Resin molded product and method for manufacturing a resin molded product

Abstract

This resin molded article comprises a first molded portion and a second molded portion. The first molded portion has a component serving as an insert and a first resin portion integrated with the component. The second molded portion has a second resin portion. The first resin portion includes a first surface, a second surface, a third surface, and a fourth surface. The second resin portion is in contact with all of the first surface, the second surface, the third surface, and the fourth surface of the first resin portion.

Description

[[Technical Field]]

[0001] The present disclosure relates to a resin molded product and a method for manufacturing a resin molded product. [[Background Art]]

[0002] For example, resin molded products including connectors are known. The resin molded product disclosed in Patent Document 1 includes a component such as a connector terminal and a resin housing integrated with the connector terminal. The housing has a fitting portion for a mating connector connected to the connector terminal. Such a resin molded product is manufactured by injection molding using a component such as a connector terminal as an insert. [[Prior Art Documents]] [[Patent Documents]]

[0003] [[Patent Document 1]] Japanese Unexamined Patent Publication No. 2022-51061 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0004] In the resin molded products as described above, there are a plurality of resin molded products in which the shape of the connector terminal is different and other specifications are the same, or a plurality of resin molded products in which the shape of the fitting portion is different and other specifications are the same. In order to manufacture these, a plurality of molds are required for each resin molded product. Each of the plurality of molds is only slightly different in shape in a partial portion, while most of the shape is the same. When there are many types of components such as connector terminals or many types of fitting portions, enormous cost is required for manufacturing and managing a large number of molds.

[0005] Accordingly, an object of the present disclosure is to provide a resin molded product that enables reduction of mold cost, and to provide a method for manufacturing such a resin molded product. [[Means for Solving the Problem]]

[0006] The resin molded product of the present disclosure is It has a first molding section and a second molding section, The first molded part has a component as an insert and a first resin part that is integrated with the component. The second molded part has a second resin part, The first resin part comprises a first surface, a second surface, a third surface, and a fourth surface. The first surface is between the first and second cycles Ring plane And, The second surface is 、 Including the normal of the first surface 4 flat surface Consists of , Between the first and third perimeters Ring on the surface , the first surface On the first circumference of the above They are placed adjacent to each other, The third aspect mentioned above is 、 A depression in the direction normal to the first surface. The side of the first groove , Between the second and fourth perimeters Ring The four planes and ,before The opposite side of the second surface with respect to the first surface. In the second circumference of the first surface They are placed adjacent to each other, The fourth side is 、 A depression in the direction normal to the second surface. The side of the second groove , Between the third and fifth perimeters Ring The four planes and ,before The second surface is the opposite side of the first surface. In the third circumference of the second surface They are placed adjacent to each other, The distance between the second surface and the third surface in the direction normal to the first surface is defined as the first distance. The distance between the first and fourth surfaces in the direction normal to the first surface of the second surface is defined as the second distance. The third distance is defined as the distance between the first surface and the position on the third surface that is furthest from the first surface, in the direction normal to the first surface of the third surface. The distance between the second surface and the position on the fourth surface furthest from the second surface in the direction normal to the second surface is defined as the fourth distance. The fourth distance has the relationship 1 / 3 ≤ fourth distance / first distance ≤ 9 / 10 with respect to the first distance, Said third distance satisfies the relationship 1 / 3 ≤ (said third distance / said second distance) ≤ 9 / 10 with respect to said second distance, Said first distance satisfies the relationship 2 / 5 ≤ (said first distance / said second distance) ≤ 5 / 2 with respect to said second distance, Said second resin portion is in contact with all of said first surface, said second surface, said third surface and said fourth surface of said first resin portion.

[0007] A method for producing a resin molded article according to the present disclosure is a method for producing said resin molded article, comprising: a preparation step of placing said first molded portion in a mold; and a molding step of supplying molten resin to said mold to mold said second molded portion; and a demolding step of removing, from said mold, the resin molded article in which said first molded portion and said second molded portion are integrated after said molten resin solidifies; and comprising the above steps.

Effects of the Invention

[0008] According to the resin molded article and the method for producing the same of the present disclosure, even when there are many types of resin molded articles, it is possible to suppress enormous costs related to the production and management of a large number of molds. According to the resin molded article of the present disclosure, the sealing performance between the first resin portion and the second resin portion is good, and moisture is less likely to penetrate into the gap between the first resin portion and the second resin portion from the external space.

