in the region that overlaps with the metal material, and the protective plate is embedded in another recess formed in the other resin substrate of the injection molded material.According to this, the protective plate can significantly reduce the force applied from the flowing resin of injection molding to the portion of the wire such as a heater wire that is floating without being fixed to the metal material, or to the portion of the wire near the metal material that is drawn out from the metal material on the side of the wire laid in the resin substrate. Therefore, in a structure in which the connection end of a conductor and a power supply connection terminal are joined to a metal material to create electrical conductivity, and the conductor is embedded between a resin substrate and another resin substrate formed by injection molding, the force applied to the conductor by the flowing resin when the other resin substrate is formed by injection molding can be significantly reduced, preventing the conductor from breaking and improving the weather resistance and durability of the conductor.

[0008] The wire connection structure of the present invention is characterized in that the protective plate is made of synthetic resin, and the protective plate and the metal material are fixed together in an overlapping region between the protective plate and the metal material so as to cover the periphery of the wire. According to this, by fixing the synthetic resin protective plate and the metal material together in an overlapping region between the protective plate and the metal material so as to cover the periphery of the wire, the force applied to the wire by the fluid resin can be further reduced, the occurrence of wire breakage can be more reliably prevented, and the weather resistance and durability of the wire can be further improved.

[0009] The wire connection structure of the present invention is characterized in that the protective plate is a laminate composed of a metal inner layer plate disposed on the resin substrate side and a synthetic resin outer layer plate disposed on the other resin substrate side, wherein the inner layer plate is fixed to the metal material in the region in which it overlaps with the metal material, and the portion of the outer layer plate that protrudes from the inner layer plate toward the power supply connection terminal is fixed to the metal material. According to this, by constructing the protective plate with a laminate of metal and synthetic resin, the strength and shape retention of the protective plate can be increased, and the force applied to the wire from the flowing resin when forming another resin substrate by injection molding can be more reliably reduced. In addition, the thermal stress repeatedly applied to the wire can be dispersed and reduced by heat conduction from the wire to the metal inner layer plate, thereby more reliably preventing wire breakage and further improving the weather resistance and durability of the wire.

[0010] The wire connection structure of the present invention is characterized in that the synthetic resin is made of an ultraviolet-curing resin. This allows for the easy formation of a protective plate and its attachment to a metal material.

[0011] The wire connection structure of the present invention is characterized in that the protective plate is made of metal. With this, the thermal stress repeatedly applied to the wire can be dispersed and reduced by heat conduction from the wire to the metal protective plate, thereby more reliably preventing wire breakage and further improving the weather resistance and durability of the wire.

[0012] The present invention provides a method for manufacturing a wire connection structure, comprising: a first step of forming an intermediate product in which a metal material is embedded in a recess formed in a resin substrate, laying a wire with its contact area fixed to the resin substrate, and placing the connection end of the wire on the metal material without fixing it; a second step of placing a power supply connection terminal on the metal material without fixing it; and joining the connection end of the wire and the power supply connection terminal to the metal material so that they are electrically connected, and attaching a protective plate to the resin substrate of the wire. The present invention is characterized by comprising: a third step of providing a protective plate on the wire-laying side of the protective plate so as to protrude from the metal material and cover the region of the conductor near the metal material that is drawn out from the metal material from the opposite side of the metal material, and fixing it to the metal material in the region that overlaps with the metal material; and a fourth step of forming another resin substrate by injection molding so as to be fixed to the resin substrate and the protective plate, embedding the protective plate in another recess formed in the other resin substrate by injection molding, and embedding the conductor between the resin substrate and the other resin substrate.According to this, the protective plate can significantly reduce the force applied by the injection-molded fluid resin to the portion of the conductor, such as a heater wire, that is placed in a floating state without being fixed to the metal material, and to the portion of the conductor near the metal material that is drawn out from the metal material on the wire-laying side of the conductor to the resin substrate. Therefore, in a structure in which the connection end of a conductor and a power supply connection terminal are joined to a metal material to create electrical conductivity, and the conductor is embedded between a resin substrate and another resin substrate formed by injection molding, the force applied to the conductor by the flowing resin when the other resin substrate is formed by injection molding can be significantly reduced, preventing the conductor from breaking and improving the weather resistance and durability of the conductor.

[0013] According to the present invention, in a structure in which the connection end of a conductor and a power supply connection terminal are joined to a metal material to make them electrically conductive, and the conductor is embedded between a resin substrate and another resin substrate formed by injection molding, the force applied to the conductor by the flowing resin when the other resin substrate is formed by injection molding is greatly reduced, preventing the conductor from breaking and improving the weather resistance and durability of the conductor.

[0014] (a) is a front view of a snow melting radome equipped with a wire connection structure according to the first embodiment of the present invention, and (b) is a partially enlarged front view of the same figure (a). Partial longitudinal cross-sectional view of a snow melting radome equipped with a wire connection structure according to the first embodiment. (a) to (e) are process diagrams illustrating the manufacturing process of the wire connection structure according to the first embodiment. Explanatory diagram showing the state in which the resin base material, metal material, heater wire, wire harness connection terminal and protective plate are arranged inside the mold in a snow melting radome equipped with a wire connection structure according to the first embodiment. (a) is a partially enlarged front view showing a first modified example of the wire connection structure according to the first embodiment, and (b) is a partially enlarged front view showing a second modified example of the wire connection structure according to the first embodiment. (a) to (c) are process diagrams illustrating modified examples of the manufacturing process of the wire connection structure according to the first embodiment. Partial enlarged front view of a snow melting radome equipped with a wire connection structure according to the second embodiment of the present invention. Partial enlarged front view of a snow melting radome equipped with a wire connection structure according to the third embodiment of the present invention. A partial longitudinal section view of a snow melting radome equipped with a wire connection structure according to the third embodiment.

