Vehicle air conditioning unit case

Abstract

To provide an air conditioner case for a vehicle which enables an intended place to be highly expanded at low cost with a simple configuration.SOLUTION: A gate part 10 is a part where a molten resin containing an expanding agent is injected in expansion molding. In a first resin part 11, a part connected to the gate part 10 extends in a direction crossing a direction at which the molten resin is injected to the gate part 10. In a second resin part 12, the part connected to the first resin part 11 extends in a direction crossing a direction in which the first resin part 11 extends. In an air conditioner case for a vehicle, plate thickness T2 of the second resin part 12 is larger than plate thickness T1 of the first resin part 11, and a total volume occupied in air bubbles per unit volume in the second resin part 12 is larger than the total volume occupied in air bubbles per unit volume in the first resin part 11.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a case for an air conditioner mounted in a vehicle. [Background technology]

[0002] Conventionally, in vehicle air conditioning device cases, in order to prevent poor fitting between products due to sinks and warping of resin products, as well as abnormal noise and increased pressure loss due to changes in air flow inside the case, support ribs have been provided inside the case or filler has been filled into the resin. However, providing support ribs inside the case can cause changes in air flow, abnormal noise, increased pressure loss, etc. Furthermore, filling the resin with filler can increase the weight of the case, which may lead to a deterioration in fuel efficiency.

[0003] Therefore, it is considered that sink marks and warpage of resin products can be improved by foam molding the vehicle air conditioner case. However, foam molding can cause uneven foam distribution within the product or foam distribution in unintended places within the product. In such cases, the physical properties change in unintended places within the product, and if the physical properties originally intended for the material cannot be obtained, there is a risk that the structural design of the vehicle air conditioner and product functions such as vibration transmission will be affected.

[0004] Patent Document 1 describes a foam molding method that is applied to vehicle air conditioning device cases and the like. In the foam molding method described in Patent Document 1, when there are multiple resin filling parts with different resin flow distances in a mold, the timing of opening multiple gates that supply molten resin to each of the multiple resin filling parts is controlled to be different. Specifically, a first gate that supplies molten resin to a resin filling part with a long distance is opened, and after a predetermined time has elapsed, a second gate that supplies molten resin to a resin filling part with a short distance is opened. In this way, Patent Document 1 makes the pressure of the molten resin supplied to each of the multiple resin filling parts uniform, improving the problem of foaming not progressing in the resin filling parts with a short distance. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 4269879 Summary of the Invention [Problem to be solved by the invention]

[0006] However, even with the foam molding method described in Patent Document 1, it is difficult to control the variation in foam distribution in each region in the product just by controlling the timing of opening multiple gates, and the cost of introducing equipment is also high. Furthermore, it is not possible to achieve high foaming in intended locations in the product just by controlling the opening and closing of multiple gates, as in the foam molding method described in Patent Document 1.

[0007] In view of the above, an object of the present invention is to provide an air-conditioning unit case for a vehicle that is capable of achieving high foaming at desired locations with a simple structure and at low cost. [Means for solving the problem]

[0008] In order to achieve the above object, the present invention relates to a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin portion (12) whose portion connected to the first resin portion extends in a direction intersecting the direction in which the first resin portion extends; a neighboring recess (13) provided in a portion of the first resin portion adjacent to the second resin portion on a side closer to the gate portion; The plate thickness (T2) of the second resin portion is formed to be larger than the plate thickness (T1) of the first resin portion, a plate thickness (T3) of a portion of the first resin portion where the adjacent recess is provided is formed smaller than a plate thickness (T1) of a portion of the first resin portion closer to the gate portion than the adjacent recess; The total volume occupied by air bubbles per unit volume in the second resin portion is larger than the total volume occupied by air bubbles per unit volume in the first resin portion. The invention according to claim 2 is a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin portion (12) whose portion connected to the first resin portion extends in a direction intersecting the direction in which the first resin portion extends; an opposite surface recess (14) provided on a surface (11e) of the first resin portion opposite to a surface (11d) on which the second resin portion is provided at a connection portion between the first resin portion and the second resin portion; The plate thickness (T2) of the second resin portion is formed to be larger than the plate thickness (T1) of the first resin portion, a distance (T4) between a surface of the first resin portion on the side where the second resin portion is provided and a surface of the opposite surface recess is formed to be smaller than a plate thickness of the first resin portion; The total volume occupied by air bubbles per unit volume in the second resin portion is larger than the total volume occupied by air bubbles per unit volume in the first resin portion. The invention according to claim 3 is a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin portion (12) whose portion connected to the first resin portion extends in a direction intersecting the direction in which the first resin portion extends; a first curved surface portion (15) provided on a side of a corner portion where the first resin portion and the second resin portion are connected, the side being closer to the gate portion; a second curved surface portion (16) provided on a corner portion where the first resin portion and the second resin portion are connected, the second curved surface portion being located on a side farther from the gate portion; The plate thickness (T2) of the second resin portion is formed to be larger than the plate thickness (T1) of the first resin portion, The radius of curvature (R1) of the first curved surface portion is smaller than the radius of curvature (R2) of the second curved surface portion, The total volume occupied by air bubbles per unit volume in the second resin portion is larger than the total volume occupied by air bubbles per unit volume in the first resin portion. The invention according to claim 4 is a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) whose portion connected to the first resin part extends in a direction intersecting the direction in which the first resin part extends, The plate thickness (T2) of the second resin portion is formed to be larger than the plate thickness (T1) of the first resin portion, the second resin portion has a shape in which the plate thickness gradually decreases as the distance from the first resin portion increases; the total volume occupied by air bubbles per unit volume in the second resin portion is larger than the total volume occupied by air bubbles per unit volume in the first resin portion, The total volume occupied by air bubbles per unit volume at a root portion (12a) of the second resin portion that is close to the first resin portion is greater than the total volume occupied by air bubbles per unit volume at a tip portion (12b) of the second resin portion that is far from the first resin portion.

[0009] According to this, when the molten resin containing the foaming agent injected from the gate into the first resin part in the mold during foam molding flows from the first resin part into the second resin part, a sudden reduction in pressure occurs due to the sudden expansion of the space in the mold, and foaming of the foaming agent contained in the molten resin in the second resin part is promoted. Therefore, the total volume occupied by air bubbles per unit volume in the second resin part is larger than the total volume occupied by air bubbles per unit volume in the first resin part. Therefore, this vehicle air conditioner case can achieve high foaming at the intended location (i.e., the second resin part) at low cost by a simple configuration in which the plate thickness of the second resin part is made larger than the plate thickness of the first resin part. As a result, it is possible to suppress sinks and warpage in the intended location (i.e., the second resin part) and improve heat insulation.