Brief Description of Drawings

[0009] [Figure 1] FIG. 1 is a perspective view showing an example of a resin molded article. [Figure 2] FIG. 2 is an explanatory diagram of the method for producing a resin molded article. [Figure 3] FIG. 3 is an explanatory diagram of the preparation step for secondary injection molding. [Figure 4] FIG. 4 is an explanatory diagram of the molding step for secondary injection molding. [Figure 5] FIG. 5 is a cross-sectional view of a part of the resin molded article. [Figure 6]Figure 6 is an explanatory diagram of a resin molded product after secondary injection molding. [Figure 7] Figure 7 is a perspective view of the first molding section. [Figure 8] Figure 8 is a cross-sectional view showing an enlarged portion of Figure 5. [Modes for carrying out the invention]

[0010] <Summary of Embodiments of the Invention Disclosed> The embodiments of the invention disclosed herein are outlined below.

[0011] (1A) The resin molded articles of this disclosure are It has a first molding section and a second molding section, The first molded part has a component as an insert and a first resin part that is integrated with the component. The second molded part has a second resin part, The first resin part comprises a first surface, a second surface, a third surface, and a fourth surface. The first surface is between the first and second cycles Ring plane And, The second surface is 、 Including the normal of the first surface 4 flat surface Consists of , Between the first and third perimeters Ring on the surface , the first surface On the first circumference of the above They are placed adjacent to each other, The third aspect mentioned above is 、 A depression in the direction normal to the first surface. The side of the first groove , Between the second and fourth perimeters Ring The four planes and ,before The opposite side of the second surface with respect to the first surface. In the second circumference of the first surface They are placed adjacent to each other, The fourth side is 、 A depression in the direction normal to the second surface. The side of the second groove , Between the third and fifth perimeters Ring The four planes and ,before The second surface is the opposite side of the first surface. In the third circumference of the second surface They are placed adjacent to each other, The distance between the second surface and the third surface in the direction normal to the first surface is defined as the first distance. The distance between the first and fourth surfaces in the direction normal to the first surface of the second surface is defined as the second distance. The third distance is defined as the distance between the first surface and the position on the third surface that is furthest from the first surface, in the direction normal to the first surface of the third surface. The distance between the second surface and the position on the fourth surface furthest from the second surface in the direction normal to the second surface is defined as the fourth distance. The fourth distance has the relationship 1 / 3 ≤ fourth distance / first distance ≤ 9 / 10 with respect to the first distance, The third distance has the relationship 1 / 3 ≤ the third distance / the second distance ≤ 9 / 10 with respect to the second distance. The first distance has the relationship 2 / 5 ≤ the first distance / the second distance ≤ 5 / 2 with respect to the second distance. The second resin portion is in contact with all surfaces of the first resin portion, including the first surface, the second surface, the third surface, and the fourth surface.

[0012] According to the resin molded product of this disclosure, even if there are many types of resin molded products, it is possible to reduce significant costs related to the manufacture and management of numerous molds. According to the resin molded product of this disclosure, the sealing performance between the first resin part and the second resin part is good, and moisture is less likely to penetrate from the external space into the gap between the first resin part and the second resin part.

[0013] When the second molded part is formed by injection molding using the first molded part as an insert, the joint strength between the first and second molded parts, and the sealing performance between them, become issues. Intrusion of moisture from the air can cause corrosion and other deterioration of the first resin part, the second resin part, and the insert. The resin molded products of this disclosure can solve these problems.

[0014] (2A) The method for manufacturing a resin molded article according to the present disclosure is the method for manufacturing a resin molded article described in (1A) above, A preparation step for placing the first molding section into the mold, A molding step of supplying molten resin to the mold to form the second molding section, Once the molten resin has solidified, a demolding step is performed to remove the resin molded product, in which the first molded part and the second molded part are integrated, from the mold. It holds.

[0015] According to the method for manufacturing resin molded products of this disclosure, if the shape of a component in the first molded part, or a part of the first resin part surrounding that component, varies, the mold for molding the first molded part can be changed. The mold for molding the second molded part can be common. This makes it possible to reduce mold costs. It also makes it possible to improve the strength between the first resin part and the second resin part, and the sealing performance between them.