[0015] [Conducting Wire Connection Structure of the First Embodiment] The conductive 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 the bumper of a vehicle. As shown in Figures 1 and 2, the snow melting radome 1 is equipped with an electromagnetic wave-transmitting base body 2, and the base body 2 is composed of, for example, a resin base material 3 arranged on the side opposite to the viewing side, which is the visible side of the snow melting radome 1, and another resin base material 4 arranged on the viewing side, which is the front side 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. Of the resin base material 3 and the other resin base material 4, at least the other resin base material 4 is an injection molded material and is formed by injection molding so as to be fixed to the resin base material 3.

[0016] The resin substrate 3 and the other resin substrate 4 are each formed from an insulating and electromagnetic wave-transmitting synthetic resin. Furthermore, the resin substrates 3 and 4 can be made into appropriate shapes within an applicable range, such as flat plates or curved plates. Different or the same type of synthetic resin can be used for the resin substrate 3 and the other resin substrate 4. It is preferable from the viewpoint of improving electromagnetic wave transmission performance to form the resin substrate 3 and the other resin substrate 4 with materials whose refractive indices n, defined based on the complex dielectric constant, are mutually matched, or whose refractive indices n are approximately the same or close in value. As for the numerical range of close refractive indices of the resin substrate 3 and the other resin substrate 4, it is good if the difference in refractive indices between the resin substrate 3 and the other resin substrate 4 is within the range of 0 to 10%.

[0017] Here, the refractive index n is a quantity defined by Equation 1 from the real part εr' and the imaginary part εr'' of the relative permittivity. From the viewpoint of transmittance, it is preferable that the magnitude of the dielectric loss tangent tanδ, defined by Equation 2 from the ratio of the imaginary and real parts at the applicable frequency, be 0.1 or less. It is also preferable that the magnitude of the real part of the relative permittivity be 3 or less. By keeping the magnitudes of the dielectric loss tangent and the real part of the non-dielectric constant below these values, it is possible to reliably reduce the reflectivity and internal loss required for the radome.

[0018]

[0019]

[0020] The synthetic resin of the resin substrate 3 and the synthetic resin of the other resin substrate 4 can be any synthetic resin appropriate within the scope of the present invention. For example, it is preferable to use one or more of the following: acrylic resins such as polymethyl methacrylate (PMMA), polycarbonate (PC), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylate copolymer (ASA), acrylonitrile-ethylenepropyl rubber-styrene copolymer (AES), polypropylene (PP), polyphenylene ether (PPE), modified polyphenylene ether (m-PPE), polystyrene (PS), etc., either alone or in combination of two or more. Additives may also be included. Furthermore, foamed synthetic resins may be used. Furthermore, regarding the thickness of the resin substrate 3 and the other resin substrate 4 in the electromagnetic wave transmission direction, the ratio of the thickness of the resin substrate 3 to the thickness of the other resin substrate 4, the thickness of the base resin 3, the thickness of the other resin substrate 4, and the total thickness of the base body 2 composed of the resin substrate 3 and the other resin substrate 4 are appropriate within a range that ensures the required electromagnetic wave transmission as a snow melting radome 1.

[0021] A heater wire 5, corresponding to the conductor in this embodiment, is wired in the planar direction of the electromagnetic wave-transparent substrate 2 within the snow-melting radome 1. The conductive material constituting the heater wire 3 can be any conductive material within the scope of the present invention; for example, copper, silver, silver-plated copper, copper-silver alloy, copper-nickel alloy, nickel-chromium alloy, iron-chromium alloy, transparent conductive film such as ITO film, or carbon fiber are suitable. Furthermore, the heater wire 5 can be laid in a linear shape by fixing its contact area to the resin substrate 3; its form before laying is not limited, and for example, wire material, conductive ink, conductive filler, etc., can be used.

[0022] In the illustrated example, the heater wire 5 is formed by meandering and folding along the direction in which the plate-shaped base body 2 expands, extending in a continuous line. The straight sections of the heater wire 5 are arranged in parallel along the plane direction of the base body 2, spaced apart, in and outside the electromagnetic wave irradiation area R of the base body 2 by radar devices such as on-board radar devices, and the direction of the current flowing through the straight sections of adjacent heater wires 5 is set to be approximately antiparallel or antiparallel to each other.

[0023] The heater wire 5, which corresponds to a conductor, is laid with a contact area fixed to the resin substrate 3, and also laid with a contact area fixed to another resin substrate 4, and is embedded between the resin substrate 3 and the other resin substrate 4. The heater wire 5 is then sandwiched between the resin substrate 3 and the other resin substrate 4 and is installed and sealed inside the base body 2, which is composed of the resin substrate 3 and the other resin substrate 4.

[0024] In the illustrated example, a groove 31 is formed on the side of the resin substrate 3 that is fixed to another resin substrate 4, and another groove 41 is formed on the side of the other resin substrate 4 that is fixed to the resin substrate 3, facing the groove 31. The heater wire 5 is partially embedded and fixed to the resin substrate 3 in the groove 31 and laid out, and partially embedded and fixed to the other resin substrate 4 in the groove 41 and laid out. In other words, the heater wire 5 is fixed so as to fit into the groove 31 of the resin substrate 3 and the other groove 41 of the other resin substrate 4 and is wired along the grooves 31 and 41 (see Figure 2). It is also possible to configure the heater wire 5 to be laid out by fixing the contact area to the resin substrate 3 without forming either or both of the grooves 31 of the resin substrate 3 and the other groove 41 of the other resin substrate 4.