[0010] Note that the reference symbols in parentheses attached to each component indicate an example of the correspondence between the component and specific components described in the embodiments described below. [Brief description of the drawings]

[0011] [Figure 1] 1 is a perspective view of a vehicle air conditioning device case according to a first embodiment. FIG. [Diagram 2] 1 is a perspective view of a component that constitutes a vehicle air-conditioning device case according to a first embodiment. FIG. [Diagram 3] 1 is a cross-sectional view of a portion of a vehicle air-conditioning device case according to a first embodiment. [Figure 4] 1 is a cross-sectional view that diagrammatically shows a portion of a vehicle air-conditioning device case according to a first embodiment. [Diagram 5] FIG. 5 is a cross-sectional view that shows a schematic diagram of a mold for foam-molding the portion shown in FIG. 4. [Figure 6] 3 is a cross-sectional view that diagrammatically shows a portion of a vehicle air-conditioning device case of a first comparative example. FIG. [Figure 7] FIG. 11 is a cross-sectional view that shows a schematic view of a portion of a vehicle air-conditioning device case of a second comparative example. [Figure 8] 5 is a cross-sectional view that illustrates a schematic view of a portion of a vehicle air-conditioning device case according to a modified example of the first embodiment. FIG. [Figure 9] FIG. 6 is a cross-sectional view that illustrates a schematic view of a portion of an air-conditioning device case for a vehicle according to a second embodiment. [Figure 10] 13 is a cross-sectional view that illustrates a schematic view of a portion of a vehicle air-conditioning device case according to a modified example of the second embodiment. FIG. [Figure 11] FIG. 11 is a cross-sectional view that shows a schematic view of a part of a vehicle air-conditioning device case according to a third embodiment. [Figure 12] FIG. 11 is a cross-sectional view that shows a schematic view of a part of a vehicle air-conditioning device case according to a fourth embodiment. [Figure 13] FIG. 11 is a cross-sectional view that shows a schematic view of a part of a vehicle air-conditioning device case according to a fifth embodiment. [Figure 14] FIG. 11 is a perspective view of the bottom of a vehicle air conditioner case of a third comparative example. [Figure 15] FIG. 11 is a cross-sectional view that illustrates a portion of a vehicle air-conditioner case of a third comparative example. [Figure 16]FIG. 13 is a cross-sectional view that diagrammatically shows a portion of a vehicle air-conditioning device case according to a sixth embodiment. [Figure 17] FIG. 13 is a cross-sectional view that illustrates a part of a vehicle air-conditioning device case according to a modified example of the sixth embodiment. [Figure 18] FIG. 13 is a cross-sectional view that illustrates a part of a vehicle air-conditioning device case according to a seventh embodiment. [Figure 19] FIG. 11 is a cross-sectional view that diagrammatically shows a portion of a vehicle air-conditioner case of a fourth comparative example. [Figure 20] FIG. 13 is a cross-sectional view that illustrates a part of a vehicle air-conditioning device case according to a modified example of the seventh embodiment. [Figure 21] FIG. 13 is a cross-sectional view that diagrammatically shows a portion of a vehicle air-conditioning device case according to an eighth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following embodiments, modifications, and comparative examples, the same or equivalent parts are denoted by the same reference numerals, and the description thereof will be omitted.

[0013] (First embodiment) The first embodiment will be described with reference to the drawings. As shown in Fig. 1, a vehicle air conditioner case 1 (hereinafter simply referred to as "air conditioner case 1") of this embodiment is a housing of an air conditioner mounted on a vehicle. The air conditioner case 1 includes a blower unit case 2 and an air conditioner unit case 3. The air conditioner is configured to blow air sucked in by driving a blower (not shown) provided inside the blower unit case 2 into an air passage in the air conditioner unit case 3, and to blow conditioned air whose temperature and humidity have been adjusted by a heat exchanger (not shown) provided in the air passage in the air conditioner unit case 3 into the vehicle interior.

[0014] The air conditioning unit case 3 is configured by fitting together various parts such as a right case 4, a center case 5, and a left case 6. FIG. 2 is a perspective view of the right case 4 as seen from inside the air conditioning unit case 3. As shown in FIG. 2, the right case 4 is provided with ribs 7, 8, 9, etc. for supporting an air cooling heat exchanger (not shown) and an air heating heat exchanger (not shown). The ribs at various locations, including the ribs 7, 8, 9 provided in the ventilation passage of the air conditioning case 1, are required to have high dimensional accuracy in order to prevent abnormal noise caused by changes in air flow and poor assembly of the heat exchanger. For this reason, the air conditioning case 1 of this embodiment includes the ribs 7, 8, 9, and further prevents the occurrence of shrinkage and warpage in all ribs that may cause abnormal noise or lead to poor assembly of the air conditioning case 1 by foam molding.

[0015] Foam molding is a method of forming a foam by injecting molten resin containing a foaming agent into a mold. For example, supercritical foam molding can be used as foam molding. Supercritical foam molding is a method of injecting carbon dioxide gas in a supercritical state as a foaming agent into a heated and melted thermoplastic resin material, melting it, and injecting it into a mold to form a resin product with bubbles. Note that a resin material (e.g. polypropylene) that has a certain degree of elasticity and excellent strength is used as the thermoplastic resin material.

[0016] Fig. 3 is a cross-sectional view of a portion of the air-conditioning case 1, and Fig. 4 is a cross-sectional view that typically shows a portion of the air-conditioning case 1. In Fig. 4, hatching that indicates a cross section has been omitted in order to make the drawing easier to see. This also applies to Figs. 5 to 13 and 15 to 21 that are referred to in each embodiment, each modified example, and each comparative example described later.

[0017] As shown in Figures 3 and 4, the air conditioning case 1 includes a gate portion 10, a first resin portion 11, and a second resin portion 12. The first resin portion 11 and the second resin portion 12 shown in Figure 4 may have curved and bent portions therebetween, as shown in Figures 2 and 3. This is the same for each of the embodiments, modified examples, and comparative examples described below.

[0018] The gate portion 10 is a portion into which molten resin containing a foaming agent is injected during foam molding. During foam molding, molten resin containing a foaming agent is injected into the gate portion 10 from the direction indicated by the arrow IN in Figs. 3 and 4. Therefore, traces of the injected molten resin remain on the gate portion 10. Note that the air-conditioning case 1 may include multiple gate portions 10 within the product. In this case, in this embodiment, the gate portion 10 refers to the gate portion 10 that supplies molten resin to the target second resin portion 12 via the first resin portion 11.

[0019] The first resin part 11 has a portion connected to the gate part 10 that extends in a direction intersecting the direction in which the molten resin is injected into the gate part 10 (in this embodiment, a direction substantially perpendicular). In this specification, "substantially perpendicular" includes a range of, for example, 80° to 100° in addition to 90°. The first resin part 11 is a part that mainly constitutes the outer contour of the air-conditioning case 1, and is also called a general part.

[0020] The second resin part 12 has a portion connected to the first resin part 11 extending in a direction intersecting the direction in which the first resin part 11 extends (in this embodiment, substantially perpendicular). The second resin part 12 is a portion that is mainly used as ribs 7, 8, 9, etc. for supporting a heat exchanger inside the air conditioning case 1. In this embodiment, high dimensional accuracy is required for this second resin part 12. Therefore, compared with the first resin part 11, the second resin part 12 is highly foamed. In other words, the total volume occupied by air bubbles per unit volume in the second resin part 12 is larger than the total volume occupied by air bubbles per unit volume in the first resin part 11. This makes it possible to suppress sink marks and warping in the second resin part 12. In FIG. 4, the highly foamed portion of the product is surrounded by a dashed line marked with the symbol HF. This is the same in each embodiment, each modified example, and each comparative example described later.

