Molded body, air conditioning system and method for manufacturing a molded body

Abstract

A molded body (100) comprises a first molded part (1) with a first outer surface (1a), which is a front face of the molded body (100), and a first connection (12) extending along an edge of a first inner surface (1b) within the molded body (100); a second molded part (2) with a second outer surface (2a), which is a rear face of the molded body (100), and a second connection (22) extending along an edge of a second inner surface (2b) within the molded body (100) and in contact with the first connection (12); and a connecting element (3) between the first connection (12) and the second connection (22). The first connection (12) and / or the second connection (22) comprises, on a surface in contact with another connection (22), a groove extending in the same direction as the first connection (12). The second connection (22) has an opening that is connected to the groove.The connecting element (3) is inserted through the opening into the groove and connects the first connection (12) and the second connection (22).

Description

Technical field

[0001] The present disclosure relates to a molded body, an air conditioning system and a method for manufacturing a molded body. State of the art

[0002] Resin-molded bodies comprise a single body with multiple molded parts. Such a body is typically manufactured by molding the parts and joining them together. More precisely, each part is cast by injecting a casting resin into a mold. The multiple injection-molded parts are then positioned at the points where they need to be joined. The molded parts are joined using a joining process to complete the body.

[0003] Examples of methods for joining such multiple molded parts include techniques using ultrasound, adhesives, or thermal fusion. These joining methods are applied after each of the multiple molded parts has been removed from a mold. The resulting molded parts are manufactured through such a lengthy and complex process.

[0004] Another method for producing a molded body with multiple molded parts is the DSI molding process (DSI: Die Slide Injection) described in patent literature 1. In the DSI molding process, the multiple molded parts are injection molded, positioned relative to each other, and joined together within a mold. The molded bodies are manufactured in a process that is neither lengthy nor complex. Citation list of patent literature

[0005] Patent literature 1: Unexamined Japanese patent disclosure no. S62 - 087 315 Overview of the invention Technical problem

[0006] The DSI molding process described above is a method for joining molded parts using a bonding resin. Molten bonding resin is injected into a mold through a parting line. The injected bonding resin joins the outer circumferences of the positioned multiple molded parts.

[0007] The outer circumferences of the joined molded parts correspond to the outer circumference of the molded body. The molded body has a connection area between the multiple molded parts on its outer surface. Therefore, the molded body produced using this method may have an imperfect appearance.

[0008] One objective of the present disclosure is to provide a molded body with multiple molded parts and an intended appearance, as well as a method for manufacturing the molded body. Solution to the problem

[0009] To achieve the aforementioned objective, a molded body, according to one aspect of the present disclosure, is a molded body made of a resin. The molded body comprises a first molded part with a first outer surface, which is a front face of the molded body, a first inner surface within the molded body, and a first connection extending along an edge of the first inner surface; a second molded part with a second outer surface, which is a rear face of the molded body, a second inner surface within the molded body, and a second connection extending along an edge of the second inner surface and in contact with the first connection; and a connecting element between the first connection and the second connection.The first connection and / or the second connection comprises a groove on a surface that is in contact with another of the first or second connection, extending in the same direction as the first and / or second connection. The second connection has an opening connected to the groove. The connecting element is inserted through the opening into the groove and joins the first and second connections. Advantageous effects of the invention

[0010] In the structure described above, the first and second molded parts are connected by the connecting element in a groove that lies between the first and second connections. The connecting element is thus located within the molded body, and the connection area between the first and second molded parts is not visible from the outside. The molded body does not exhibit any impairment of its appearance. Brief description of the drawings Fig. Figure 1 is a perspective view of an air conditioning system with a flap as a molded body according to embodiment 1; Fig. Figure 2 is a perspective view of the flap as a molded body according to embodiment 1; Fig. 3 is a perspective exploded view of the in Fig. 2 flap shown as a molded body according to embodiment 1; Fig. Figure 4 is a perspective view of a base as the first molded part according to embodiment 1, showing the exterior; Fig. 5A is an enlarged perspective view of the base as the first molded part according to embodiment 1, showing the exterior of a first end; Fig. 5B is an enlarged perspective view of the base as the first molded part according to embodiment 1, showing the exterior of a second end; Fig. Figure 6 is a perspective view of the base as the first molded part according to embodiment 1, showing the interior; Fig. Figure 7 is a perspective view of a cover as a second molded part according to embodiment 1, showing the exterior; Fig. Figure 8A is an enlarged perspective view of the cover as the second molded part according to embodiment 1, showing the exterior of a first end; Fig. Figure 8B is an enlarged perspective view of the cover as the second molded part according to embodiment 1, showing the exterior of a second end; Fig. Figure 9 is a perspective view of the cover as the second molded part according to embodiment 1, showing the interior; Fig. Figure 10A is a cross-sectional view of the flap as a shaped body according to embodiment 1 along the line Xa-Xa in Fig. 2, seen in the positive Y direction; Fig. 10B is an enlarged view of a sub-area T1, which is in Fig. 10A is surrounded by a dashed line; Fig. 10C is an enlarged view of a sub-area T2, which is in Fig. 10A is surrounded by a dashed line; Fig. 11A is a cross-sectional view of the flap as a molded body according to embodiment 1 along line XIa-XIa in Fig. 2, seen in the negative Y direction; Fig. 11B is an enlarged view of a sub-area T3, which is in Fig. 11A is surrounded by a dashed line; Fig. 11C is an enlarged view of a sub-area T4, which is in Fig. 11A is surrounded by a dashed line; Fig. 12A is a diagram describing a method for manufacturing the flap as a molded body according to embodiment 1 and a schematic cross-sectional view along XII-XII in Fig. 2 points in the positive X direction; Fig. Figure 12B is a diagram describing the method for manufacturing the flap as a molded body according to embodiment 1 and a schematic cross-sectional view along XII-XII in Fig. 2 points in the positive X direction; Fig. 12C is a diagram describing the process for manufacturing the flap as a molded body according to embodiment 1 and a schematic cross-sectional view along XII-XII in Fig. 2 points in the positive X direction; Fig. 12D is a diagram that describes the method for manufacturing the flap as a molded body according to embodiment 1 and shows a schematic cross-sectional view along XII-XII in Fig. 2 points in the positive X direction; Fig. 13 is a perspective diagram showing a bonding resin in embodiment 1, which is injected into a groove between the cover and the base using a point-seal method; Fig. 14A is an enlarged cross-sectional view of the sub-area T1, which is located in Fig. 10A is surrounded by the dotted line, for a flap as a shaped body according to embodiment 2; Fig. 14B is an enlarged cross-sectional view of the area defined by the dashed line in Fig. 10A surrounded sub-area T2 for the flap as a shaped body according to embodiment 2; Fig. Figure 15 is a perspective view of a base as the first molded part in embodiment 3, showing the interior; Fig. 16A is an enlarged perspective view of a base as the first molded part in embodiment 4, showing the exterior of a first end; Fig. 16B is an enlarged perspective view of the base as the first molded part in embodiment 4, showing the exterior of a second end; Fig. Figure 17 is an enlarged cross-sectional view of a flap as a shaped body according to a modification along the line Xa-Xa in Fig. 2, seen in the positive Y direction; Fig. Figure 18 is a perspective view of a flap as a shaped body according to a modification; and Fig. Figure 19 is an enlarged perspective view of a flap as a shaped body according to a modification. Description of the embodiments

[0011] A molded body according to one or more embodiments is described below with reference to the drawings of a flap as an example. Identical reference numerals denote identical or corresponding components in the drawings.