[0025] In the region of the substrate 2 other than the electromagnetic wave transmission region R, in this embodiment, the region of the tab 21 which is formed to protrude laterally, a first recess 32 and a second recess 33 corresponding to recesses are formed on the fixing surface side of the resin substrate 3, separated from each other. A first metal plate 61 and a second metal plate 62, which are conductive plates corresponding to metal materials, are fitted and embedded in the first recess 32 and the second recess 33, respectively, and the first metal plate 61 and the second metal plate 62 are provided in an insulated state from each other.

[0026] One connection end 51 of the heater wire 5 and one wire harness connection terminal 71, which corresponds to a power supply connection terminal, are placed on the mounting surface 611 of the first metal plate 61. In the illustrated example, one connection end 51 of the heater wire 5 and one wire harness connection terminal 71 are arranged to be in contact with each other. The first metal plate 61 and one connection end 51 of the heater wire 5 are joined at a joint 8, and the first metal plate 61 and one wire harness connection terminal 71 are also joined at a joint 8, so that electrical conductivity is maintained between the one connection end 51 of the heater wire 5 and the one wire harness connection terminal 71, at least through the first metal plate 61. In the first embodiment, the one connection end 51 of the heater wire 5, one wire harness connection terminal 71, and the first metal plate 61 are joined together by a joint 8 made of a conductive joining material with added solder, brazing material, etc.

[0027] The other connection end 52 of the heater wire 5 and another wire harness connection terminal 72 corresponding to the power supply connection terminal are placed on the mounting surface 621 of the second metal plate 62, and in the illustrated example, the other connection end 52 of the heater wire 5 and the other wire harness connection terminal 72 are arranged to be in contact with each other. The second metal plate 62 and the other connection end 52 of the heater wire 5 are joined at the joint 8, and the second metal plate 62 and the other wire harness connection terminal 72 are also joined at the joint 8, so that electrical conductivity is maintained between the other connection end 52 of the heater wire 5 and the other wire harness connection terminal 72, at least through the second metal plate 62. In the first embodiment, the other connection end 52 of the heater wire 5, the other wire harness connection terminal 72 and the second metal plate 62 are joined together by a joint 8 made of a conductive joining material with added solder, brazing material, etc.

[0028] In the first embodiment, the heater wire 5 is routed along the bonding surfaces of the resin substrate 3 and another resin substrate 4, and one connection end 51 of the heater wire 5, which is not bent in the lamination direction of the resin substrate 3 and the other resin substrate 4, is electrically connected to a wire harness connection terminal 71 that is positioned to overlap and contact the one connection end 51 of the heater wire 5. In addition, the other connection end 52 of the heater wire 5, which is not bent in the lamination direction of the resin substrate 3 and the other resin substrate 4, is electrically connected to another wire harness connection terminal 72 that is positioned to overlap and contact the other connection end 52 of the heater wire 5.

[0029] Furthermore, in another resin substrate 4 formed by injection molding, a first recess 42 and a second recess 43 are formed as separate recesses, with the first recess 42 and the second recess 43 being separated from each other. A first protective plate 91 and a second protective plate 92, which correspond to protective plates, are embedded in the first recess 42 and the second recess 43, respectively, so as to fit into them.

[0030] The first protective plate 91 is provided so as to protrude from the first metal plate 61 that it covers the area of ​​the heater wire 5, which is drawn out from the first metal plate 61 on the side of the heater wire 5, which is laid out on the resin substrate 3, from the opposite side of the first metal plate 61 in the thickness direction of the base 2 or the thickness direction of the resin substrate 3, and is fixed to the first metal plate 61 in the area that overlaps with the first metal plate 61.

[0031] The second protective plate 92 is provided so as to protrude from the second metal plate 62 that it covers the area of ​​the heater wire 5, which is drawn out from the second metal plate 62 on the side of the heater wire 5 that is laid out on the resin substrate 3, from the opposite side of the second metal plate 62 in the thickness direction of the base 2 or the thickness direction of the resin substrate 3, and is fixed to the second metal plate 62 in the area that overlaps with the second metal plate 62.

[0032] The first protective plate 91 and the second protective plate 92 are formed from synthetic resins such as ultraviolet-curing resins, and are fixed to the first metal plate 61 and the second metal plate 62 in contact areas by adhesive bonding, heat compression bonding, or welding, respectively. Preferably, the fixing area between the first protective plate 91 and the first metal plate 61 is formed in the overlapping area of ​​the first protective plate 91 and the first metal plate 61 so as to cover the periphery of the heater wire 5 corresponding to the conductor, and the fixing area between the second protective plate 92 and the second metal plate 62 is formed in the overlapping area of ​​the second protective plate 92 and the second metal plate 62 so as to cover the periphery of the heater wire 5 corresponding to the conductor, thereby further reducing the force applied to the heater wire 5 from the flowing resin when another resin substrate 4 is formed by injection molding, more reliably preventing the occurrence of breakage of the heater wire 5, and further improving the weather resistance and durability of the heater wire 5. Furthermore, preferably, the first protective plate 91 and the second protective plate 92 are fixed to the resin substrate 3 by adhesive, heat compression, or welding.

[0033] Furthermore, as shown in the first modified example in Figure 5(a), the first protective plate 91 and the second protective plate 92 can be made of metal or the like, and in the overlapping region, the first protective plate 91 and the second protective plate 92 can be fixed in a point-like manner to the first metal plate 61 and the second metal plate 62, respectively, by joints 8 made of a conductive bonding material such as solder or brazing material.