[0021] Here, as shown in FIGS. 3 and 4, let the plate thickness of the gate portion 10 be Tg, the plate thickness of the first resin portion 11 be T1, and the plate thickness of the second resin portion 12 be T2. At this time, in the present embodiment, the relationship of Tg > T1 and T1 < T2 is satisfied. That is, the plate thickness T1 of the first resin portion 11 is smaller than the plate thickness Tg of the gate portion 10. Also, the plate thickness T2 of the second resin portion 12 is larger than the plate thickness T1 of the first resin portion 11. In this specification, the relationship of Tg > T1 and T1 < T2 means that the differences between the plate thickness Tg of the gate portion 10, the plate thickness T1 of the first resin portion 11, and the plate thickness T2 of the second resin portion 12 are larger than the manufacturing tolerance. As will be described later, in order to generate a rapid pressure reduction of the molten resin in the second resin portion 12 during foam molding, the plate thickness T2 of the second resin portion 12 is preferably 1.5 times or more, more preferably 2 times or more, the plate thickness T1 of the first resin portion 11. Also, in order to suppress the pressure reduction of the molten resin in the first resin portion 11 during foam molding, the plate thickness Tg of the gate portion 10 is preferably 1.5 times or more, more preferably 2 times or more, the plate thickness T1 of the first resin portion 11.

[0022] In the configuration of the air-conditioning case 1 of the present embodiment, the reasons for setting the plate thickness Tg of the gate portion 10, the plate thickness T1 of the first resin portion 11, and the plate thickness T2 of the second resin portion 12 as Tg > T1 and T1 < T2 will be described.

[0023] FIG. 5 is a cross-sectional view schematically showing molds 20 and 21 for foam molding a part of the air-conditioning case 1 shown in FIG. 4. In FIG. 5, the parting surface 23 of the molds 20 and 21 shows an example.

[0024] In foam molding, the molten resin containing a foaming agent is injected from the gate portion 10 into the space (i.e., cavity) 24 in the mold. The molten resin flows from the gate portion 10 to the first resin portion 11 as shown by the arrow A. At this time, in the present embodiment, since the plate thickness T1 of the first resin portion 11 is smaller than the plate thickness Tg of the gate portion 10, the pressure reduction of the molten resin flowing from the gate portion 10 to the first resin portion 11 is suppressed, and foaming in the first resin portion 11 is suppressed. Subsequently, the molten resin flows into the second resin portion 12 from the first resin portion 11 as shown by the arrow B. At this time, in the present embodiment, since the plate thickness T2 of the second resin portion 12 is larger than the plate thickness T1 of the first resin portion 11, when the molten resin flows from the first resin portion 11 to the second resin portion 12, the space 24 in the mold rapidly expands, so that a rapid pressure reduction occurs in the molten resin, and foaming in the second resin portion 12 is promoted. Thus, in the present embodiment, by setting the relationship between the plate thickness Tg of the gate portion 10, the plate thickness T1 of the first resin portion 11, and the plate thickness T2 of the second resin portion 12 as Tg > T1 and T1 < T2, high foaming of the second resin portion 12 can be achieved, and sink marks and warping of the second resin portion 12 can be prevented.

[0025] Next, for comparison with the above-described first embodiment, the air-conditioning case 1 of the first comparative example and the second comparative example will be described.

[0026] FIG. 6 is a cross-sectional view schematically showing a part of the air-conditioning case 101 of the first comparative example. The air-conditioning case 101 of the first comparative example is formed of a resin (i.e., solid) that does not contain bubbles, rather than by foam molding. Also, in the first comparative example, the plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 are the same. In this case, in the first comparative example, as shown by the broken line C, warping or sink marks may occur in the second resin portion 12.

[0027] On the other hand, FIG. 7 is a cross-sectional view that shows a schematic view of a part of the air conditioning case 102 of the second comparative example. The air conditioning case 102 of the second comparative example is formed by foam molding. In the second comparative example, as in the first comparative example, the plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 are the same. Therefore, in the second comparative example, as shown by the air bubbles 100 inside the product in FIG. 7, there is a variation in the foam distribution inside the product. Therefore, in the second comparative example, the physical properties change in unintended places of the product, and the physical properties that are originally desired for the material may not be obtained.

[0028] Compared with the above-mentioned first and second comparative examples, the air-conditioning case 1 of this embodiment provides the following advantages. (1) The air conditioning case 1 of this embodiment is configured such that the plate thickness T2 of the second resin part 12 is greater than the plate thickness T1 of the first resin part 11, and the total volume occupied by air bubbles per unit volume in the second resin part 12 is greater than the total volume occupied by air bubbles per unit volume in the first resin part 11. According to this, when the molten resin injected from the gate portion 10 into the first resin portion 11 in the mold during foam molding flows from the first resin portion 11 into the second resin portion 12, a sudden reduction in pressure occurs due to the sudden expansion of the space in the mold, and foaming of the foaming agent contained in the molten resin in the second resin portion 12 is promoted. Therefore, this air conditioning case 1 can achieve high foaming at the intended location (i.e., the second resin portion 12) at low cost by a simple configuration in which the plate thickness T2 of the second resin portion 12 is made larger than the plate thickness T1 of the first resin portion 11. Therefore, it is possible to suppress sink marks and warpage in the second resin portion 12, which requires high dimensional accuracy.

[0029] (2) In the air-conditioning case 1 of this embodiment, the plate thickness T1 of the first resin portion 11 is smaller than the plate thickness Tg of the gate portion . According to this, during foam molding, by preventing the pressure of the molten resin injected from the gate portion 10 into the first resin portion 11 in the mold from rapidly expanding, it is possible to make the first resin portion 11 a low foam. And when the molten resin flows from the first resin portion 11 into the second resin portion 12, by generating a rapid pressure reduction, it is possible to make the second resin portion 12 a high foam with respect to the first resin portion 11. Therefore, the first resin portion 11 can have the physical properties of a resin close to solid, and the second resin portion 12 can be made into a product having the physical properties of a high foam resin.

[0030] (Modification of the First Embodiment) A modification of the first embodiment will be described. As shown in FIG. 8, also in the modification of the first embodiment, the air conditioning case 1 includes a gate portion 10, a first resin portion 11, and a second resin portion 12. As described above, the first resin portion 11 may have a curved portion and a bent portion in the middle thereof. In this modification, the first resin portion 11 has a first part 11a connected to the gate portion 10, and a second part 11b and a third part 11c respectively provided at both ends of the first part 11a. Note that the first part 11a extends in a direction intersecting the direction in which the molten resin is injected into the gate portion 10 (in this modification, a substantially perpendicular direction). The second part 11b and the third part 11c extend in a direction intersecting the first part 11a.

[0031] The second resin portion 12 is connected to the middle of the first part 11a of the first resin portion 11 and extends in a direction intersecting the direction in which the first part 11a extends (in this modification, a substantially perpendicular direction). In FIG. 8, the direction in which the molten resin flows from the gate portion 10 into the first resin portion 11 and the second resin portion 12 during foam molding is indicated by an arrow D. This is the same for each of the embodiments, modifications, and comparative examples described below.

[0032] Also in the modification of the first embodiment, the plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 have a relationship of T1 < T2. Therefore, also in this modification, the intended portion (that is, the second resin portion 12) can be made into a high foam, and sink marks and warping in the second resin portion 12 can be suppressed.