[0012] In Fig. For clarity, a left-handed XYZ-orthogonal coordinate system is defined in section 2. The transverse direction of the flap corresponds to an X-direction, the longitudinal direction of the flap corresponds to a Y-direction, and a direction perpendicular to both the X-axis and the Y-axis corresponds to a Z-direction. The XYZ-orthogonal coordinate system is described in the Fig. Shown 2 to 19. Design 1

[0013] As in Fig. As shown in Figure 1, a flap 100 according to the present embodiment is attached to an air outlet AP of an air conditioning system AC in an openable manner. As shown in Figure 1, a flap 100 is attached to an air outlet AP of an air conditioning system AC in an openable manner. Fig. As shown in Figure 2, flap 100 is a strip-shaped sheet. The air conditioner (AC) is installed on the ceiling above the eye level of a user to efficiently cool or heat the interior of a building.

[0014] In a cross-section along an XZ plane in the Fig. 10A and Fig. In 11A, the flap 100 is wing-shaped and has a hermetic interior S. As in Fig. As shown in Figure 3, the flap 100 comprises a base 1 as the first molded part in a lower area and a cover 2 as the second molded part in an upper area.

[0015] Base 1 has an outer surface 1a as its first outer surface, which faces outwards from the air outlet AP when the flap 100 closes the air outlet AP of the air conditioner AC. Thus, from the outside, the outer surface 1a of Base 1 serves as the outer surface of the flap 100, which is clearly visible to a user looking up at the air conditioner AC. In other words, the outer surface 1a of Base 1 serves as the design surface of the flap 100 from the perspective of the air conditioner AC user.

[0016] The cover 2 has a second outer surface 2a, which faces inwards from the air outlet AP when the flap 100 closes the air outlet AP of the air conditioner AC. The outer surface 2a of the cover 2 is thus less visible to the user looking up at the air conditioner AC and, viewed from the outside, serves as the back of the flap 100, onto which air from the air outlet AP is blown. In other words, using the position of the user's eye as the reference point, the outer surface 2a of the cover 2 acts as the control surface for the flap 100, which regulates the airflow exiting the air outlet AP.

[0017] As in Fig. As shown in Figure 3, a connecting element 3 is located between the base 1 and the cover 2, joining the base 1 and the cover 2. The connecting element 3 is a solidified bonding resin. In a top view, the connecting element 3 extends in a loop along the circumferences of the facing surfaces of the base 1 and the cover 2.

[0018] A process for manufacturing a molded body made from a resin, comprising two or more molded parts, is the DSI molding process. The DSI molding process reduces manufacturing costs and improves productivity when used to produce a molded part comprising multiple molded parts.

[0019] The DSI molding process is a method for producing a molded part that comprises a primary molding process, a mold sliding process, and a secondary molding process. In the primary molding process, molten casting resin injected into a mold solidifies, forming multiple parts. In the mold sliding process, the mold is moved to align the injection-molded parts. In the secondary molding process, a bonding resin extends along the circumferences of the facing parts, joining their outer surfaces.

[0020] In the secondary molding process, the molten bonding resin is injected into the mold through a parting line. The injected resin joins the outer surfaces of the multiple molded parts within the mold and solidifies to form a bonded element.

[0021] In other words, a molded part produced using ordinary DSI molds has an exterior surface where a connection area—a joining area between the multiple molded parts—and a connecting element made of solidified compound resin are exposed. This can affect the appearance of the molded part, which is visible to the user viewing it.

[0022] However, the bonding resin can be positioned offset inwards from the outer circumferences of the multiple molded parts. The bonding area between the multiple molded parts is thus located within the molded body. The bonding area and the bonding element are therefore not exposed on the outside.

[0023] However, if the joining area between the multiple molded parts is located within the molded body, the bonding state of the resin in the joining area is not visible. If the joining area between the multiple molded parts is not sufficiently filled with the resin, a bonding defect can occur at the insufficiently filled point. A bonding defect can weaken the connection between the multiple molded parts and thus reduce the mechanical strength of the molded body.

[0024] In particular, in the case of the molded body, which is the flap 100 with the airtight interior S, an area with a connection defect is a region where the interior S and the exterior are connected. The flap 100 therefore has an interior S with reduced airtightness.

[0025] If the flap 100 is washed with reduced airtightness, water penetrates the interior S of the flap 100 through the area with the connection defect. The water penetrating the interior S of the flap 100 promotes the growth of mold and bacteria. The flap 100 can therefore become a source of unpleasant odors and foreign matter.

[0026] Checking the connection status between the multiple molded parts requires destroying flap 100 and exposing the connection area to the outside.

[0027] The flap 100, as a molded body according to the present embodiment, has an outer surface on which the connection area between the base 1 and the cover 2 is not visible, and features a structure that allows non-destructive inspection of the connecting element 3 that joins the base 1 and the cover 2. The structure is described below.

[0028] First, base 1, which serves as the first molded part, is described. As in Fig. As shown in Figure 6, the base 1 has the shape of a thin and long box with an upper opening 1c. The base 1 comprises a first plate 11, which corresponds to a bottom plate of the flap 100, and a first connection 12, which corresponds to a side plate of the flap 100.

[0029] Base 1 is made from a new resin, specifically a raw synthetic resin, to give the outer surface 1a the desired appearance. More precisely, Base 1 is made from a raw acrylonitrile butadiene styrene (ABS) resin, which is durable and heat-resistant.

[0030] As in Fig. As shown in Figure 4, the outer surface 1a of the base 1 comprises, as the first outer surface, an outer surface 11a of the first plate 11 and an outer surface 12a of the first connection 12. As shown in Fig. As shown in Figure 6, an inner surface 1b of the base 1 comprises as the first inner surface an inner surface 11b of the first plate 11 and an inner surface 12b of the first connection 12.

[0031] The first plate 11 is rectangular when viewed in the negative Z direction and has an arc-shaped cross-section along the XZ plane in Fig. 10A, which protrudes in the middle in the negative Z direction.

[0032] The first connection 12 is connected to a second connection element 22 in the cover 2 with the connection element 3. The first connection 12 extends, viewed in the negative Z direction, along the edge of the inner surface 11b of the first plate 11 in a loop and extends in the positive Z direction.