[0016] (1B) From other perspectives, the resin molded articles of this disclosure are: A first molded part having a component as an insert and a first resin part integrated with that component, It comprises a second molded part which is integrated with the first molded part which serves as an insert, The second molded portion has a second resin portion that covers at least the peripheral edge of the first resin portion, As the bonding interface between the first resin portion and the second resin portion, The first interface and A second annular interface having a surface that is continuous with the entire circumferential edge of the first interface and intersects with the first interface, The first concave interface recessed from the first interface, A second concave interface that is recessed from the second interface, It has, The first concave interface is formed in an annular shape along the edge region of the first interface, The second concave interface is formed in an annular shape along the second interface within the range that overlaps with the edge region.

[0017] In the aforementioned resin molded product, if the shape of the component in the first molded part, or a part of the first resin part surrounding that component, varies, the mold for molding the first molded part can be changed. The mold for molding the second molded part can be common. Therefore, mold costs can be reduced compared to conventional methods.

[0018] When the second molded part is formed by injection molding using the first molded part as an insert, the joint strength between the first and second molded parts, and the airtightness between them, become issues. Therefore, in the resin molded product of this disclosure, the first concave interface and the second concave interface are concave in different directions. The first concave interface is located in the edge region of the first interface, and the second concave interface is located within the range that overlaps with the edge region, so the first and second concave interfaces are in close proximity. The resin of the second resin part enters into and contacts the first and second concave interfaces. As a result, shrinkage of the second resin part during molding makes it possible to increase the strength of the joint between the first and second resin parts and the airtightness between them.

[0019] (2B) Preferably, the first interface has a first planar surface, the second interface has a second planar surface perpendicular to the first surface, the first concave interface has a third surface located on the opposite side of the second surface and perpendicular to the first surface, and the second concave interface has a fourth surface located on the opposite side of the first surface and perpendicular to the second surface. According to the above configuration, the first surface and the second surface are perpendicular to each other. The third surface is perpendicular to the first surface, and the fourth surface is perpendicular to the second surface. When the first molded part is manufactured by injection molding, it is less likely to cause forced removal of the mold, and the mold release performance is high.

[0020] (3B) Preferably, the distance along the first surface between the second surface and the third surface is defined as the first distance, the distance along the second surface between the first surface and the fourth surface is defined as the second distance, the distance along the third surface from the first surface to the position on the third surface furthest from the first surface is defined as the third distance, and the distance along the fourth surface from the second surface to the position on the fourth surface furthest from the second surface is defined as the fourth distance. 1 / 3 × the first distance ≤ the fourth distance ≤ 9 / 10 × the first distance 1 / 3 × the second distance ≤ the third distance ≤ 9 / 10 × the second distance 0.4 ≤ the first distance / the second distance ≤ 2.5 The relationship satisfies the given equation.

[0021] With the above configuration, it is possible to further improve the strength of the joint between the first molded part and the second molded part. In the first molded part, it is possible to suppress the decrease in strength of the resin portion including the edge region of the first interface. It is possible to more reliably ensure the strength of the joint due to shrinkage during molding of the second resin part.

[0022] (4B) A method for manufacturing a resin molded article of the present disclosure from another perspective is a method for manufacturing a resin molded article described in any one of (1B) to (3B) above, A preparation step for placing the first molding section into the mold, A molding step of supplying molten resin to the mold to form the second molding section, Once the molten resin hardens, a demolding step is performed to remove the resin molded product, in which the first molded part and the second molded part are integrated, from the mold. It holds.

[0023] According to the method for manufacturing resin molded products of this disclosure, if the shape of a component in the first molded part, or a part of the first resin part surrounding that component, varies, only the mold for molding the first molded part needs to be changed. The mold for molding the second molded part can be common. This makes it possible to reduce mold costs. It also makes it possible to improve the strength of the joint between the first resin part and the second resin part, and the airtightness between them.