[0033] Also in this modification, the plate thickness Tg of the gate portion 10 and the plate thickness T1 of the first resin portion 11 have a relationship of Tg > T1. Therefore, the first resin portion 11 can be made into a low-foamed state, and the second resin portion 12 can be made into a high-foamed state with respect to the first resin portion 11. Accordingly, the first resin portion 11 can have the physical properties of a resin close to a solid, and the second resin portion 12 can be made into a product having the physical properties of a high-foamed resin.

[0034] (Second Embodiment) The second embodiment will be described. The second embodiment is obtained by changing a part of the configuration of the air-conditioning case 1 with respect to the first embodiment, and since the rest is the same as the first embodiment, only the parts different from the first embodiment will be described.

[0035] As shown in FIG. 9, the air-conditioning case 1 of the second embodiment also includes a first resin portion 11 and a second resin portion 12. The plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 have a relationship of T1 < T2. In FIG. 9 as well, the direction in which the molten resin flows with respect to the first resin portion 11 and the second resin portion 12 during foam molding is indicated by an arrow D. Therefore, although illustration is omitted, the gate portion 10 that supplies the molten resin to the first resin portion 11 and the second resin portion 12 during foam molding is disposed on the left side of the paper surface of FIG. 9.

[0036] Furthermore, the air-conditioning case 1 of the second embodiment includes an adjacent recess 13 on the side closer to the gate portion 10 among the portions adjacent to the second resin portion 12 in the first resin portion 11. The adjacent recess 13 is a portion that is recessed from the surface 11d of the first resin portion 11 on the side where the second resin portion 12 is provided, in a direction opposite to the direction in which the second resin portion 12 extends.

[0037] Here, the thickness of the portion of the first resin portion 11 where the adjacent recess 13 is provided is defined as T3. The thickness of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13 is defined as T1. In this case, in the second embodiment, there is a relationship of T1>T3. That is, the thickness T3 of the portion of the first resin portion 11 where the adjacent recess 13 is provided is smaller than the thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13. In the second embodiment, the relationship of T1>T3 means that the difference between the thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13 and the thickness T3 of the portion of the first resin portion 11 where the adjacent recess 13 is provided is larger than the manufacturing tolerance.

[0038] As a result, in the second embodiment, during foam molding, compared to a configuration in which the molten resin flows directly from the first resin portion 11 to the second resin portion 12, the space inside the mold expands more rapidly when the molten resin flows into the second resin portion 12 through the narrow in-mold flow path of the adjacent recess 13. Therefore, according to the configuration of the second embodiment, the pressure fluctuation (i.e., the degree of pressure reduction) of the molten resin when the molten resin flows from the narrow in-mold flow path of the adjacent recess 13 into the second resin portion 12 can be made larger, and foaming of the foaming agent contained in the molten resin in the second resin portion 12 can be more promoted.

[0039] The air conditioning case 1 of the second embodiment described above has a simple configuration in which the first resin part 11 has an adjacent recess 13 on the side closer to the gate part 10 than the second resin part 12, thereby making it possible to more reliably achieve high foaming in the intended area (i.e., the second resin part 12) at low cost.

[0040] (Modification of the second embodiment) A modified example of the second embodiment will be described. As shown in Fig. 10, the air conditioning case 1 also includes a gate portion 10, a first resin portion 11, and a second resin portion 12 in the modified example of the second embodiment. Furthermore, the air conditioning case 1 includes an adjacent recess 13 on the side of the first resin portion 11 that is adjacent to the second resin portion 12 and is closer to the gate portion 10.

[0041] In a modification of the second embodiment, the first resin portion 11 has a first portion 11a connected to the gate portion 10, and second and third portions 11b and 11c provided at both ends of the first portion 11a, respectively. The first portion 11a extends in a direction intersecting the direction in which the molten resin is injected into the gate portion 10 (in this modification, a substantially perpendicular direction). The second portion 11b and the third portion 11c extend in a direction intersecting the first portion 11a. The second resin portion 12 is connected to the middle of the first portion 11a of the first resin portion 11 and extends in a direction intersecting the direction in which the first portion 11a extends (in this modification, a substantially perpendicular direction).

[0042] Also in the modification of the second embodiment, the plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 have a relationship of T1 < T2. Therefore, also in this modification, the intended location (i.e., the second resin portion 12) can be highly foamed, and sink marks and warping in the second resin portion 12 can be suppressed.

[0043] Further, also in the modification of the second embodiment, the plate thickness Tg of the gate portion 10 and the plate thickness T1 of the first resin portion 11 have a relationship of Tg > T1. Therefore, it is possible to make the first resin portion 11 low-foamed and the second resin portion 12 highly foamed with respect to the first resin portion 11. Accordingly, the first resin portion 11 can have the physical properties of a resin close to solid, and the second resin portion 12 can be made into a product having the physical properties of a highly foamed resin.

[0044] Furthermore, also in the modification of the second embodiment, the plate thickness T1 of the portion of the first resin portion 11 on the gate portion 10 side of the adjacent recess 13 and the plate thickness T3 of the portion of the first resin portion 11 where the adjacent recess 13 is provided have a relationship of T1 > T3. Therefore, during foam molding, the pressure fluctuation (i.e., the degree of pressure reduction) of the molten resin when the molten resin flows into the second resin portion 12 from the narrow mold internal flow path of the adjacent recess 13 can be made larger, and the second resin portion 12 can be more reliably highly foamed.

[0045] (Third Embodiment) A description will be given of the third embodiment. The third embodiment is also a modification in which a part of the configuration of the air-conditioning case 1 is changed with respect to the first embodiment and the like, and since the other parts are the same as those of the first embodiment and the like, only the parts different from the first embodiment and the like will be described.

[0046] As shown in FIG. 11, the air-conditioning case 1 of the third embodiment also includes a first resin part 11 and a second resin part 12. The plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 have a relationship of T1 < T2. Although not shown, the gate part 10 for supplying the molten resin to the first resin part 11 and the second resin part 12 during foam molding is arranged on the left side of the paper surface of FIG. 11.

[0047] Furthermore, the air-conditioning case 1 of the third embodiment has a counter-surface recess 14 on the surface 11e of the first resin part 11 that is opposite to the surface 11d on the side where the second resin part 12 is provided at the connection portion between the first resin part 11 and the second resin part 12. The counter-surface recess 14 is a portion that is recessed in the direction in which the second resin part 12 extends on the surface 11e of the first resin part 11 that is opposite to the surface 11d on the side where the second resin part 12 is provided.

[0048] Here, let the distance between the surface 11d on the side where the second resin part 12 is provided in the first resin part 11 and the surface of the counter-surface recess 14 be T4. At this time, in the third embodiment, it has a relationship of T1 > T4. That is, the distance T4 between the surface 11d on the side where the second resin part 12 is provided in the first resin part 11 and the surface of the counter-surface recess 14 is smaller than the plate thickness T1 of the first resin part 11. In the third embodiment, the relationship of T1 > T4 means that the difference between the distance T4 between the surface 11d on the side where the second resin part 12 is provided in the first resin part 11 and the surface of the counter-surface recess 14 and the plate thickness T1 of the first resin part 11 is larger than the manufacturing tolerance.