[0034] Furthermore, as shown in the second modified example in Figure 5(b), the first protective plate 91 and the second protective plate 92 may each be made of laminated plates, and consist of an inner layer plate 93 made of metal or the like, which is arranged on the resin substrate 3 side and fixed to the first metal plate 61 and the second metal plate 62, and an outer layer plate 94 made of synthetic resin such as ultraviolet curing resin, which is arranged on the other resin substrate 4 side and fixed to the inner layer plate 93 over its entirety. In this case, for example, the inner layer plate 93 may be fixed in the same way as the first protective plate 91 and the second protective plate 92 in the first modified example, and the outer layer plate 94 may be fixed by applying a paste-like ultraviolet curing resin to the outside of the inner layer plate 94 and curing it. In the illustrated example of this second modified example, the portion of the outer layer plate 94 that protrudes from the inner layer plate 93 of the first protective plate 91 and the second protective plate 92 toward the wire harness connection terminals 71 and 72 is fixed to the first metal plate 61 and the second metal plate 62, respectively.

[0035] When manufacturing the snow-melting radome 1 equipped with the wire connection structure of the first embodiment, an intermediate product is formed in which the first metal plate 61 and the second metal plate 62 are fitted and embedded in the first recess 32 and the second recess 33, which are formed in isolation in the resin substrate 3 in an area other than the electromagnetic wave transmission region R (see Figure 3(a)). In forming this intermediate product, for example, the non-penetrating first recess 32 and the second recess 33 are formed in isolation in an area other than the electromagnetic wave transmission region R on one side of the resin substrate 3, and the first metal plate 61 and the second metal plate 62 are fitted and embedded in the first recess 32 and the second recess 33, respectively. The first recess 32 and the second recess 33 may be formed by corresponding shaped protrusions in the mold when the resin substrate 3 is formed by injection molding, or they may be formed on one side of the resin substrate 3 by cutting or the like.

[0036] Then, for example, by welding using ultrasonic vibration or printing, the heater wire 5, which corresponds to the conductor, is laid out in a predetermined pattern such as a meandering shape, with the contact area fixed to the resin base material 3. One connection end 51 of the heater wire 5 is placed unglued on the exposed mounting surface 611 of the first metal plate 61, and the other connection end 52 of the heater wire 5 is placed unglued on the exposed mounting surface 621 of the second metal plate 62 (see Figure 3(b)). The method of laying out the conductor is appropriate within the applicable range.

[0037] Furthermore, as a modified manufacturing method, as shown in Figures 6(a) to (c), the heater wire 5 is laid in a predetermined pattern on one surface of the resin substrate 3 in an area that does not overlap with the first recess 32 and the second recess 33 of the resin substrate 3. Then, the first metal plate 61 and the second metal plate 62 are fitted into the first recess 32 and the second recess 33, respectively. After that, the heater wire 5 is laid to connect in the area that overlaps with the first recess 32 and the second recess 33. One connecting end 51 of the heater wire 5 is placed on the exposed mounting surface 611 of the first metal plate 61, and the other connecting end 52 of the heater wire 5 is placed on the exposed mounting surface 621 of the second metal plate 62. The laying of the heater wire 5 in the area that overlaps with the first recess 32 and the second recess 33 may be performed using the heater wire 5 that has been laid in advance to be placed on the first metal plate 61 and the second metal plate 62 before fitting.

[0038] Subsequently, one wire harness connection terminal 71, corresponding to a power supply connection terminal, is positioned close to one connection end 51 of the heater wire 5 on the mounting surface 611 of the first metal plate 61, and another wire harness connection terminal 72, corresponding to a power supply connection terminal, is positioned close to the other connection end 52 of the heater wire 5 on the mounting surface 621 of the second metal plate 62 (see Figure 3(c)). In the illustrated example, the wire harness connection terminals 71 and 72 are positioned to be placed on the connection ends 51 and 52 of the heater wire 5.

[0039] Next, as shown in Figure 3(d), one connection end 51 of the heater wire 5, which corresponds to a conductor, and one wire harness connection terminal 71, which corresponds to a power supply connection terminal, are joined at the joint 8 to the first metal plate 61, which corresponds to a metal material, so that the two connection ends 51 and one wire harness connection terminal 71 are electrically connected. At the same time, the other connection end 52 of the heater wire 5, which corresponds to a conductor, and the other wire harness connection terminal 72, which corresponds to a power supply connection terminal, are joined at the joint 8 to the second metal plate 62, which corresponds to a metal material, so that the two connection ends 52 and the other wire harness connection terminal 72 are electrically connected.

[0040] Furthermore, as shown in Figure 3(e), the first protective plate 91 is provided on the resin substrate 3 where the joint portion 8 is provided. This is done by placing, for example, a paste-like ultraviolet-curing resin that will serve as a protective plate in a predetermined area and irradiating it with ultraviolet light, so that the first protective plate 91 protrudes from the first metal plate 61 so as to cover the area near the metal material of the heater wire 5 that is drawn out from the first metal plate 61 on the side of the heater wire 5 that is laid out on the resin substrate 3, from the opposite side of the first metal plate 61 in the thickness direction of the resin substrate 3, and is fixed to the first metal plate 61 in the area that overlaps with the first metal plate 61. In addition, the second protective plate 92 is provided on the resin substrate 3 where the joint portion 8 is provided. This is done by protruding from the second metal plate 62 so as to cover the area near the metal material of the heater wire 5 that is drawn out from the second metal plate 62 on the side of the heater wire 5 that is laid out on the resin substrate 3, from the opposite side of the second metal plate 62 in the thickness direction of the resin substrate 3, and is fixed to the second metal plate 62 in the area that overlaps with the second metal plate 62.