[0024] <Details of the embodiments of the invention disclosed herein> Embodiments of the invention described herein will be explained below. [Regarding resin molded products and their manufacturing methods] Figure 1 is a perspective view showing an example of a product. Product 1 shown in Figure 1 comprises a resin molded part 10, a substrate 14, and a lid 15. The resin molded part 10 includes a connector terminal 11, which is a first component, a sensor 12, which is a second component, and a housing 13. The connector terminal 11, the sensor 12, and the housing 13 are not separable. The substrate 14 is mounted on the housing 13. The lid 15 is fixed to the housing 13. Figure 1 shows product 1 with the substrate 14, the lid 15, and the resin molded part 10 separated. Product 1 is a sensor device.

[0025] The housing 13 is made of resin. The resin molded product 10 is a composite part formed by integrally molding the housing 13, the connector terminal 11, and the sensor 12 by injection molding. The resin molded product 10 can be divided into a first molded part 16 and a second molded part 18. Injection molding includes primary injection molding and secondary injection molding. Figure 2 is an explanatory diagram of the manufacturing method of the resin molded product 10. The primary injection molding is an injection molding process in which the connector terminal 11 is used as an insert and the first resin part 17 is integrally molded. The first molded part 16 is the part that has the connector terminal 11 (part) and the first resin part 17. The connector terminal 11 (part) and the first resin part 17 are integrally molded.

[0026] The secondary injection molding is an injection molding process in which the first molded part 16 and the sensor 12 are used as inserts to form the second resin part 19. The second molded part 18 is the part that contains the sensor 12 and the second resin part 19. The resin molded product 10 is manufactured by secondary injection molding. The resin molded product 10 is a composite part in which the first molded part 16 and the second molded part 18 are integrated. The housing 13 includes a first resin part 17 and a second resin part 19. The housing has a mating portion 55 on the first resin part 17. The connector terminal 11 is fixed to the mating portion 55 of the housing 13. A mating connector (not shown) is mated to the mating portion 55. The mating connector is separate from the resin molded product 10. When the mating portion 55 and the mating connector are connected, the connector terminals 11 are connected to the mating connector terminals of the mating connector.

[0027] Figures 3 and 4 are explanatory diagrams of secondary injection molding. Figure 3 shows the preparation process for placing the first molding section 16 into the molds 7a and 7b. The first molding section 16 and a sensor 12 (not shown in Figure 3) are placed in predetermined positions in the molds 7a and 7b.

[0028] Figure 4 shows a molding process in which the first molding section 16 and the sensor 12 are placed as inserts in the cavities 8 of the molds 7a and 7b, and then molten resin 19a is supplied to integrally mold the second resin section 19. The secondary injection molding is an injection molding process in which the molten resin 19a supplied into the cavity 8 solidifies. The first molding section 16 and the second molding section 18 become one unit as the molten resin 19a solidifies. Figure 5 is a cross-sectional view of a portion of the resin molded product 10 obtained after being removed from the molds 7a and 7b. Figure 5 is a cross-sectional view taken along the line V in Figure 1, and is a cross-sectional view in the plane containing the central reference line C of the first molded portion 16. The resin molded product 10, in which the first molded part 16 and the second molded part 18 are integrated, is removed from the molds 7a and 7b. The process of removing the resin molded product 10, in which the first molded part 16 and the second molded part 18 are integrated, from the molds 7a and 7b is called the removal process. The solidified portion of the molten resin 19a is the second resin part 19. The second resin part 19 covers a portion of the first resin part 17.

[0029] As shown in Figure 1, the resin molded product 10 manufactured by secondary injection molding has a housing space 20. The substrate 14 is mounted in the housing space 20. The substrate 14 is electrically connected to the connector terminal 11. The substrate 14 is electrically connected to the sensor 12. The lid 15 closes the housing space 20. The lid 15, which is made of resin, is fixed to the resin molded product 10, for example, by laser welding. The housing space 20 becomes a closed space. The process of mounting the substrate 14 to the resin molded product 10 and fixing the lid 15 to the resin molded product 10 is an assembly process.

[0030] As described above, the following steps are performed in order: preparation (see Figure 3), molding (see Figure 4), removal (see Figure 5), and assembly (see Figure 1). The preparation (see Figure 3) is the process of placing the first molded part 16, manufactured by primary injection molding, into molds 7a and 7b. The molding process is the process of supplying molten resin 19a to molds 7a and 7b and solidifying the molten resin 19a to form the second molded part 18. The removal process is the process of removing the resin molded product 10, which is an integrated unit of the first molded part 16 and the second molded part 18, from molds 7a and 7b. The assembly process is the process of assembling the substrate 14 and the lid 15 onto the resin molded product 10. Product 1 is completed through these four steps.