[0033] The first connection 12 has a groove 4 at an end surface that comes into contact with the second connection 22 of the cover 2, which is described later. The groove 4 extends as shown in Fig. 6 shown, viewed in the negative Z direction, in a loop in one extension direction of the first connection 12 and is, as in Fig. 10B and Fig. 10C shown, recessed in the negative Z direction.

[0034] More precisely, the first connection 12 comprises an outer circumferential wall 41 and an inner circumferential wall 42, which is located within and parallel to the outer circumferential wall 41. The groove 4 is bounded between the outer circumferential wall 41 and the inner circumferential wall 42.

[0035] The outer circumferential wall 41 extends slightly further in the positive Z direction than the inner circumferential wall 42. In other words, the opening edge of the upper opening 1c is bounded by an upper end of the outer circumferential wall 41 and an upper end of the inner circumferential wall 42.

[0036] As described in detail later, the base 1 comprises form engagement area 5 on the outer surfaces 12a at both ends in the Y direction, as shown in the Fig. 5A and Fig. Figure 5B shows the form engagement areas 5. These areas comprise a first engagement area 51 on the outer surface 12a of a first outer wall 41L and a second engagement area 52 on the outer surface 12a of a second outer wall 41R. The first outer wall 41L and the second outer wall 41R are located at the two ends of the outer circumferential wall 41 of the first connection 12 in the Y direction.

[0037] The first engagement area 51 and the second engagement areas 52 are grooves extending in the X direction and recessed inwards into the base 1 in a cross-section along a YZ plane. The first engagement area 51 and the second engagement areas 52 engage with the mold to reduce shrinkage and deformation of the base 1 during the primary molding process and to allow the mold, moving during the mold sliding process, to hold the base 1.

[0038] As in Fig. As shown in Figure 6, the inner surface 1b of the base 1, or in other words, the inner surface 11b of the first plate 11, has no rib or recess for reinforcement or fitting. This structure is less susceptible to form defects such as joins and sink marks during the primary forming process. The base 1 can therefore have the outer surface 1a with an intended design.

[0039] Now, cover 2, which serves as the second molded part, will be described. As in Fig. As shown in Figure 7, the cover 2 has the shape of a thin and elongated lid. In plan view, the cover 2 has the same shape as the opening surface of the upper opening 1c of the base 1. More precisely, the cover 2 fits against the opening edge of the base 1 to close the upper opening 1c. The cover 2 includes a second plate 21 and the second connection 22.

[0040] Cover 2 is made from recycled resin, meaning it uses used resin to reduce manufacturing costs and environmental impact. More specifically, cover 2 is made from durable and heat-resistant recycled ABS resin.

[0041] The outer surface 2a of the cover 2 as the second outer surface corresponds to an outer surface 21a of the second plate 21. An inner surface 2b of the cover 2 as the second inner surface comprises an inner surface 21b of the second plate 21 and an inner surface 22b of the second connection 22.

[0042] The second plate 21 corresponds to an upper plate of the flap 100. The second plate 21 is rectangular when viewed in the negative Z direction and has a front end that is bent downwards in a cross-section along the XZ plane.

[0043] As described in detail later, the cover 2 includes a shrinkage-protection groove 6 on its outer surface 2a. The shrinkage-protection groove 6 extends along the edge of the outer surface 2a of the second plate 21 and is recessed in the negative Z-direction of the cover 2. In a top view of the cover 2, the shrinkage-protection groove 6 extends parallel to the first edge in the negative X-direction of the second plate 21 and to a second edge and a third edge at both ends in the Y-direction of the second plate 21. The shrinkage-protection groove 6 reduces shrinkage and deformation of the cover 2 during the primary molding process and enables the mold to retain the cover 2 during the mold sliding process.

[0044] As in the Fig. 8A and Fig. As shown in Figure 8B, the cover comprises two bearings 7, which are rotatably mounted on an opening-closing shaft at the opening edge of the air outlet AP of the air conditioner AC. More precisely, the bearings 7 comprise a first bearing 71 and a second bearing 72 on the second plate 21.

[0045] The first bearing 71 is located at one end of the outer surface 2a of the second plate 21 in the positive X-direction and positive Y-direction. The second bearing 72 is located at one end of the outer surface 2a of the second plate 21 in the positive X-direction and negative Y-direction.

[0046] The first bearing 71 has a bore 71a, and the second bearing 72 has a bore 72a. Bores 71a and 72a are through holes extending in the Y-direction of the flap 100. Bores 71a and 72a accommodate the opening / closing shaft in the air outlet AP of the air conditioning AC. In addition to their function as bearings, bearings 71 and 72 also reduce shrinkage and deformation of the cover 2 during the primary molding process and enable the mold to hold the cover 2 during the sliding molding process.

[0047] As in Fig. As shown in Figure 9, the second connection 22 is connected to the first connection 12 of the base 1 by the connecting element 3. The second connection 22 comprises a flange 81, which forms a circumference of the second plate 21, and a contact wall 82, which is located inside the flange 81.

[0048] When the cover 2 is attached to the opening edge of the base 1, the flange 81 closes the groove 4 at the first connection 12 and is in contact with the end face of the inner circumferential wall 42 of the first connection 12, as shown in the Fig. 10A to 10C are shown. Flange 81 is located inside the outer wall 41 of the first connection 12.

[0049] More precisely, when the cover 2 is fitted to the opening edge of the base 1, the groove 4 and the flange 81 define a space between the first connection 12 and the second connection 22. This space is filled with the connecting element 3. The space defined between the first connection 12 and the second connection 22 is referred to below as groove space 4S.

[0050] The contact wall 82 on the inner surface 21b of the second plate 21 extends parallel to the flange 81 and also extends downwards perpendicular to the longitudinal direction of the cover 2. The contact wall 82 is located directly below the shrink-protection groove 6.

[0051] When the cover 2 is fitted to the opening edge of the base 1, the contact wall 82 is in internal contact with the inner perimeter wall 42 of the first connection 12. The contact wall 82 is also located within the inner perimeter wall 42 of the first connection 12. The interior space S in the flap 100 is defined within the contact wall 82.

[0052] In other words, the first connection 12 and the second connection 22 divide the interior of the flap 100 into the interior space S, which makes up most of the space in the center of the flap 100, and the groove space 4S, which extends along the inner circumference of the flap 100 and surrounds an outer circumference of the interior space S.

[0053] The contact wall 82 reduces the probability that the pressure generated by injecting the bonding resin into the groove 4S during the secondary forming process will lead to deformation or collapse of the inner circumferential wall 42 or to leakage of the bonding resin from the groove 4S into the interior S.

[0054] As in the Fig. 11B and Fig. As shown in Figure 11C, the second connection 22 comprises gates 91 as openings connected to the groove 4, with the cover 2 attached to the opening edge of the base 1. Each gate 91 is formed by cutting a portion of the outer circumferential edge of the flange 81 of the second connection 22 into a rectangular shape, for example, a square shape.