[0049] As a result, in the third embodiment, during foam molding, when the molten resin flows into the second resin portion 12 through the narrow mold internal flow path formed between the surface 11d on the side where the second resin portion 12 is provided in the first resin portion 11 and the surface of the counter surface recess 14, the space in the mold expands more rapidly. Therefore, according to the configuration of the third embodiment, the pressure fluctuation (i.e., the degree of pressure reduction) of the molten resin when the molten resin flows from the narrow mold internal flow path into the second resin portion 12 can be made larger, and the foaming of the foaming agent contained in the molten resin in the second resin portion 12 can be promoted more effectively.

[0050] The air conditioning case 1 of the third embodiment described above has a simple configuration with a counter surface recess 14 provided at the connection portion between the first resin portion 11 and the second resin portion 12, and thus can surely achieve high foaming at the intended location (i.e., the second resin portion 12) at low cost.

[0051] (Fourth Embodiment) The fourth embodiment will be described. The fourth embodiment is also a modification of a part of the configuration of the air conditioning case 1 with respect to the first embodiment and the like. Since the other parts are the same as those of the first embodiment and the like, only the parts different from the first embodiment and the like will be described.

[0052] As shown in FIG. 12, the air conditioning case 1 of the fourth embodiment also includes a first resin portion 11 and a second resin portion 12. The plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 have a relationship of T1 < T2. Although not shown in the figure, the gate portion 10 for supplying the molten resin to the first resin portion 11 and the second resin portion 12 during foam molding is arranged on the left side of the paper surface of FIG. 12.

[0053] Furthermore, the air conditioning case 1 of the fourth embodiment includes a first curved surface portion 15 provided on the side closer to the gate portion 10 in the connecting portion where the first resin portion 11 and the second resin portion 12 are connected, and a second curved surface portion 16 provided on the side farther from the gate portion 10 in the connecting portion where the first resin portion 11 and the second resin portion 12 are connected.

[0054] Here, let the radius of curvature of the first curved surface portion 15 be R1, and the radius of curvature of the second curved surface portion 16 be R2. At this time, in the fourth embodiment, there is a relationship of R1 < R2. That is, the radius of curvature R1 of the first curved surface portion 15 is smaller than the radius of curvature R2 of the second curved surface portion 16. In the fourth embodiment, the relationship of R1 < R2 means that the difference between the radius of curvature R1 of the first curved surface portion 15 and the radius of curvature R2 of the second curved surface portion 16 is larger than the manufacturing tolerance.

[0055] By the way, if the radius of curvature R1 of the first curved surface portion 15 is increased, when foam molding, since the pressure of the molten resin is gradually reduced as the molten resin passes through the first curved surface portion 15 from the first resin portion 11, the promotion of the foaming of the foaming agent contained in the molten resin in the second resin portion 12 will be reduced.

[0056] On the other hand, in the fourth embodiment, since the radius of curvature R1 of the first curved surface portion 15 is made as small as possible, when the molten resin flows from the first resin portion 11 through the first curved surface portion 15 to the second resin portion 12 during foam molding, the space in the mold expands rapidly. Therefore, according to the configuration of the fourth embodiment, the pressure fluctuation (i.e., the degree of pressure reduction) of the molten resin when the molten resin flows from the first resin portion 11 to the second resin portion 12 can be increased, and the foaming of the foaming agent contained in the molten resin in the second resin portion 12 can be promoted.

[0057] The air-conditioning case 1 of the fourth embodiment described above can foam the intended location (i.e., the second resin portion 12) highly at low cost with a simple configuration in which the radius of curvature R1 of the first curved surface portion 15 is made smaller than the radius of curvature R2 of the second curved surface portion 16.

[0058] (Fifth Embodiment) The fifth embodiment will be described. The fifth embodiment is also a modification of a part of the configuration of the air-conditioning case 1 with respect to the first embodiment and the like. Since the other parts are the same as those of the first embodiment and the like, only the parts different from the first embodiment and the like will be described.

[0059] As shown in FIG. 13, the air-conditioning case 1 of the fifth embodiment also includes a first resin part 11 and a second resin part 12. The plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 have a relationship of T1 < T2. In the fifth embodiment, the plate thickness T2 of the second resin part 12 refers to the plate thickness of the base part 12a of the second resin part 12 that is close to the first resin part 11. Although not shown, the gate part 10 that supplies the molten resin to the first resin part 11 and the second resin part 12 during foam molding is arranged on the left side of the paper surface of FIG. 13.

[0060] Furthermore, in the fifth embodiment, the second resin part 12 has a shape in which the plate thickness gradually decreases as it moves away from the first resin part 11. Specifically, let the plate thickness of the base part 12a of the second resin part 12 that is close to the first resin part 11 be T2. Let the plate thickness of the tip part 12b of the second resin part 12 that is far from the first resin part 11 be T5. At this time, in the fifth embodiment, it has a relationship of T2 > T5. In the fifth embodiment, the relationship of T2 > T5 means that the difference between the plate thickness T2 of the base part 12a and the plate thickness T5 of the tip part 12b is larger than the manufacturing tolerance. Also, in the fifth embodiment, the shape in which the plate thickness gradually decreases refers to a change in plate thickness that is steeper than the minimum draft angle of the mold. Therefore, the base part 12a of the second resin part 12 has a higher degree of foaming than the tip part 12b of the second resin part 12. In other words, the total volume occupied by the bubbles per unit volume at the base part 12a of the second resin part 12 is larger than the total volume occupied by the bubbles per unit volume at the tip part 12b of the second resin part 12. Thereby, warping of the second resin part 12 is prevented, and the tip part 12b has resin physical properties close to those of a solid.

[0061] Generally, in a resin molded product having a first resin portion 11 and a second resin portion 12, warping of the second resin portion 12 is likely to occur at the base portion 12a of the second resin portion 12. In contrast, in the fifth embodiment, the space in the mold is suddenly expanded at the base portion 12a of the second resin portion 12 during foam molding, causing a rapid reduction in pressure in the molten resin, making the base portion 12a highly foamed, and preventing warping of the second resin portion 12. On the other hand, the space in the mold is gradually reduced at the tip portion 12b of the second resin portion 12, so that the pressure of the molten resin is gradually increased during foam molding, making it possible to achieve low foaming.

[0062] The air conditioning case 1 of the fifth embodiment described above has a simple configuration in which the plate thickness T2 of the second resin part 12 is made smaller the farther away from the first resin part 11, so that the base part 12a of the second resin part 12 is highly foamed to prevent warping of the second resin part 12, and the tip part 12b has physical properties of a resin close to that of a solid.

[0063] (Third Comparative Example) In the above-mentioned first to fifth embodiments, the second resin part 12 provided in the air-conditioning case 1 mainly corresponds to the ribs 7, 8, and 9 provided in the ventilation passage of the air-conditioning case 1, and has been described as preventing shrinkage and warping of the ribs 7, 8, and 9. In contrast, in the third comparative example and sixth embodiment described below, the second resin part 12 provided in the air-conditioning case 1 will be described as mainly corresponding to an outer rib provided on the outer wall of the bottom of the air-conditioning case 1 (i.e., the part on the lower side in the direction of gravity).

[0064] Before describing the sixth embodiment, a third comparative example will be described with reference to Fig. 14 and Fig. 15. The air-conditioning case 103 of the third comparative example is a conventional, general one, which is not foam-molded but is made of resin that does not contain bubbles (i.e., solid).