[0031] As shown in Figure 1, a portion of the connector terminals 11 is exposed within the housing space 20 in a rectangular area from the housing 13. The X direction is perpendicular to the plane containing the rectangle. The Y direction is perpendicular to the X direction and along the longer side of the rectangle. The Z direction is perpendicular to the X and Y directions and along the shorter side of the rectangle. Each figure shows the X, Y, and Z directions, respectively. In each diagram, the arrowhead side of the X-direction arrow is the first side in the X-direction, and the side opposite the arrowhead is the second side in the X-direction. In each diagram, the arrowhead side of the Y-direction arrow is the first side in the Y-direction, and the side opposite the arrowhead is the second side in the Y-direction. In each diagram, the arrowhead side of the Z-direction arrow is the first side in the Z-direction, and the side opposite the arrowhead is the second side in the Z-direction.

[0032] The configurations shown in Figures 1 and 2 include a connector terminal 11 as a first component in the first molded section 16 of the resin molded product 10, and a sensor 12 as a second component in the second molded section 18, however the second component may be omitted. The first component may be a component other than the connector terminal 11. If the second component is included in the resin molded product 10, the second component may be a component other than the sensor 12.

[0033] [Regarding the first molding section 16 and the second molding section 18] As explained in Figure 2, the first molded part 16 is manufactured by primary injection molding. The first molded part 16 has a connector terminal 11 as an insert and a first resin part 17 which is integrated with the connector terminal 11. The second molded part 18 is manufactured by secondary injection molding. The second molded part 18 has a second resin part 19 which is integrated with the first molded part 16 as an insert. Figure 6 is an explanatory diagram of the resin molded product 10 after secondary injection molding. Figure 6 is an image diagram in which the first molded part 16 is separated from the second molded part 18 in order to explain the first molded part 16 separately.

[0034] As described above (see Figure 4), the molten resin 19a formed by secondary injection molding solidifies to become the second resin portion 19 of the second molded portion 18. The second resin portion 19 covers a part of the first resin portion 17. As shown in Figure 6, the second resin portion 19 has an annular portion. The annular portion covers the first resin portion 17 in an annular manner. The second resin portion 19 covers at least a part of the first resin portion 17 in an annular manner.

[0035] As shown in Figure 7, the first resin part 17 includes a first groove 26 and a second groove 27. The first groove 26 is an annular groove that is recessed in the X direction from a plane whose vertical direction is the X direction. The second groove 27 is an annular groove having groove portions recessed from two planes whose vertical direction is the Y direction, and groove portions recessed from two planes whose vertical direction is the Z direction. As shown in Figure 8, the second resin part 19 completely fills the first groove 26 and the second groove 27. The second resin part 19 is in contact with each surface constituting the first groove 26 and each surface constituting the second groove 27.

[0036] The first resin part 17 comprises a first surface 31, a second surface 32, a third surface 33, and a fourth surface 34. The third surface 33 is the surface adjacent to the first surface 31 of the first groove 26. The fourth surface 34 is the surface adjacent to the second surface 32 of the second groove 27. The first resin part 17 further comprises a fifth surface 35, a sixth surface 36, a seventh surface 37, an eighth surface 38, a ninth surface 39, and a tenth surface 40. The fifth surface 35 is the surface opposite to the first surface 31 of the first groove 26. The fifth surface 35 and the first surface 31 lie on the same plane. Each surface of the sixth surface 36 is the surface opposite to each surface of the second surface 32 of the second groove 27. Each surface of the sixth surface 36 and each surface of the second surface 32 lie on the same plane. The seventh surface 37 is the surface adjacent to the fifth surface 35 of the first groove 26. The eighth surface 38 is the surface opposite to the third surface 33 and The seventh side, page 37 These are the surfaces between them. Each surface of the ninth surface 39 is adjacent to each surface of the sixth surface 36 of the second groove 27. Each surface of the tenth surface 40 is the surface between each surface of the fourth surface 34 and each surface of the ninth surface 39.