[0055] More precisely, several gates 91 are formed at regular intervals in one direction of extension of the flange 81, along which the groove 4S extends. The gates 91 serve as injection openings through which the molten compound resin is injected into the groove 4S during the secondary molding process.

[0056] The second connection 22 includes windows 92 connected to the groove 4S, with the cover 2 fitted to the opening edge of the base 1. The windows 92 are rectangular openings, for example square openings, extending in the Z direction through the flange 81 as the perimeter of the second plate 21.

[0057] More precisely, the multiple windows 92, in a top view of the cover 2, are each equidistant from the adjacent gates 91 and arranged at regular intervals in the direction of extension of the flange 81. The windows 92 serve as viewing windows through which the bonding resin is visible, which fills the groove 4S between the adjacent gates 91 after it has been injected into the groove 4S through the gates 91 in the secondary molding process. Now, connecting element 3 will be described.

[0058] The connecting element 3 is formed from the molten joining resin, which has cooled and solidified in the groove 4S. The connecting element 3 extends along the edges of the base 1 and the cover 2 to join them. More precisely, the connecting element 3 joins the first connection 12 of the base 1 and the second connection 22 of the cover 2. More precisely, the connecting element 3 is formed when the joining resin fills the groove 4S through the gates 91 and solidifies integrally with the outer circumferential wall 41 and the inner circumferential wall 42 of the first connection 12 and the flange 81 in the second connection 22.

[0059] The connection area between base 1 and cover 2, connected to connecting element 3, extends along the edge inside the flap 100. The connection area between base 1 and cover 2, connected to connecting element 33, is not visible on the outside of the flap 100. The flap 100 can therefore have a desired appearance. The interior space S within the flap 100 is airtight. This airtight seal prevents water from entering the interior space S. The flap 100 is thus less susceptible to unpleasant odors and foreign matter. The interior space S provides thermal insulation and reduces condensation on the flap 100 caused by cooled air during operation of the air conditioning system (AC). The airtight interior space S can be filled with a heat-insulating gas. Argon gas is one example of a heat-insulating gas.The interior space S, filled with a heat-insulating gas, further improves the thermal insulation properties. The interior space S can also be filled with a heat-insulating material such as polyurethane.

[0060] The connector 3 is made from recycled resin, which is a used resin used to reduce manufacturing costs and environmental impact. More specifically, the connector 3 is made from durable and heat-resistant recycled ABS resin.

[0061] The connecting element 3, consisting of a bonding resin that has solidified after being poured into the groove 4S, is exposed through the windows 92 at the edge of the outer surface 2a of the cover 2. Thus, by simply visually checking whether the connecting element 3 is visible through the windows 92, it can be determined whether the groove 4S between the adjacent gates 91 is filled with the bonding resin.

[0062] In other words, the connecting element 3, which joins the base 1 and the cover 2, is visible without having to break the flap 100. The connection status between the base 1 and the cover 2 can therefore be easily checked.

[0063] The connecting element 3, exposed by the gates 91 and the windows 92, is flush with the outer surface 2a of the cover 2. In other words, the connecting element 3, exposed by the gates 91 and the windows 92, is part of the outer surface 2a of the cover 2. It is therefore unlikely that the flap 100 has a compromised design.

[0064] The following describes a method for manufacturing the flap 100 as a molded body. The method for manufacturing the flap 100 according to the present embodiment using a two-color molding machine comprises a DSI molding process that includes the primary molding process, the mold sliding process, and the secondary molding process, which are carried out sequentially. The primary forming process will now be described.

[0065] As in Fig. As shown in Figure 12A, the base 1 and the cover 2 are formed in the primary molding process by injection molding from the casting resin in a closed mold M. The mold M comprises a first mold M1, which is movable in the Z-direction, and a second mold M2, which is movable in both the Z- and Y-directions.

[0066] The first form M1 comprises a first cavity M11 for forming the outside of the base 1 and a second core M22 for forming the inside of the cover 2. The first cavity M11 and the second core M22 border a parting line between the first form M1 and the second form M2.

[0067] The second form M2 comprises a first core M12 for forming the interior of the base 1 and a second cavity M21 for forming the exterior of the cover 2. The first core M12 and the second cavity M21 border the parting line between the second form M2 and the first form M1 and face the first cavity M11 and the second core M22 of the first form M1.

[0068] The first cavity M11 includes engagement area forms M5 for forming the form engagement areas 5 of the base 1. The first core M12 includes a groove form M4, which forms the groove 4 on the base 1.

[0069] The second cavity M21 comprises a groove form (not shown) for forming the shrink-protection groove 6 on the cover 2 and bearing forms M7 for forming the bearings 7 in the cover 2. The second core M22 comprises a contact wall form (not shown) for forming the contact wall 82, gate forms (not shown) for forming the gates 91, and window forms (not shown) for forming the windows 92.

[0070] When the shape M is closed with this structure, a first cavity MS1 is bounded between the first cavity M11 and the first core M12, and a second cavity MS2 is bounded between the second cavity M21 and the second core M22.

[0071] The second mold M2 comprises a first gate SP1 and a second gate SP2. The first gate SP1 connects the first cavity MS1 to an injection channel of a first injection molding machine (not shown), which injects the casting resin as new resin. The second gate SP2 connects the second cavity MS2 to an injection channel of a second injection molding machine (not shown), which injects the casting resin as recycled resin.

[0072] The molten casting resin injected into the first cavity MS1 and the second cavity MS2 is cooled and solidifies. This creates the base 1 with the first plate 11 and the first connection 12, and the cover 2 with the second plate 21 and the second connection 22.

[0073] As the casting resin cools, it shrinks in volume. This can lead to deformation of the base 1 and the cover 2. More precisely, as it cools, the base 1 in the first cavity MS1 tends to shrink and deform in the direction from the first cavity M11 to the first core M12. The cover 2 in the second cavity MS2 also tends to shrink and deform in the direction from the second cavity M21 to the second core M22.

[0074] To reduce such shrinkage during forming, the base 1 is designed such that it has the first engagement area 51 and the second engagement areas 52 on the outer surface 12a of the first connection 12.

[0075] The first engagement area 51 and the second engagement areas 52 engage with the engagement area shapes M5 at the first cavity M11 during cooling. The base 1 is held in the first cavity M11, more precisely by the first shape M1 at both ends in the longitudinal direction, and shrinks less in the direction of the second shape M2. The base 1 therefore exhibits no deformation.

[0076] Similarly, the cover 2 includes the shrinkage protection groove 6 and the bearings 7 on the outer surface 2a. During cooling, the shrinkage protection groove 6 and the bearings 7 engage in the groove form (not shown) and the bearing forms M7 on the second cavity M21. The cover 2 is thus held in the second cavity M21, more precisely by the second form M2. The cover 2, held in the second form M2, shrinks less in the direction of the first form M1. The cover 2 therefore exhibits no deformation.