[0041] Alternatively, instead of this process, a conductive bonding material such as solder or brazing material is applied to a predetermined location, the joint portion 8 is formed by curing, a first protective plate 91 and a second protective plate 92 made of metal or the like are arranged in a predetermined region, and the bonding material 8 is melted once and then cured again, so that the first protective plate 91 is fixed to the first metal plate 61 in the region overlapping the first metal plate 61, and the second protective plate 92 is fixed to the second metal plate 62 in the region overlapping the second metal plate 62 (see FIG. 5(a)).

[0042] Alternatively, instead of this process, a conductive bonding material such as solder or brazing material is applied to a predetermined location, the joint portion 8 is formed by curing, an insertion plate 93 made of metal or the like is arranged in a predetermined region, and the bonding material 8 is melted once and then cured again, so that the inner layer plate 93 is fixed to the first metal plate 61 in the region overlapping the first metal plate 61, and the inner layer plate 93 is fixed to the second metal plate 62 in the region overlapping the second metal plate 62. Thereafter, a paste-like ultraviolet curable resin before curing is arranged in a predetermined region such as a region overlapping the inner layer plate 93 and irradiated with ultraviolet rays or the like, so that the outer layer plate 94 is fixed to the metal plates 61 and 62 in the region overlapping the metal plates 61 and 62 (see FIG. 5(b)).

[0043] Thereafter, as shown in FIG. 4, the resin base material 3 to which the heater wire 5, the first metal plate 61 and the second metal plate 62, the first protective plate 91 and the second protective plate 92, the joint portion 8, and the wire harness connection terminals 71 and 72 are attached is arranged inside a mold 100 formed by a split mold. At this time, the wire harness connection portion 7 from which the wire harness connection terminals 71 and 72 are drawn out is led out of the mold 100 from a lead-out port 102 formed in a part of the mold 100 to the outside of the mold 100.

[0044] Then, molten resin MR is poured into the mold 100 from the injection port 101 to perform injection molding, and another 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 other resin base material 4 is fixed to the first resin base material 3. The interface where the other resin base material 4 is laminated by injection molding is molded and welded to the resin base material 3, heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminal 72, first protective plate 91 and second protective plate 92, and the heater wire 5, first metal plate 61, one wire harness connection terminal 71, second metal plate 62, other wire harness connection terminal 72, joint 8, first protective plate 91 and second protective plate 92 are embedded between the resin base material 3 and the other resin base material 4. Furthermore, the first protective plate 91 and the second protective plate 92 are embedded so as to fit into the first recess 42 and the second recess 43 of another resin substrate 4 formed by injection molding.

[0045] In this case, the areas near the metal material of the heater wire 5 drawn from the first metal plate 61 and the areas near the metal material of the heater wire 5 drawn from the second metal plate 62, etc., that are covered by the first protective plate 91 and the second protective plate 92 on the side where another resin substrate 4 is formed, are protected by the first protective plate 91 and the second protective plate 92 from forces applied from the flowing resin that will become the other resin substrate 4.

[0046] Furthermore, since the other resin substrate 4 is formed to cover the portion of the heater wire 5 that protrudes outside the groove 31, the portion of the heater wire 5 that protrudes outside the groove 31 is molded and fixed to the other resin substrate 4 by insert molding, and the heater wire 5 is fitted into another groove 41 of the other resin substrate 4. After the formation of the other resin substrate 4, the mold 100 is demolded to obtain the snow melting radome 1 equipped with the wire connection structure of the first embodiment.

[0047] According to the first embodiment, by the first protective plate 91 and the second protective plate 92, for example, the portion of the heater wire 5 placed in a floating state without being fixed to the metal plates 61 and 62, and the portion of the vicinity of the metal material of the heater wire 5 drawn out from the metal plates 61 and 62 to the wiring side of the resin base material 3 of the heater wire 5, the force applied from the flowing resin in injection molding can be significantly reduced. Therefore, in the structure where the connection end portions 51 and 52 of the heater wire 5 and the wire harness connection terminals 71 and 72 are joined and electrically connected to the metal plates 61 and 62, and the heater wire 5 is embedded between the resin base material 3 and another resin base material 4 formed by injection molding, when the other resin base material 4 is formed by injection molding, the force applied from the flowing resin to the heater wire 5 can be significantly reduced, the occurrence of disconnection of the heater wire 5 can be prevented, and the weather resistance and durability of the heater wire 5 can be enhanced.

[0048] Also, when the synthetic resin protective plates 91 and 92 and the metal plates 61 and 62 are fixed so as to cover the periphery of the heater wire 5 in the overlapping region between the protective plates 91 and 92 and the metal plates 61 and 62, the force applied from the flowing resin to the heater wire 5 can be further reduced, the occurrence of disconnection of the heater wire 5 can be more reliably prevented, and the weather resistance and durability of the heater wire 5 can be further enhanced.

[0049] Also, when the protective plates 91 and 92 are made of metal, the thermal stress repeatedly applied to the heater wire 5 can be dispersed and reduced by the heat conduction from the heater wire 5 to the metal protective plates 91 and 92, the occurrence of disconnection of the heater wire 5 can be more reliably prevented, and the weather resistance and durability of the heater wire 5 can be further enhanced.