[0037] The first surface 31 is a first annular plane perpendicular to the X-axis. The first surface 31 is parallel to the Y-axis and parallel to the Z-axis. The first surface 31 is an annular plane between the first perimeter 61 and the second perimeter 62. The first perimeter 61 has a first long side 61a, a second long side 61b, a first short side 61c, and a second short side 61d of a rectangle. The second perimeter 62 has a third long side 62a, a fourth long side 62b, a third short side 62c, and a fourth short side 62d of a rectangle. The third long side 62a and the fourth long side 62b are located between the first long side 61a and the second long side 61b. The first long side 61a, the second long side 61b, the third long side 62a, and the fourth long side 62b are coplanar and parallel. The third short side 62c and the fourth short side 62d are located between the first short side 61c and the second short side 61d. The first short side 61c, the second short side 61d, the third short side 62c, and the fourth short side 62d are all on the same plane and are parallel to each other.

[0038] The second face 32 is a face whose perpendicular line is perpendicular to the X-axis. The second face 32 is a face that contains the normal to the first face 31. The second face 32 is an annular face along the first face 31. The second face 32 is an annular face between the first perimeter 61 and the third perimeter 63. The third perimeter 63 coincides with the perimeter obtained by moving the first perimeter 61 to the second side in the X direction. The third perimeter 63 includes the fifth long side 63a, the sixth long side 63b, the fifth short side 63c, and the sixth short side 63d of the rectangle. The fifth long side 63a is located on the second side in the X direction of the first long side 61a. The sixth long side 63b is located on the second side in the X direction of the second long side 61b. The fifth short side 63c is located on the second side in the X direction of the first short side 61c. The sixth short side 63d is located on the second side in the X direction of the second short side 61d. The space between the first long side 61a and the fifth long side 63a is the second plane 72. The space between the second long side 61b and the sixth long side 63b is the third plane 73. The space between the first short side 61c and the fifth short side 63c is the fourth plane 74. The space between the second short side 61d and the sixth short side 63d is the fifth plane 75. The second face 32 has the second plane 72, the third plane 73, the fourth plane 74, and the fifth plane 75.

[0039] The third face 33 is the face opposite the second face 32 to the first face 31. The third face 33 is recessed in the direction normal to the first face 31. The third face 33 is the side surface of the first groove 26. The third face 33 is an annular face along the first face 31. The third face 33 is an annular face between the second perimeter 62 and the fourth perimeter 64. The fourth perimeter 64 coincides with the perimeter obtained by shifting the second perimeter 62 to the second side in the X direction. The fourth perimeter 64 includes the seventh long side 64a, the eighth long side 64b, the seventh short side 64c, and the eighth short side 64d of the rectangle. The seventh long side 64a is located on the second side in the X direction of the third long side 62a. The eighth long side 64b is located on the second side in the X direction of the fourth long side 62b. The seventh short side 64c is located on the second side in the X direction of the third short side 62c. The eighth short side 64d is located on the second side in the X direction of the fourth short side 62d. The space between the third long side 62a and the seventh long side 64a is the sixth plane 76. The space between the fourth long side 62b and the eighth long side 64b is the seventh plane 77. The space between the third short side 62c and the seventh short side 64c is the eighth plane 78. The space between the fourth short side 62d and the eighth short side 64d is the ninth plane 79. The third face 33 has the sixth plane 76, the seventh plane 77, the eighth plane 78, and the ninth plane 79.

[0040] The fourth face 34 is opposite to the first face 31 with respect to the second face 32. The fourth face 34 is recessed in the direction normal to the second face. The fourth face 34 is the side surface of the second groove 27. The fourth face 34 is an annular tenth plane 80 along the second face 32. The fourth face 34 is an annular face between the third perimeter 63 and the fifth perimeter 65. The fifth perimeter 65 includes the ninth long side 65a, the tenth long side 65b, the ninth short side 65c, and the tenth short side 65d of a rectangle. The ninth long side 65a is located on the first side in the Z direction of the fifth long side 63a. The tenth long side 65b is located on the second side in the Z direction of the sixth long side 63b. The ninth short side 65c is located on the first side in the Y direction of the fifth short side 63c. The tenth short side 65d is located on the second side in the Y direction of the sixth short side 63d. The ninth long side 65a and the tenth long side 65b are located between the fifth long side 63a and the sixth long side 63b. The fifth long side 63a and the sixth long side 63b, and the ninth long side 65a and the tenth long side 65b are on the same plane and are parallel. The ninth short side 65c and the tenth short side 65d are located between the fifth short side 63c and the sixth short side 63d. The fifth short side 63c and the sixth short side 63d and The Ninth Short Piece 65c and Tenth short piece 65d is both coplanar and parallel.