[0077] The following describes the form-sliding process. As in the Fig. 12B and Fig. As shown in Figure 12C, the second form M2 and the first form M1 move into their positions to align and fit the cover 2 and the base 1 together in the form-sliding process.

[0078] More precisely, the second form M2 moves parallel to the parting line between the second form M2 and the first form M1 in order to position the cover 2, held in the second cavity M21, over the base 1, held in the first cavity M11, as shown in Fig. 12C shown.

[0079] The first form M1 then moves perpendicular to the dividing surface between the first form M1 and the second form M2 to close the form, as shown in Fig. Figure 12D shows that the cover 2 and the base 1 are thus fitted together. The groove 4 at the first connection 12 of the base 1 is then closed with the second connection 22 of the cover 2.

[0080] The groove space 4S is thus bounded between the first connection 12 and the second connection 22. The interior space S is also bounded inwards by the first connection 12 and the second connection 22. The gates 91 and the windows 92 in the cover 2 are arranged to correspond to the groove 4 at the base 1, as shown in Fig. 3 shown.

[0081] Now the secondary forming process is described. As in Fig. As shown in Figure 13, in the secondary forming process the molten connecting element 3 is injected through the multiple gates 91 into the groove 4S using a spot-gating method to join the first connection 12 and the second connection 22, or in other words, the base 1 and the cover 2. Fig. The form is not shown in 13 for better understanding.

[0082] The mold further comprises a third mold with a connecting gate (not shown) through which the connecting element 3 is injected from a recycled resin. The second mold M2 also includes several sprue distributors M30, which are connected to the connecting gate in the third mold and through which the connecting resin flows.

[0083] The bonding resin from an injection molding machine flows through the joining gate and the gate distributors M30 and is then injected through each of the multiple gates 91 in the cover 2 into the groove 4S. The bonding resin injected through each gate 91 into the groove 4S flows in the direction of extension of the first joint 12 and the second joint 22.

[0084] The bonding resin flowing through the groove 4S joins the first connection 12 and the second connection 22 to form the solid connecting element 3. The bonding resin flowing through the windows 92 comes into contact with the second form M2 and is cooled to solidify. The parts of the connecting element 3 exposed through the windows 92 are thus flush with the outer surface 2a of the cover 2.

[0085] When the bonding resin flows through the groove 4S, the internal pressure in the groove 4S increases. This internal pressure acts on the inner circumferential wall 42 of the first connection 12, which delimits the groove 4S. This can lead to deformation or collapse of the inner circumferential wall 42, or to the bonding resin escaping from the groove 4S into the interior S.

[0086] However, the second connection 22 of the cover 2 includes the contact wall 82, which, as shown in the Fig. Figures 10A to 11C show that the inner circumferential wall 42 of the first connection 12 is in contact with the inner circumferential wall 42. The inner circumferential wall 42 thus exhibits improved stiffness. With this structure, the inner circumferential wall 42 does not deform or collapse, and the bonding resin does not leak from the groove 4S into the interior S. The bonding resin can therefore be stably distributed throughout the entire groove 4S.

[0087] The first form M1 and the second form M2 are then separated, and form M is opened. The in Fig. The flap 100 shown in Figure 2 is removed from the mold. The connecting element 3, made from the solidified bonding resin, is visually inspected to ensure that it is exposed through the windows 92 in the cover 2 of the flap 100. It is also determined whether the bonding resin completely fills the groove 4S.

[0088] If the connecting element 3 is visible through all of the multiple windows 92, the base 1 and the cover 2 are considered to be connected to the connecting element 3 without gaps. However, if the connecting element 3 is not visible through any of the multiple connecting windows 92, an area between the window and an adjacent window through which the connecting element is visible is considered a connection defect. Using the method for manufacturing the molded body according to the present embodiment, the flap 100 with the airtight interior S and the connection area not visible from the outside can be manufactured as described above. Design 2

[0089] In the Fig. 10B and Fig. The structure shown in Figure 10C comprises the base 1 as the first molded part, the groove 4, and the cover 2 as the second molded part, the contact wall 82. However, the structure with the groove 4 and the contact wall 82 is not limited to the example mentioned above. A specific example is described below.

[0090] In the present embodiment, a cover 2 has the shape of a thin and long box with an opening. As shown in the Fig. 14A and Fig. As shown in Figure 14B, a second connection 22 in the cover 2 includes a groove 4 at an end face which is in contact with a first connection 12 of a base 1.

[0091] An outer surface 2a of the cover 2 as a second outer surface comprises an outer surface 21a of a second plate 21 and an outer surface 22a of the second connection 22. An inner surface 2b of the cover 2 as a second inner surface comprises an inner surface 21b of the second plate 21 and an inner surface 22b of the second connection 22.

[0092] The second connection 22 extends in a loop along the edge of the inner surface 21b of the second plate 21 in a top view and extends in the negative Z direction. A groove 4 extends in a loop in a direction in which the second connection 22 extends in the positive Z direction and is recessed into the second connection 22 in the positive Z direction.

[0093] More precisely, the second connection 22 comprises an outer circumferential wall 41 and an inner circumferential wall 42, which is located within and parallel to the outer circumferential wall 41. The groove 4 is located between the outer circumferential wall 41 and the inner circumferential wall 42.

[0094] At the edge of the inner surface 21b of the second plate 21, the outer perimeter wall 41 extends slightly longer than the inner perimeter wall 42 in the negative Z-direction of the cover 2. In other words, the opening edge of the cover 2 is bounded by the end of the outer perimeter wall 41 in the Z-direction and the end of the inner perimeter wall 42 in the Z-direction. The base 1 is fitted to the opening edge of the cover 2.

[0095] An outer surface 1a of the base 1 as the first outer surface corresponds to an outer surface 11a of a first plate 11. An inner surface 1b of the base 1 as the first inner surface comprises an inner surface 11b of the first plate 11 and an inner surface 12b of the first connection 12.

[0096] The first connection 12 of the base 1 comprises a flange 81 as the edge of the first plate 11 and the contact wall 82, which is located inside the flange 81.

[0097] When the base 1 is attached to the opening edge of the cover 2, the flange 81 closes the groove 4 on the second connection 22 and is in contact with the end face of the inner circumferential wall 42 of the second connection 22. The flange 81 is located inside the outer circumferential wall 41 of the first connection 12. This defines a groove space 4S between the first connection 12 and the second connection 22.

[0098] The contact wall 82 extends parallel to the flange 81 and runs in the positive Z direction on the inner surface 11b of the first plate 11. The contact wall 82 is in contact with the inner circumferential wall 42 of the second connection 22 from the inside.

[0099] The second connection 22 also includes several gates 91 which are connected to the slot space 4S, as shown in Fig. 7 shown. The multiple gates 91 are formed at regular intervals in the direction in which the groove 4S extends, or in other words, in the direction of extension of the flange 81.