[0065] 14, a plurality of outer ribs 30 are provided on the bottom of the air-conditioning case 103 of the third comparative example. The plurality of outer ribs 30 are mainly provided at a position below, in the direction of gravity, an air-cooling heat exchanger provided in the ventilation passage of the air-conditioning case 1. The plurality of outer ribs 30 have the function of improving the thermal insulation of the air-conditioning case 103 and preventing the occurrence of condensation due to temperature changes caused by the operation of the air-cooling heat exchanger.

[0066] Fig. 15 is a cross-sectional view showing a schematic view of the bottom of the air-conditioning case 103 shown in Fig. 14. The air-conditioning case 103 of the third comparative example also includes a first resin part 11 and a second resin part 12. Although not shown in the figure, the gate part 10 that supplies molten resin to the first resin part 11 and the second resin part 12 during injection molding is disposed on the left side of the paper surface of Fig. 15.

[0067] The first resin part 11 is a part that mainly constitutes the outer shell of the air-conditioning case 103, and is also called a general part. The multiple second resin parts 12 are connected to the first resin part 11, and extend in a direction intersecting the direction in which the first resin part 11 extends (in this embodiment, a direction substantially perpendicular to the direction in which the first resin part 11 extends). The multiple second resin parts 12 correspond to the outer ribs 30, and are provided in large numbers on the bottom part of the air-conditioning case 103 to improve the thermal insulation of the air-conditioning case 103 and prevent condensation.

[0068] Sixth embodiment Next, a sixth embodiment will be described with reference to Fig. 16. The air-conditioning case 1 of the sixth embodiment is formed by foam molding.

[0069] As shown in Fig. 16, the air-conditioning case 1 of the sixth embodiment also includes a first resin part 11 and a second resin part 12. The first resin part 11 is a part that constitutes the outer shell of the air-conditioning case 1, and is also called a general part. The second resin part 12 corresponds to the outer rib 30. Although not shown in the figure, the gate part 10 that supplies molten resin to the first resin part 11 and the second resin part 12 during foam molding is disposed on the left side of the paper surface of Fig. 16.

[0070] The plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 have a relationship of T1 < T2. Therefore, also in the sixth embodiment, with a simple configuration, the second resin part 12 can be highly foamed at low cost. By making the second resin part 12 (i.e., the outer rib 30) highly foamed, the total volume occupied by the air bubbles in the resin product increases, so that weight reduction is possible. Therefore, in the sixth embodiment, without increasing the weight, a plurality of the second resin parts 12 (i.e., the outer ribs 30) described in the third comparative example can be integrally formed. Thereby, the heat insulation property can be further enhanced and the weight can be reduced.

[0071] (Modification of the Sixth Embodiment) A modification of the sixth embodiment will be described. As shown in FIG. 17, the air-conditioning case 1 of the modification of the sixth embodiment includes a first resin part 11 and a plurality of second resin parts 12. Also in this modification, the plate thickness T1 of the first resin part 11 and the plate thickness T2 of the plurality of second resin parts 12 have a relationship of T1 < T2. Therefore, also in the modification of the sixth embodiment, with a simple configuration, the second resin part 12 can be highly foamed at low cost.

[0072] In the modification of the sixth embodiment, the plate thickness T2 of the second resin part 12 is larger than the plate thickness T2 of the second resin part 12 described in the third comparative example. Therefore, in the modification of the sixth embodiment, the number of the second resin parts 12 can be reduced compared to the third comparative example. Thus, also in the modification of the sixth embodiment, by making the second resin part 12 (i.e., the outer rib 30) highly foamed, the heat insulation property can be enhanced and the weight can be reduced.

[0073] (Seventh Embodiment) The seventh embodiment will be described. The seventh embodiment is a modification of a part of the configuration of the second resin part 12 included in the air-conditioning case 1, and since the other parts are the same as those in the first embodiment and the like, only the parts different from the first embodiment and the like will be described.

[0074] As shown in FIG. 18, the air-conditioning case 1 of the seventh embodiment includes a first resin part 11 and a plurality of second resin parts 12. The gate part 10 for supplying molten resin to the first resin part 11 and the plurality of second resin parts 12 during foam molding is arranged on the left side of the paper surface of FIG. 18. Therefore, the plurality of second resin parts 12 are arranged in the direction in which the molten resin flows from the gate part 10 to the first resin part 11 during foam molding. In the following description, among the plurality of second resin parts 12, the second resin part 12 closest to the gate part 10 from the first resin part 11 is referred to as the "upstream second resin part 121", and the second resin part 12 farther from the gate part 10 than the upstream second resin part 121 is referred to as the "downstream second resin part 122".

[0075] Here, let the distance between the upstream second resin part 121 and the downstream second resin part 122 be D1. At this time, in the seventh embodiment, it has the relationship of T1 < D1. That is, the distance D1 between the plurality of second resin parts 12 adjacent to each other in the direction in which the molten resin flows through the first resin part 11 is larger than the plate thickness T1 of the first resin part 11. In the seventh embodiment, the relationship of T1 < D1 means that the difference between the distance D1 between the plurality of second resin parts 12 and the plate thickness T1 of the first resin part 11 is larger than the manufacturing tolerance.

[0076] The reason why the interval D1 between the plurality of second resin parts 12 is made larger than the plate thickness T1 of the first resin part 11 is as follows. That is, when the molten resin changes its flow direction when flowing from the first resin part 11 into the upstream second resin part 121 during foam molding, peeling E occurs in the upstream region of the resin flow near the inlet of the upstream second resin part 121, causing a rapid reduction in pressure. This promotes foaming of the foaming agent contained in the molten resin in the upstream second resin part 121. In the seventh embodiment, the interval D1 between the plurality of second resin parts 12 is made larger than the plate thickness T1 of the first resin part 11, so that the distance (i.e., D1) of the first resin part 11 connecting the plurality of second resin parts 12 becomes farther. Therefore, as shown by the arrow F, the inertia of the molten resin that has changed its flow direction from the first resin part 11 to the upstream second resin part 121 is reduced while the molten resin flows through the interval D1 between the plurality of second resin parts 12 in the first resin part 11. As a result, when the molten resin flows from the first resin portion 11 into the downstream second resin portion 122, the molten resin changes its flow direction, causing separation G in the upstream region of the resin flow near the inlet of the downstream second resin portion 122, resulting in a rapid reduction in pressure. Therefore, foaming of the foaming agent contained in the molten resin is promoted also in the downstream second resin portion 122.

[0077] Here, for comparison with the above-described seventh embodiment, an air-conditioning case 104 of a fourth comparative example will be described.

[0078] As shown in FIG. 19, in the air-conditioning case 104 of the fourth comparative example, the interval D2 between the multiple second resin parts 12 adjacent to each other in the direction in which the molten resin flows through the first resin part 11 is smaller than the plate thickness T1 of the first resin part 11. That is, there is a relationship of T1>D2. In the fourth comparative example, when the molten resin flows from the first resin part 11 into the upstream second resin part 121 during foam molding, separation H occurs in the upstream region of the resin flow near the inlet of the upstream second resin part 121, causing a rapid reduction in pressure. This promotes foaming of the foaming agent contained in the molten resin in the upstream second resin part 121. However, in the fourth comparative example, the interval D2 between the multiple second resin parts 12 is smaller than the plate thickness T1 of the first resin part 11, so the distance (i.e., D2) of the first resin parts 11 connecting the multiple second resin parts 12 is close. Therefore, as shown by arrow I, the molten resin flows from the first resin part 11 to the downstream second resin part 122 under the influence of the inertia of the molten resin that has changed its flow direction from the first resin part 11 to the upstream second resin part 121. Therefore, when the molten resin flows from the first resin part 11 to the downstream second resin part 122, the molten resin hardly changes its flow direction, so no separation occurs near the inlet of the downstream second resin part 122 and no pressure reduction occurs. As a result, in the fourth comparative example, foaming of the foaming agent contained in the molten resin is suppressed in the downstream second resin part 122.