[0050] Also, when the protective plate is constituted by a laminated plate composed of a metal inner layer plate 93 and a synthetic resin outer layer plate 94, the strength and shape retention of the protective plates 91 and 92 can be enhanced, and the force applied from the flowing resin to the heater wire 5 can be more reliably reduced when the other resin base material 4 is formed by injection molding. Also, the thermal stress repeatedly applied to the heater wire 5 can be dispersed and reduced by the heat conduction from the heater wire 5 to the metal inner layer plate 93, the occurrence of disconnection of the heater wire 5 can be more reliably prevented, and the weather resistance and durability of the heater wire 5 can be further enhanced.

[0051] Furthermore, if the synthetic resin of the protective plates 91 and 92 is made of ultraviolet-curing resin, the protective plates 91 and 92 can be easily formed and fixed to the metal plates 61 and 62.

[0052] [Conductor connection structure of the second embodiment] The conductor connection structure of the second embodiment according to the present invention is installed in a snow melting radome 1a such as a bumper cover attached to the bumper of a vehicle. As shown in Figure 7, a redundant wiring section 53 is locally provided in the portion of the heater wire 5 that corresponds to a conductor and is arranged on the side of the heater wire 5 that is laid on the resin base material 3, and the redundant wiring section 53 is fixed to the resin base material 3 in the contact area and laid. In the illustrated example, a first protective plate 91 is provided protruding from the first metal plate 61 so as to cover the redundant wiring section 53 located in the region of the heater wire 5 near the metal material from the opposite side of the first metal plate 61, and a second protective plate 92 is provided protruding from the second metal plate 62 so as to cover the redundant wiring section 53 located in the region of the heater wire 5 near the metal material from the opposite side of the second metal plate 62.

[0053] The redundant wiring section 53 is redundantly wired as part of the heater wire 5 in the vicinity of the first metal plate 61 or the second metal plate 62, and is fixed to the resin substrate 3 and another resin substrate 4. In the illustrated example, the redundant wiring section 53 is formed to meander in a direction perpendicular to the extension direction of one wire harness connection terminal 71 or the other wire harness connection terminal, and is formed to meander in a rectangular wave shape that bends at a right angle or approximately at a right angle. The number of meanders corresponding to one period of the rectangular wave in the redundant wiring section 53 is preferably one or more, but two or more is more preferable from the viewpoint of improving the dispersion of thermal stress. Furthermore, the meandering width corresponding to the fluctuation width of the rectangular wave in the redundant wiring section 53 is preferably five times or more the wire width of the heater wire 5 from the viewpoint of improving the dispersion of thermal stress, and more preferably ten times or more. Also, from the viewpoint of minimizing the installation space of the redundant wiring section 53, it is preferable to have a meandering width of 30 times or less the wire width of the heater wire 5.

[0054] The wiring shape of the redundant wiring section 53 is not limited to the illustrated example. For example, it may be formed in a meandering manner perpendicular to the extension direction of one wire harness connection terminal 71 or another wire harness connection terminal, and may be formed in a curved, S-shaped meandering manner. In the case of a sinusoidal shape, it is preferable to use the same number of meandering repetitions and the meandering variation range as in the case of a rectangular wave shape.

[0055] Furthermore, the wiring shape of the redundant wiring section 53 may be formed to meander in the extension direction of one wire harness connection terminal 71 or another wire harness connection terminal, and may also be formed to meander in a rectangular wave shape that bends at a right angle or approximately at a right angle. When meandering in the extension direction, the number of repetitions of the meander and the variation range of the meander are preferably the same as when meandering in a direction perpendicular to the extension direction. In addition, the wiring shape of the redundant wiring section 53 may be formed in a spiral shape that folds back in the middle. Furthermore, the redundant wiring section 53 may be formed to meander in a predetermined periodic pattern other than the above example.

[0056] Apart from the configuration of the redundant wiring section 53 and covering part or all of the redundant wiring section 53 with protective plates 91 and 92, the configuration and modifications of the conductor connection structure or snow melting radome 1a of the second embodiment are the same as those of the first embodiment. Furthermore, the snow melting radome 1a equipped with the conductor connection structure of the second embodiment can be manufactured by following the manufacturing process for the snow melting radome 1 equipped with the conductor connection structure of the first embodiment, by fixing the contact area of ​​the heater wire 5, which corresponds to the conductor, to the resin base material 3 by, for example, welding by ultrasonic vibration, and laying it in a predetermined pattern such as a meandering shape, and when one connection end 51 or the other connection end 52 of the heater wire 5 is placed on the exposed mounting surface 611 or mounting surface 621 of the first metal plate 61 or the second metal plate 62 without fixing, the redundant wiring section 53 of the heater wire 5 is laid so that it is fixed to the resin base material 3 in the contact area.

[0057] According to the second embodiment, the redundant wiring section 53, which is locally provided on the portion of the heater wire 5 that is laid on the resin substrate 3, can disperse and reduce the thermal stress repeatedly applied to the portion of the heater wire 5 that is laid on the resin substrate 3 near the first metal plate 61 or the second metal plate 62. Therefore, the occurrence of breakage of the heater wire 5 can be prevented more reliably, and the weather resistance and durability of the heater wire 5 can be further improved. Furthermore, the second embodiment exhibits corresponding effects from a configuration corresponding to that of the first embodiment.