[0041] The first distance L1 is the distance on the first face 31 in the direction normal to the second face 32 of any point on the first perimeter 61, and is the distance between the second face 32 and the third face 33. The first distance L1 is the distance on the first face 31 in the direction normal to the second plane 72 of any point on the first long side 61a surface The distance is on plane 31 and includes the distance between the first long side 61a and the third long side 62a. The first distance L1 is the first distance in the direction normal to the third plane 73 of any point on the second long side 61b. surface The distance is on plane 31 and includes the distance between the second long side 61b and the fourth long side 62b. The first distance L1 is the first distance from any point on the first short side 61c in the direction normal to the fourth plane 74. surface 31 is the distance on plane 61c, and includes the distance between the first short side 61c and the third short side 62c. The first distance L1 is the first distance in the direction normal to the fifth plane 75 of any point on the second short side 61d. surfaceThis is the distance on 31, and includes the distance between the second short side 61d and the fourth short side 62d.

[0042] The second distance L2 is the distance on the second face 32 in the direction normal to the first face 31 of any point on the first perimeter 61, and is the distance between the first face 31 and the fourth face 34. The second distance L2 is the distance on the first face 32 of any point on the first long side 61a surface The second distance L2 is the distance on the second plane 72 in the direction normal to 31, and includes the distance between the first long side 61a and the fifth long side 63a. The second distance L2 is the distance between any point on the second long side 61b and the first long side 63a. surface This is the distance on the third plane 73 in the direction normal to 31, and includes the distance between the second long side 61b and the sixth long side 63b. The second distance L2 is the distance between any point on the first short side 61c. surface The distance on the fourth plane 74 in the direction normal to 31, including the distance between the first short side 61c and the fifth short side 63c. The second distance L2 is the distance between any point on the second short side 61d and the first surface This is the distance on the fifth plane 75 in the direction of the normal of 31, and includes the distance between the second short side 61d and the sixth short side 63d.

[0043] The third distance L3 is the distance on the third face 33 in the direction normal to the first face 31 of any point on the second perimeter 62, and is the distance between the first face 31 and the point furthest from the first face 31. The third distance L3 is the distance on the third face 33 in the direction normal to the first face 31 of any point on the third long side 62a surface This is the distance on the sixth plane 76 in the direction normal to 31, and includes the distance between the third long side 62a and the seventh long side 64a. The third distance L3 is the first distance of any point on the fourth long side 62b surface The distance on the seventh plane 77 in the direction normal to 31, including the distance between the fourth long side 62b and the eighth long side 64b. The third distance L3 is the distance between any point on the third short side 62c. surface This is the distance on the eighth plane 78 in the direction normal to 31, and includes the distance between the third short side 62c and the seventh short side 64c. The third distance L3 is the first distance of any point on the fourth short side 62d surface This is the distance on the ninth plane 79 in the direction of the normal of 31, and includes the distance between the fourth short side 62d and the eighth short side 64d.

[0044] The fourth distance L4 is the distance on the fourth plane 34 in the direction normal to the second plane 32 of any point on the third perimeter 63, and is the distance between the second plane 32 and the point furthest from the second plane 32. The fourth distance L4 is the distance on the tenth plane 80 in the direction normal to the second plane 72 of any point on the fifth long side 63a, and includes the distance between the fifth long side 63a and the ninth long side 65a. The fourth distance L4 is the distance on the tenth plane 80 in the direction normal to the third plane 73 of any point on the sixth long side 63b, and includes the distance between the sixth long side 63b and the tenth long side 65b. The fourth distance L4 is the distance on the tenth plane 80 in the direction normal to the fourth plane 74 of any point on the fifth short side 63c, and includes the distance between the fifth short side 63c and the ninth short side 65c. The fourth distance L4 is, Sixth This is the distance on the tenth plane 80 in the direction normal to the fifth plane 75 from any point on the short side 63d, and includes the distance between the sixth short side 63d and the tenth short side 65d.