[0079] Compared with the above-mentioned fourth comparative example, the air-conditioning case 1 of the seventh embodiment has the following advantages. The air-conditioning case 1 of the seventh embodiment is configured such that the distance D1 between the upstream second resin portion 121 and the downstream second resin portion 122 is larger than the plate thickness T1 of the first resin portion 11. That is, the air-conditioning case 1 of the seventh embodiment can highly foam both of the multiple second resin portions 12 (i.e., the upstream second resin portion 121 and the downstream second resin portion 122) at low cost due to a simple configuration in which the distance between the multiple second resin portions 12 adjacent to each other in the flow direction of the molten resin is larger than the plate thickness of the first resin portion 11.

[0080] (Modification of the seventh embodiment) A modification of the seventh embodiment will be described. As shown in FIG. 20, also in the modification of the seventh embodiment, the air conditioning case 1 includes a first resin portion 11 and a plurality of second resin portions 12. The plurality of second resin portions 12 include those extending to one side in the plate thickness direction of the first resin portion 11 and those extending to the other side in the plate thickness direction of the first resin portion 11. Among those extending to the other side in the plate thickness direction of the first resin portion 11, the interval D1 between the plurality of second resin portions 12 arranged in the direction in which the molten resin flows through the first resin portion 11 is larger than the plate thickness T1 of the first resin portion 11. Therefore, also in this modification, during foam molding, peeling J, K, and L occur near the inlets of the plurality of second resin portions 12, causing a rapid pressure reduction. As a result, all of the plurality of second resin portions 12 can be highly foamed.

[0081] (Eighth Embodiment) The eighth embodiment will be described. The eighth embodiment is a modification of the configuration of the gate portion 10 provided in the air conditioning case 1, and since the other aspects are the same as those of the first embodiment and the like, only the parts different from the first embodiment and the like will be described.

[0082] As shown in FIG. 21, in the eighth embodiment, the gate portion 10 has a plate thickness Tg and the first resin portion 11 has a plate thickness T1, and they have a relationship of Tg < T1. That is, the plate thickness T1 of the first resin portion 11 is larger than the plate thickness Tg of the gate portion 10. In this specification, the relationship of Tg < T1 means that the difference between the plate thickness Tg of the gate portion 10 and the plate thickness T1 of the first resin portion 11 is larger than the manufacturing tolerance.

[0083] As shown by the arrow D in FIG. 21, when the molten resin injected from the gate portion 10 into the first resin portion 11 in the mold during foam molding flows from the gate portion 10 to the first resin portion 11, a rapid pressure reduction occurs due to the sudden expansion of the space in the mold, and the foaming of the foaming agent contained in the molten resin is promoted in the first resin portion 11. Thus, the air conditioning case 1 of the eighth embodiment can highly foam the first resin portion 11 at low cost with a simple configuration of making the plate thickness T1 of the first resin portion 11 larger than the plate thickness Tg of the gate portion 10.

[0084] Note that, by combining the eighth embodiment with each of the above-described embodiments and each modification (i.e., by making the plate thickness T2 of the second resin portion 12 larger than the plate thickness T1 of the first resin portion 11, etc.), the first resin portion 11 can be highly foamed and the second resin portion 12 can also be highly foamed.

[0085] (Other Embodiments) (1) In the first embodiment and the like, it has been described that the plate thickness T1 of the first resin portion 11 and the plate thickness T2 of the second resin portion 12 have a relationship of T1 < T2. However, the relationship may be, for example, T1 × 1.1 < T2.

[0086] (2) In the first embodiment and the like, it has been described that the plate thickness Tg of the gate portion 10 and the plate thickness T1 of the first resin portion 11 have a relationship of Tg > T1. However, the relationship may be, for example, Tg > T1 × 1.1.

[0087] (3) In the second embodiment, it has been described that the plate thickness T1 of the portion of the first resin portion 11 on the gate portion 10 side rather than the adjacent recess 13 and the plate thickness T3 of the portion of the first resin portion 11 where the adjacent recess 13 is provided have a relationship of T1 > T3. However, the relationship may be, for example, T1 > T3 × 1.1.

[0088] (4) In the third embodiment, it has been described that the distance T4 between the surface of the opposite surface recess 14 and the surface 11d of the first resin portion 11 on the side where the second resin portion 12 is provided, and the plate thickness T1 of the first resin portion 11 have a relationship of T1 > T4. However, the relationship may be, for example, T1 > T4 × 1.1.

[0089] (5) In the fourth embodiment, it has been described that the radius of curvature R1 of the first curved surface portion 15 and the radius of curvature R2 of the second curved surface portion 16 have a relationship of R1 < R2. However, the relationship may be, for example, R1 × 1.1 < R2.

[0090] (6) In the fifth embodiment, it has been described that the plate thickness T2 of the root portion 12a and the plate thickness T5 of the tip portion 12b in the second resin portion 12 have a relationship of T2 > T5. However, the relationship may be, for example, T2 > T5 × 1.1.

[0091] (7) In the seventh embodiment, it has been described that the thickness T1 of the first resin portion 11 and the distance D1 between a plurality of second resin portions 12 adjacent to each other in the direction in which the molten resin flows satisfy the relationship of T1 < D1. However, the relationship may be, for example, T1 × 1.1 < D1.

[0092] (8) In the eighth embodiment, it has been described that the thickness Tg of the gate portion 10 and the thickness T1 of the first resin portion 11 satisfy the relationship of Tg < T1. However, the relationship may be, for example, Tg × 1.1 < T1.

[0093] (9) In the above first embodiment, the first resin portion 11 has been described as a portion constituting the outer shell of the air conditioning case 1. However, it is not limited thereto, and the first resin portion 11 can be applied to each portion that requires physical properties of resin close to solid in the air conditioning case 1. Alternatively, as described in the eighth embodiment, the first resin portion 11 can also be applied to each portion that requires heat insulation by foam molding or each portion that requires dimensional accuracy in the air conditioning case 1.

[0094] (10) In the above first embodiment and the like, the second resin portion 12 includes ribs 7, 8, and 9 provided in the ventilation path of the air conditioning case 1, and it has been described that it is applied to all ribs that may cause abnormal noise or lead to poor assembly of the air conditioning case. In the sixth embodiment and the like, it has been described that it is applied to the outer rib 30 provided on the outer wall of the bottom of the air conditioning case 1. However, it is not limited thereto. The second resin portion can be applied to each portion that requires heat insulation by foam molding or each portion that requires dimensional accuracy in the air conditioning case 1.