[0058] [Wire Connection Structure of the Third Embodiment] The wire connection structure of the third embodiment according to the present invention is installed in a snow-melting radome 1b such as a bumper cover attached to the bumper of a vehicle. As shown in Figures 8 and 9, the connection ends 51 and 52 of the heater wire 5, which corresponds to a conductor, and the wire harness connection terminals 71 and 72, which correspond to a power supply connection terminal, are joined to metal plates 61 and 62, which correspond to a metal material, by a joint consisting of a heater wire joint 81 and a connection terminal joint 82, and are electrically connected via the metal plates 61 and 62.

[0059] Specifically, the mounting surface 611 of the first metal plate 61 is placed such that one connection end 51 of the heater wire 5 and one wire harness connection terminal 71 are spaced apart, and the first metal plate 61 and one connection end 51 of the heater wire 5 are joined so that they are electrically connected at the heater wire joint 81, and the first metal plate 61 and one wire harness connection terminal 71 are joined so that they are electrically connected at a connection terminal joint 82 which is spaced apart from the heater wire joint 81. Furthermore, the mounting surface 621 of the second metal plate 62 is placed such that the other connection end 52 of the heater wire 5 and another wire harness connection terminal 72 are spaced apart, and the second metal plate 62 and the other connection end 52 of the heater wire 5 are joined so that they are electrically connected at the heater wire joint 81, and the second metal plate 62 and the other wire harness connection terminal 72 are joined so that they are electrically connected at a connection terminal joint 82 which is spaced apart from the heater wire joint 81.

[0060] The heater wire joint 81 and the connection terminal joint 82 can each be configured in a suitable manner to enable electrical connection. For example, it is preferable to have a joint made of a conductive joining material with added solder or brazing material, or a joint made of a weld such as laser welding. Furthermore, the heater wire joint 81 and the connection terminal joint 82 may be made of different types of joints rather than the same type.

[0061] Furthermore, on the resin substrate 3, which is provided with a heater wire joint 81 and a connection terminal joint 82, a first protective plate 91 is provided so as to protrude from the first metal plate 61 and cover the area near the metal material of the heater wire 5 that is drawn out from the first metal plate 61 on the side of the heater wire 5 being laid onto the resin substrate 3, from the side opposite to the first metal plate 61, and is fixed to the first metal plate 61 in the area that overlaps with the first metal plate 61. Also, on the resin substrate 3, which is provided with a heater wire joint 8 and a connection terminal joint 82, a second protective plate 92 is provided so as to protrude from the second metal plate 62 and cover the area near the metal material of the heater wire 5 that is drawn out from the second metal plate 62 on the side of the heater wire 5 being laid onto the resin substrate 3, from the side opposite to the second metal plate 62, and is fixed to the second metal plate 62 in the area that overlaps with the second metal plate 62.

[0062] In the illustrated example, the first protective plate 91 and the second protective plate 92 are provided to cover both the heater wire joint 81 and the connection terminal joint 82. However, it is also preferable to provide them to cover only the heater wire joint 81 and not the connection terminal joint 82, or to provide them to not cover either the heater wire joint 81 or the connection terminal joint 82. Furthermore, it is also preferable to provide the protective plates 91 and 92 with a metal inner layer plate 93 and a synthetic resin outer layer plate 94, with the inner layer plate 93 fixed to the metal plates 61 and 62 so as to cover only the heater wire joint 81, and the outer layer plate 94 fixed to the metal plates 61 and 62 so as to cover both the heater wire joint 81 and the connection terminal joint 82.

[0063] Furthermore, as a modification of the third embodiment, it is also preferable to provide a redundant wiring section 53 as in the second embodiment, and to provide the first protective plate 91 and the second protective plate 92 so as to cover part or all of the redundant wiring section 53. Other conductor connection structures or configurations and modifications of the snow melting radome 1a of the third embodiment are the same as in the first embodiment.

[0064] Furthermore, the snow melting radome 1b equipped with the wire connection structure of the second embodiment is based on the manufacturing process for the snow melting radome 1 equipped with the wire connection structure of the first embodiment, with one connection end 51 of the heater wire 5 and one wire harness connection terminal 71 placed on the mounting surface 611 of the first metal plate 61 so as to be spaced apart, the first metal plate 61 and one connection end 51 of the heater wire 5 are joined together at the heater wire joint 81 so as to be electrically connected, and the first metal plate 61 and one wire harness connection terminal 71 are spaced apart from the heater wire joint 81. The product can be manufactured by joining the connection terminals at the connection terminal joint 82 in a position where electrical conductivity is maintained, placing the other connection end 52 of the heater wire 5 and the other wire harness connection terminal 72 on the mounting surface 621 of the second metal plate 62 so that they are spaced apart, joining the second metal plate 62 and the other connection end 52 of the heater wire 5 at the heater wire joint 81 so that electrical conductivity is maintained, and joining the second metal plate 62 and the other wire harness connection terminal 72 at a position spaced apart from the heater wire joint 81 so that electrical conductivity is maintained at the connection terminal joint 82.

[0065] According to the second embodiment, for example, the metal plates 61 and 62 can be joined to the connection ends 51 and 52 of the heater wire 5 by soldering or brazing, and the metal plates 61 and 62 can be joined to the wire harness connection terminals 71 and 72 by laser welding. By using an appropriate joining method according to the design conditions and manufacturing environment, the metal plates 61 and 62 can be joined to the connection ends 51 and 52 of the heater wire 5, and the metal plates 61 and 652 can be joined to the wire harness connection terminals 71 and 72, thereby increasing the freedom and diversity of joining methods. Furthermore, since the connection ends 51 and 52 of the heater wire 5 and the wire harness connection terminals 71 and 72 are electrically connected via the metal plates 61 and 62, the length and amount of heater wire 5 used can be reduced, thereby reducing component costs and manufacturing costs. Moreover, the third embodiment exhibits corresponding effects from a configuration corresponding to the first embodiment.