[0100] The second connection 22 includes windows 92 that are connected to the groove 4S. The multiple windows 92 are each equidistant from the adjacent gates 91 and are formed at regular intervals in the extension direction of the flange 81 in a top view of the cover 2.

[0101] The method for manufacturing the flap 100 with the base 1 and the cover 2 differs from the method for manufacturing the flap 100 according to embodiment 1 in the shape used in the primary forming process.

[0102] In other words, the second core M22 of the first mold M1 for forming the inner surface 2b of the cover 2 includes a groove shape (not shown) used to form the groove 4. The first core M12 of the second mold M2 for forming the inner surface 1b of the base 1 includes a contact wall shape (not shown) used to form the contact wall 82.

[0103] In the present embodiment, the bonding resin, which fills the groove 4S through the gates 91, connects the first connection 12 and the second connection 22 as in embodiment 1. In this case, the bonding area, in which the connecting element 3 joins the base 1 and the cover 2, extends along the edge inside the flap 100. The bonding area between the base 1 and the cover 2 is therefore not visible on the outside of the flap 100. The flap 100 can thus have a desired appearance. This structure also defines an airtight interior space S. The flap 100 is therefore less susceptible to unpleasant odors and foreign matter. The interior space S provides thermal insulation and reduces condensation on the flap 100 caused by cooled air during operation of the air conditioning system.The interior space S can be filled with a heat-insulating gas such as argon gas or a heat-insulating material such as polyurethane to further improve the heat insulation properties.

[0104] The connecting element 3 is visible through the windows 92 at the edge of the outer surface 2a of the cover 2. Thus, a simple visual inspection to determine whether the connecting element 3 is visible through the windows 92 can be used to ascertain whether the groove 4S between the adjacent gates 91 is filled with the connecting resin flowing through the gates 91.

[0105] In other words, the connecting element 3, which joins the base 1 and the cover 2, is visible without having to break the flap 100. The connection status between the base 1 and the cover 2 for the airtight interior S in the manufactured flap 100 can therefore be easily checked. embodiment 3

[0106] In the Fig. 5A and Fig. In the structure shown in Figure 5B, the form engagement areas 5 are formed longitudinally on the two end faces of the base 1. However, the form engagement areas 5 of the base 1 can also be arranged in other positions. A specific example is described below.

[0107] As in Fig. As shown in Figure 15, the form engagement areas 5 in the present embodiment comprise a first engagement area 53 and a second engagement area 54 on an outer surface 12a of a base 1 at both ends in the X direction.

[0108] An outer perimeter wall 41 of a first connection 12 comprises a third outer wall 41F and a fourth outer wall 41B at both ends in the X direction. The first engagement area 53 is a groove on the outer surface 12a of the third outer wall 41F. The second engagement area 54 is a groove on the outer surface 12a of the fourth outer wall 41B. The first engagement area 53 and the second engagement area 54 extend in the Y direction of the base 1 and are recessed into the base 1 in a cross-section along the XZ plane.

[0109] A method for manufacturing the flap 100 with the base 1, which has the aforementioned mold engagement areas 5 on the outer surface 1a, differs from the method for manufacturing the flap 100 according to embodiment 1 in the mold used in the primary molding process. In other words, the first cavity M11 for molding the outer surface 1a of the base 1 includes engagement area molds (not shown) to form the mold engagement areas 5 of the base 1 at the front and rear.

[0110] In the present embodiment, the mold engagement areas 5 also engage with the mold engagement areas (not shown) on the first cavity M11 during cooling in the primary molding process, as in embodiment 1. In other words, the base 1 is held in the first cavity M11, with the first engagement area 53 located on the third outer wall 41F and the second engagement area 54 on the fourth outer wall 41B of the outer circumferential wall 41.

[0111] In particular, the form engagement areas 5 in the present embodiment are longer than those in embodiment 1. The base 1 and the first form are therefore in contact over a larger area. Furthermore, the base 1 is less prone to shrinking towards the second form M2. The base 1 thus exhibits no deformation. Design 4

[0112] In the Fig. 5A and Fig. In the structure shown in Figure 5B, the form engagement areas 5 are grooves recessed inwards along the longitudinal direction of the base 1. However, the form engagement areas 5 are not limited to grooves. A specific example is described below.

[0113] As in the Fig. 16A and Fig. As shown in Figure 16B, the form engagement areas 5 in the present embodiment comprise a projecting first engagement area 55 and projecting second engagement areas 56 on the outer surfaces of a base 1 at both ends in the Y direction.

[0114] More precisely, a first connection 12 comprises an outer perimeter wall 41 with a first outer wall 41L and a second outer wall 41R at both ends in the Y direction. The first engagement area 55 is a projection extending outwards from the outer surface of the first outer wall 41L. The second engagement areas 56 are projections extending outwards from the outer surface of the second outer wall 41R. The first engagement area 55 and the second engagement areas 56 extend in the X direction of the base 1 and project outwards from the base 1 in a cross-section along the YZ plane.

[0115] A method for manufacturing the flap 100 with the base 1, which has the aforementioned form engagement areas 5 on the outer surface 1a, differs from the method for manufacturing the flap 100 according to embodiment 1 in the mold used in the primary forming process. In other words, the engagement area shapes (not shown) on the first cavity M11 for forming the outer surface 2a of the base 1 are designed as grooves recessed in the first mold.

[0116] In the present embodiment, as in embodiment 1, the form engagement areas 5 engage in the engagement area forms (not shown) on the first cavity M11 during the primary forming process. In other words, the base 1 is held in the first form M1, with the first engagement area 55 located on the first outer wall 41L and the second engagement areas 56 on the second outer wall 41R of the outer circumferential wall 41. The base 1 held in the first form M1 is less prone to shrinking towards the second form M2. The base 1 thus exhibits no deformation.

[0117] Although the embodiments have been described above, the present disclosure is not limited to these embodiments and may be modified as described below.

[0118] In the Fig. 2 and Fig. In the structure shown in Figure 3, the molded body according to the present embodiment is the flap 100, which comprises the base 1, the cover 2, and the connecting element 3. However, the molded body is not limited to the flap 100 and can be any molded body formed from a resin, including the first molded part with outer surface 1a as the surface of the molded body, the second molded part with outer surface 2a as the back of the molded body, and the connecting element 3, which joins the inner circumferences of the first and second molded parts. The molded body can, for example, be a drain pipe forming a flow path, a toner container for a printer, or a figure, such as a character figure or a toy vehicle. In other words, the molded body may or may not have the interior S, or it may have the interior S that is not airtight and is open to the outside.

[0119] The molded body comprises the first molded part and / or the second molded part and can include three or more molded parts. The molded body can be produced by joining several molded parts, for example, a third molded part joined to the second molded part and a fourth molded part joined to the third molded part.

[0120] In the present embodiment, the base 1 is formed as the first molded part from a new resin, i.e., an unused resin, and the cover 2 as the second molded part and the connecting element 3 are formed from a recycled resin, i.e., a used resin. However, the base 1, the cover 2, and the connecting element 3 can also be formed from other materials.