[0095] The present invention is not limited to the above-described embodiments, and can be appropriately modified within the scope of the claims. Moreover, the above-described embodiments are not unrelated to each other, and can be appropriately combined, except when the combination is clearly impossible. Moreover, in each of the above-described embodiments, it goes without saying that the elements constituting the embodiments are not necessarily essential, except when they are specifically stated to be essential or when they are clearly considered to be essential in principle. Moreover, in each of the above-described embodiments, when the numbers, values, amounts, ranges, etc. of the components of the embodiments are mentioned, they are not limited to the specific numbers, except when they are specifically stated to be essential or when they are clearly limited to a specific number in principle. Moreover, in each of the above-described embodiments, when the shapes, positional relationships, etc. of the components are mentioned, they are not limited to the shapes, positional relationships, etc., except when they are specifically stated to be essential or when they are clearly limited to a specific shape, positional relationship, etc. in principle.

[0096] (Features of the present invention) The features of the present invention are as follows. [Claim 1] In a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) whose portion connected to the first resin part extends in a direction intersecting the direction in which the first resin part extends, A vehicle air conditioning case, wherein the second resin portion has a plate thickness (T2) greater than the plate thickness (T1) of the first resin portion, and the total volume occupied by air bubbles per unit volume in the second resin portion is greater than the total volume occupied by air bubbles per unit volume in the first resin portion. [Claim 2] 2. The vehicle air-conditioner case according to claim 1, wherein a thickness of the first resin portion is smaller than a thickness (Tg) of the gate portion. [Claim 3] 2. The vehicle air-conditioner case according to claim 1, wherein the first resin portion has a thickness greater than a thickness of the gate portion. [Claim 4] an adjacent recess (13) provided on a side of the first resin portion adjacent to the second resin portion that is closer to the gate portion; 4. A vehicle air conditioning case as described in any one of claims 1 to 3, wherein a plate thickness (T3) of the first resin part at a portion where the adjacent recess is provided is smaller than a plate thickness (T1) of a portion of the first resin part on the gate portion side than the adjacent recess. [Claim 5] an opposite surface recess (14) provided on a surface (11e) of the first resin portion opposite to a surface (11d) on which the second resin portion is provided at a connection portion between the first resin portion and the second resin portion; 5. A vehicle air conditioning case as described in any one of claims 1 to 4, wherein a distance (T4) between a surface of the first resin part on which the second resin part is provided and a surface of the opposite surface recess is smaller than a plate thickness of the first resin part. [Claim 6] a first curved surface portion (15) provided on a side closer to the gate portion of a corner portion where the first resin portion and the second resin portion are connected, and a second curved surface portion (16) provided on a side farther from the gate portion of a corner portion where the first resin portion and the second resin portion are connected, 6. The vehicle air-conditioner case according to claim 1, wherein a radius of curvature (R1) of the first curved surface portion is smaller than a radius of curvature (R2) of the second curved surface portion. [Claim 7] the second resin portion has a shape in which a plate thickness gradually decreases as the plate thickness increases away from the first resin portion, 7. The vehicle air conditioning case according to claim 1, wherein a total volume occupied by air bubbles per unit volume at a root portion (12a) of the second resin portion that is close to the first resin portion is greater than a total volume occupied by air bubbles per unit volume at a tip portion (12b) of the second resin portion that is far from the first resin portion. [Claim 8] a plurality of the second resin portions (121, 122) arranged in a direction in which the molten resin flows from the gate portion through the first resin portion during foam molding; 8. The vehicle air-conditioning case according to claim 1, wherein a distance (D1) between adjacent second resin portions in a direction in which molten resin flows through the first resin portion is greater than a plate thickness of the first resin portion. [Explanation of symbols]

[0097] 10 Gate section 11 First resin part 12 Second resin part T1 Plate thickness of first resin part T2 Plate thickness of second resin part

Claims

1. In a vehicle air conditioning device case formed by foam molding, a gate portion (10) into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) having a portion connected to the first resin part extending in a direction intersecting with a direction in which the first resin part extends; an adjacent recess (13) provided on a side of the first resin portion adjacent to the second resin portion that is closer to the gate portion; The plate thickness (T2) of the second resin portion is formed larger than the plate thickness (T1) of the first resin portion, a plate thickness (T3) of a portion of the first resin portion where the adjacent recess is provided is formed smaller than a plate thickness (T1) of a portion of the first resin portion closer to the gate portion than the adjacent recess, a total volume of air bubbles per unit volume in the second resin portion is greater than a total volume of air bubbles per unit volume in the first resin portion.

2. In a vehicle air conditioning device case formed by foam molding, a gate portion (10) as a portion into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) having a portion connected to the first resin part extending in a direction intersecting with a direction in which the first resin part extends; an opposite surface recess (14) provided on a surface (11e) of the first resin portion opposite to a surface (11d) on which the second resin portion is provided at a connection point between the first resin portion and the second resin portion; The plate thickness (T2) of the second resin portion is formed larger than the plate thickness (T1) of the first resin portion, a distance (T4) between a surface of the first resin portion on a side where the second resin portion is provided and a surface of the opposite-surface recess is formed to be smaller than a plate thickness of the first resin portion, a total volume of air bubbles per unit volume in the second resin portion is greater than a total volume of air bubbles per unit volume in the first resin portion.

3. In a vehicle air conditioning device case formed by foam molding, a gate portion (10) as a portion into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) having a portion connected to the first resin part extending in a direction intersecting with a direction in which the first resin part extends; a first curved surface portion (15) provided on a side of a corner portion where the first resin portion and the second resin portion are connected, the side being closer to the gate portion; a second curved surface portion (16) provided on a side of a corner portion where the first resin portion and the second resin portion are connected, the side being farther from the gate portion; The plate thickness (T2) of the second resin portion is formed larger than the plate thickness (T1) of the first resin portion, The radius of curvature (R1) of the first curved surface portion is smaller than the radius of curvature (R2) of the second curved surface portion, a total volume of air bubbles per unit volume in the second resin portion is greater than a total volume of air bubbles per unit volume in the first resin portion.

4. In a vehicle air conditioning device case formed by foam molding, a gate portion (10) as a portion into which molten resin containing a foaming agent is injected during foam molding; a first resin portion (11) having a portion connected to the gate portion extending in a direction intersecting a direction in which the molten resin is injected into the gate portion; a second resin part (12) whose portion connected to the first resin part extends in a direction intersecting with a direction in which the first resin part extends, The plate thickness (T2) of the second resin portion is formed larger than the plate thickness (T1) of the first resin portion, the second resin portion has a shape in which a plate thickness gradually decreases as the plate thickness increases away from the first resin portion, a total volume occupied by air bubbles per unit volume in the second resin portion is larger than a total volume occupied by air bubbles per unit volume in the first resin portion, a total volume occupied by air bubbles per unit volume at a root portion (12a) of the second resin portion that is close to the first resin portion is greater than a total volume occupied by air bubbles per unit volume at a tip portion (12b) of the second resin portion that is far from the first resin portion.

5. An air conditioning case for a vehicle as described in any one of claims 1 to 4, wherein the plate thickness of the first resin portion is smaller than the plate thickness (Tg) of the gate portion.

6. The second resin portion (121, 122) is arranged in a direction in which molten resin flows from the gate portion through the first resin portion during foam molding, 5. A vehicle air conditioning case as described in claim 1, wherein a distance (D1) between adjacent second resin portions in a direction in which molten resin flows through the first resin portion is greater than a plate thickness of the first resin portion.

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