[0066] [Scope of the Inventions Disclosed herein] The inventions disclosed herein include, in addition to each invention and each embodiment listed as an invention, the inventions disclosed herein also include, to the extent applicable, those that are specified by modifying part of these inventions with other content disclosed herein, or by adding other content disclosed herein to these inventions, or by deleting part of these inventions to the extent that partial effects can be obtained and defining them as higher-level concepts. Furthermore, the inventions disclosed herein also include the following modifications and additions.

[0067] For example, in the above embodiment, an example was illustrated and explained in which the connection ends 51 and 52 of the heater wire 5, which correspond to the conductor, and the wire harness connection terminals 71 and 72, which correspond to the power supply connection terminals, are arranged in a straight line. However, in order to ensure electrical connectivity, it is also acceptable to arrange the connection ends 51 and 52 of the heater wire 5 so as to intersect the wire harness connection terminals 71 and 72 at an angle. Furthermore, the power supply connection terminals in the present invention include appropriate connection terminals for supplying power to the conductor, and in addition to the wire harness connection terminals of the wire harness in the above example, they also include, for example, the connection terminals of a connector.

[0068] Furthermore, the wire connection structure of the present invention includes a structure for connecting wires other than the heater wires of a snow melting radome, and also includes a wire connection structure such as a structure for connecting heater wires other than those of a snow melting radome, or a wire connection structure such as a resin molded product on which wires such as a MID (Molded Interconnect Device) are laid. In addition, the function of the wires in the wire connection structure of the present invention can be as appropriate, such as an antenna, wireless power supply and transmission, or an electromagnetic tag.

[0069] Furthermore, when manufacturing the snow-melting radomes 1, 1a, and 1b in the above embodiment, the step of forming an intermediate product in which the first metal material 61 and the second metal material 62 are fitted and embedded in the first recess 32 and the second recess 33, which are isolated and formed in the resin substrate 3 in a region other than the electromagnetic wave transmission region R, is not limited to the above example. For example, the resin substrate 3 may be injection molded so that the first metal material 61 and the second metal material 62 are fitted and embedded in the isolated first recess 32 and the second recess 33, respectively.

[0070] Furthermore, the synthetic resin constituting the protective plate can be any suitable synthetic resin within the scope of the present invention, such as epoxy resin or silicone resin, and is not limited to the ultraviolet-curing resin of the above embodiment.

[0071] This invention can be used, for example, in a connection structure for conductive wires such as heater wires in snow-melting radomes.

[0072] 1, 1a, 1b...Snow melting radome 2...Base 21...Tab 3...Resin substrate 31...Groove 32...First recess 33...Second recess 4...Another resin substrate 41...Groove 42...First recess 43...Second recess 5...Heater wire 51...One connection end 52...Other connection end 53...Redundant wiring section 61...First metal plate 611...Exposed surface 62...Second metal plate 621...Exposed surface 7...Wire harness connection section 71...One wire harness connection terminal 72...Other wire harness connection terminal 8...Joint 81...Heater wire joint 82...Connection terminal joint 91...First protective plate 92...Second protective plate 93...Inner layer plate 94...Outer layer plate 100...Mold 101...Injection port 102...Outlet R...Electromagnetic wave irradiation area MR...Molten resin

Claims

1. A wire connection structure characterized in that a wire laid in a resin substrate is embedded between the resin substrate and another resin substrate, a metal material is embedded in a recess formed in the resin substrate, the connection end of the wire and the power supply connection terminal are joined to the metal material so as to be electrically conductive, a protective plate is provided protruding from the metal material so as to cover the region of the wire near the metal material that is drawn out from the metal material on the side of the wire laid in the resin substrate, and is fixed to the metal material in the region that overlaps with the metal material, and the protective plate is embedded in another recess formed in the other resin substrate of the injection molded material.

2. The wire connection structure according to claim 1, characterized in that the protective plate is made of synthetic resin, and the protective plate and the metal material are fixed together in an overlapping region of the protective plate and the metal material so as to cover the periphery of the wire.

3. The wire connection structure according to claim 1, wherein the protective plate is a laminate composed of a metal inner layer plate disposed on the resin substrate side and a synthetic resin outer layer plate disposed on the other resin substrate side, the inner layer plate is fixed to the metal material in the region in which it overlaps with the metal material, and the portion of the outer layer plate that protrudes from the inner layer plate toward the power supply connection terminal is fixed to the metal material.

4. The wire connection structure according to claim 2 or 3, characterized in that the synthetic resin is an ultraviolet curing resin.

5. The wire connection structure according to claim 1, characterized in that the protective plate is made of metal.

6. An intermediate product is formed in which a metal material is embedded in a recess formed in a resin substrate, and a conductor is laid out on the resin substrate with its contact area fixed, and the connection end of the conductor is placed on the metal material without being fixed; a power supply connection terminal is placed on the metal material without being fixed; the connection end of the conductor and the power supply connection terminal are joined to the metal material so that they are electrically connected, and a protective plate is provided protruding from the metal material so as to cover the area of ​​the conductor near the metal material that is drawn out from the metal material on the side of the conductor laid out on the resin substrate, and is fixed to the metal material in the area that overlaps with the metal material; A method for manufacturing a wire connection structure, comprising a fourth step of forming another resin substrate by injection molding so as to be fixed to the aforementioned resin substrate and the protective plate, embedding the protective plate in another recess formed in the other resin substrate by injection molding, and embedding the wire between the resin substrate and the other resin substrate.

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