[0121] For example, the base material 1 is intended to create the outer surface 1a with a desired appearance and can be made from recycled resin or a bio-based resin that is biologically derived and costs less than virgin resin. The cover 2 and the connecting element 3 can also be made from virgin resin or a bio-based resin that is biologically derived. The bio-based resin is produced from plant-based carbon sources, such as sugar or starch, which are derived from plants like corn, sugarcane, or sugar beets. The cover 2 and the connecting element 3 made from a bio-based resin are environmentally friendly because they reduce, for example, carbon dioxide emissions or the use of synthetic resins derived from fossil fuels.

[0122] Although the base 1, the cover 2, and the connecting element 3 are formed from an ABS resin according to the present embodiment, they could, for example, be formed from nylon or polypropylene. However, the ABS resin can be used to ensure thermal resistance and durability.

[0123] In the Fig. 6, Fig. 11B and Fig. The structure shown in Figure 11C includes only the first connection 12 of the base 1 with the groove 4, while the second connection 22 of the cover 2 does not include a groove 4. In the Fig. 14A and Fig. In the structure shown in Figure 14B, the second connection 22 of the cover 2 includes the groove 4, and the first connection 12 of the base 1 does not include groove 4. As shown in Fig. As shown in Figure 17, both the first connection 12 and the second connection 22 can each have the groove 4 to define a groove space 4S between the first connection 12 and the second connection 22, which are in contact with each other. The connecting element 3 is located in the groove space 4S. In the structure comprising the first connection 12 and the second connection 22, each having the groove 4, the probability of leakage of the connecting resin is lower than in the structure in which either the first connection 12 or the second connection 22 has the groove 4.

[0124] In the Fig. The structure shown in Figure 7 comprises several gates 91 through which molten compound resin is injected. Each gate is formed by cutting a portion of the outer circumferential edge of the flange 81 into a square shape in plan view and is arranged at regular intervals along the extension of the flange 81. The gates 91, which are connected to the grooves 4 and spaced such that the compound resin flows in the groove space 4S between the gates, can, however, be any number of gates with any shape and spacing.

[0125] In the Fig. In the structure shown in Figure 7, the second connection 22 of the cover 2 has windows 92 through which the connecting element 3 is exposed. In the molded body made of a transparent resin, the connecting element 3 is visible in the groove 4S, and the windows 92 can be omitted.

[0126] In the Fig. In the structure shown in Figure 7, the multiple windows 92 are square openings in plan view, extending in the Z-direction through the edge of the second plate 21 and each equidistant from the adjacent gates 91. The windows 92, formed at positions based on the flowability of the molten compound resin flowing from one position of each gate 91 into the groove 4S between adjacent gates 91, can, however, have any number of windows of any shape. Two or more windows 92 can be arranged between adjacent gates 91, or each window 92 can be circular, elliptical, or rectangular, as shown in the figures. Fig. 18 and Fig. 19 shown in a top view.

[0127] In the Fig. In the structure shown in Figure 3, the connecting element 3, which connects the first connection 12 of the base 1 and the second connection 22 of the cover 2, is the solidified connecting resin. However, the connecting element 3, which is located in the groove 4S between the first connection 12 and the second connection 22 and connects the first connection 12 and the second connection 22, is not limited to being formed from a resin, but can also be formed from an inorganic silicone material.

[0128] In the Fig. In the structure shown in Figure 7, the shrinkage protection groove 6 is formed as the second molded part on the outer surface 2a of the cover 2. However, the shrinkage protection groove 6 can also be formed as the first molded part on the outer surface 1a of the base 1 without affecting the appearance.

[0129] The flap as a molded part according to the above-mentioned embodiments is not limited to a part installed on the air outlet of an air conditioner, but can be any part that shields the interior from outside light while maintaining ventilation, such as a blind installed on a window or the front of a shelf with storage space inside.

[0130] In the structure described in the embodiments mentioned above, the multiple gates 91 are arranged at regular intervals in the direction of extension of the flange 81. However, the adjacent gates 91 can also be arranged at irregular intervals instead of at regular intervals.

[0131] In the structure described in the embodiments mentioned above, the multiple windows 92 are each equidistant from the adjacent gates 91 and arranged at regular intervals in the direction of extension of the flange 81. However, the adjacent windows 92 can also be arranged at irregular intervals instead of at regular intervals.

[0132] This application claims priority over Japanese patent application No. 2023-122846, filed on July 27, 2023, the entire disclosure of which is incorporated herein by reference.

[0133] The following section provides a supplementary description of various aspects of the present revelation. Annex 1

[0134] Resin molds the molded body comprises: a first molded part comprising a first outer surface which is a front face of the molded body, a first inner surface within the molded body and a first connection extending along an edge of the first inner surface; a second molded part with a second outer surface, which is a back side of the molded body, a second inner surface within the molded body, and a second connection extending along an edge of the second inner surface and in contact with the first connection; and a connecting element between the first connection and the second connection, wherein the first connection and / or the second connection has a groove on a surface that is in contact with another of the first connection or the second connection, the groove extending in a direction in which the first connection and / or the second connection extends, wherein the second connection has an opening connected to the groove, and wherein the connecting element is inserted through the opening into the groove and connects the first connection and the second connection. Appendix 2

[0135] Molded bodies according to Annex 1, wherein the molded body is a flap for opening or closing an air outlet of an air conditioning system, and where the first outer surface of the air outlet faces outwards when the flap closes the air outlet. Appendix 3

[0136] Molded bodies according to Annex 1 or 2, wherein the first connection and / or the second connection comprises an outer perimeter wall and an inner perimeter wall which is arranged within the outer perimeter wall, and the groove is arranged between the outer perimeter wall and the inner perimeter wall. Appendix 4

[0137] Molded bodies according to Annex 3, wherein the other of the first connection or the second connection comprises a contact wall which is in contact with the inner circumferential wall of inside the first connection and / or the second connection when the first connection and the second connection are in contact with each other. Appendix 5

[0138] Molded body according to one of Annexes 1 to 4, wherein the second connection has a plurality of openings arranged in a direction in which the groove extends. Appendix 6

[0139] Molded body according to one of Annexes 1 to 5, the second connection has a window through which the connecting element is exposed in the groove. Appendix 7

[0140] Molded body according to one of Annexes 1 to 6, wherein the first molded part comprises a new resin, which is a previously unused synthetic resin, and wherein the second molded part and the connecting element comprise a recycled resin, which is a used resin, or a bio-based resin, which is a biologically derived resin. Appendix 8

[0141] Molded body according to one of Annexes 1 to 7, wherein the molded body is a flap for opening or closing an air outlet of an air conditioning system, wherein the first molded part is a base that includes the first outer surface facing outwards from the air outlet when the flap closes the air outlet, wherein the second molded part is a cover that includes the second outer surface, which faces inwards from the air outlet when the flap closes the air outlet, and wherein the cover on the second outer surface includes a bearing which is rotatably mounted on an opening-closing shaft at an opening edge of the air outlet. Appendix 9

[0142] Molded body according to one of Annexes 1 to 8, wherein the molded body comprises an interior space bounded by the first connection and the second connection, and the interior is hermetically sealed with the connecting element. Appendix 10

[0143] Molded bodies according to Annex 9, wherein the molded body includes a heat-insulating gas in the interior. Annex 11

[0144] Air conditioning, comprehensive: the flap, which is the molded body according to Annex 8. Appendix 12

[0145] Method for producing a shaped body, the procedure includes: Forming a first molded part with a first joint and a second molded part with a second joint by injecting a molten casting resin into a mold comprising a first mold and a second mold, and allowing the molten casting resin to solidify. wherein the first connection and / or the second connection has a groove on a surface of the first connection and / or the second connection, where the surface is facing either the first or the second connection, the second connection has an opening, wherein the first mold part is held in the first mold and the second mold part is held in the second mold; Moving the first mold or the second mold into a position in which the first mold part held in the first mold and the second mold part held in the second mold are facing each other, and joining the first mold part and the second mold part to connect the groove and the opening; and The first connection and the second connection are joined by filling the groove with a molten joining resin through the opening and allowing the molten casting resin to solidify. Appendix 13

[0146] Procedure according to Annex 12, wherein the forming includes forming the first mold part, which has a forming engagement area on an outer surface of the first mold part that can be brought into engagement with the first mold, and wherein the first molded part is held in the first mold with the mold engagement area. Appendix 14

[0147] Procedure according to Annex 12 or 13, wherein the forming includes forming the second mold part which has a shrinkage protection groove on an outer surface of the second mold part to reduce shrinkage during forming. Reference symbol list 100 flaps (molded bodies) 1 Base (first molded part) 1a Exterior surface (first exterior surface) 1b Inner surface (first inner surface) 1c upper opening 11 first record 11a Outdoor area 11b Interior surface 12 first connection 12a Outdoor area 12b Interior surface 2 Cover (second molded part) 2a Exterior surface (second exterior surface) 2b Inner surface (second inner surface) 21 second record 21a Outdoor area 21b Interior surface 22 second connection 22a Outdoor area 22b Interior surface 3 Connecting element 4 groove 41 Outer perimeter wall 41L first exterior wall 41R second exterior wall 41F third exterior wall 41B fourth exterior wall 42 Inner perimeter wall 4S slot space 5 Mold engagement area 51, 53, 55 first intervention area 52, 54, 56 second intervention area 6 shrink protection groove 7 warehouses 71 first camp 72 second camp 71a, 72a Borehole 81 Flange 82 contact wall 91 Gate (opening) 92 windows M Form M1 first form M2 second form M11 first cavity M12 first core M21 second cavity M22 second core M30 connection distributor M4 groove shape M5 Intervention area shape M7 bearing type S interior AC air conditioning AP air outlet QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] JP 62 - 087 315 ​​

[0005] JP 2023-122846

[0132]

Claims

[1] Resin molded body, the molded body comprising: a first molded part comprising a first outer surface which is a front face of the molded body, a first inner surface within the molded body and a first connection extending along an edge of the first inner surface; a second molded part with a second outer surface, which is a back side of the molded body, a second inner surface within the molded body and a second connection extending along an edge of the second inner surface and in contact with the first connection; and a connecting element between the first connection and the second connection, where the first connection and / or the second connection is on a surface, which is in contact with another of the first connection or the second connection, has a groove extending in a direction in which the first connection and / or the second connection extends, wherein the second connection has an opening connected to the groove, and wherein the connecting element is inserted through the opening into the groove and connects the first connection and the second connection. [2] Molded body according to claim 1, wherein the molded body is a flap for opening or closing an air outlet of an air conditioning system, and where the first outer surface of the air outlet faces outwards when the flap closes the air outlet. [3] Molded body according to claim 1 or 2, wherein the first connection and / or the second connection comprises an outer perimeter wall and an inner perimeter wall which is arranged within the outer perimeter wall, and the groove is arranged between the outer perimeter wall and the inner perimeter wall. [4] Molded body according to claim 3, wherein the other of the first connection or the second connection comprises a contact wall which is in contact with the inner circumferential wall from within the first connection and / or the second connection when the first connection and the second connection are in contact with each other. [5] Molded body according to any one of claims 1 to 4, wherein the second connection has a plurality of openings arranged in a direction in which the groove extends. [6] Molded body according to any one of claims 1 to 5, wherein the second connection has a window through which the connecting element is exposed in the groove. [7] Molded body according to any one of claims 1 to 6, wherein the first molded part comprises a new resin, which is a previously unused synthetic resin, and wherein the second molded part and the connecting element comprise a recycled resin, which is a used resin, or a bio-based resin, which is a biologically derived resin. [8] Molded body according to any one of claims 1 to 7, wherein the molded body is a flap for opening or closing an air outlet of an air conditioning system, wherein the first molded part is a base that includes the first outer surface facing outwards from the air outlet when the flap closes the air outlet, wherein the second molded part is a cover that includes the second outer surface, which faces inwards from the air outlet when the flap closes the air outlet, and wherein the cover on the second outer surface includes a bearing which is rotatably mounted on an opening-closing shaft at an opening edge of the air outlet. [9] Molded body according to any one of claims 1 to 8, wherein the molded body comprises an interior space bounded by the first connection and the second connection, and the interior is hermetically sealed with the connecting element. [10] Molded body according to claim 9, wherein the molded body comprises a heat-insulating gas in the interior. [11] Air conditioning, comprehensive: the flap, which is the molded body according to claim 8. [12] Method for producing a shaped body, the method comprising: Forming a first molded part with a first joint and a second molded part with a second joint by injecting a molten casting resin into a mold comprising a first mold and a second mold, and allowing the molten casting resin to solidify. wherein the first connection and / or the second connection has a groove on a surface of the first connection and / or the second connection, where the surface faces either the first connection or the second connection, the second connection has an opening, wherein the first mold part is held in the first mold and the second mold part is held in the second mold; Moving the first mold or the second mold into a position in which the first mold part held in the first mold and the second mold part held in the second mold are facing each other, and joining the first mold part and the second mold part to connect the groove and the opening; and Connecting the first connection and the second connection by filling the groove with a molten bonding resin through the opening and Allowing the molten casting resin to solidify. [13] Method according to claim 12, wherein the forming includes forming the first mold part, which has a forming engagement area on an outer surface of the first mold part that can be brought into engagement with the first mold, and wherein the first molded part is held in the first mold with the mold engagement area. [14] Method according to claim 12 or 13, wherein the forming comprises forming the second mold part which has a shrinkage protection groove on an outer surface of the second mold part to reduce shrinkage during forming.

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