[0045] After secondary injection molding, the second resin part 19 is in contact with all surfaces of the first resin part 17: the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34. After secondary injection molding, each of the surfaces of the first resin part 17—the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34—becomes an interface with the second resin part 19. After secondary injection molding, the second resin part 19 is in contact with all surfaces of the first groove 26 and the second groove 27 of the first resin part 17. The first surface 31 and the second surface 32 are connected at a corner. The trajectory of this corner is the first circumference 61. The first surface 31 and the third surface 33 are connected at a corner. The trajectory of this corner is the second circumference 62. The second surface 32 and the fourth surface 34 are connected at a corner. The trajectory of this corner is the third lap, 63.

[0046] [Regarding resin molded product 10] Since the second molded part 18 is injection molded with the first molded part 16 as an insert (insert part), a bonding interface 25 is obtained between the first resin part 17 and the second resin part 19 (see Figure 5). The bonding interface 25 between the first resin part 17 and the second resin part 19 has a first interface 21, a second interface 22, a first concave interface 23, and a second concave interface 24. The second resin part 19 covers the entire surface of the first interface 21 and the entire surface of the second interface 22. The second resin part 19 covers the entire surface of the first concave interface 23 and the entire surface of the second concave interface 24.

[0047] In the configuration shown in Figure 5, the first interface 21 is a part of the upper surface 29 of the first molded part 16 that faces in the X direction. The second resin part 19 has an annular portion that covers the peripheral edge 17a of the first resin part 17 (see Figures 5 and 6). The first interface 21 is an annular surface centered on the central reference line C in the X direction. The first interface 21 has a first planar surface 31. Furthermore, the first interface 21 has a fifth surface 35 opposite to the first surface 31, with the first concave interface 23 in between.

[0048] The second interface 22 has sides facing the Y direction, the opposite direction of the Y direction, the Z direction, and the opposite direction of the Z direction. In other words, the second interface 22 is an annular (cylindrical) surface. The second interface 22 has a second surface 32. The second surface 32 is continuous with the entire circumferential edge 21a of the first interface 21 and intersects with the first interface 21. In this embodiment, the second surface 32 is a plane perpendicular to the first surface 31. Furthermore, the second interface 22 has a sixth surface 36 on the opposite side of the second surface 32, with the second concave interface 24 in between.

[0049] The second interface 22 has four planar second surfaces 32, each facing in the Y direction, the opposite direction of the Y direction, the Z direction, and the opposite direction of the Z direction. The second surfaces 32 extend in a direction perpendicular to the first surface 31 (first interface 21). The second interface 22 also has four planar sixth surfaces 36, each facing in the same direction as the second surfaces 32.

[0050] Figure 7 is a perspective view of the first molded section 16. The first concave interface 23 is a surface that is recessed from the first interface 21. The first concave interface 23 is continuous along the annular first interface 21. When the first molded section 16 is viewed alone, the first concave interface 23 is the annular first groove 26. Figure 8 is a cross-sectional view showing an enlarged portion of Figure 5. The first concave interface 23 has a third surface 33, a first opposing surface (seventh surface 37), and a first bottom surface (eighth surface 38). The third surface 33 is located on the opposite side of the second surface 32 and is perpendicular to the first surface 31. The first opposing surface (seventh surface 37) is the surface opposite to the third surface 33. The first bottom surface (eighth surface 38) is the bottom surface of the first groove 26 and connects the third surface 33 and the first opposing surface (seventh surface 37).

[0051] As shown in Figure 7, the second concave interface 24 is a surface that is recessed from the second interface 22. The second concave interface 24 is continuous along the annular second interface 22. When the first molded part 16 is viewed in isolation, the second concave interface 24 is the annular second groove 27. As shown in Figure 8, the second concave interface 24 has a fourth surface 34, a second opposing surface (ninth surface 39), and a second bottom surface (tenth surface 40). The fourth surface 34 is located on the opposite side of the first surface 31 and is perpendicular to the second surface 32. The second opposing surface (ninth surface 39) is the surface opposite to the fourth surface 34. The second bottom surface (tenth surface 40) is the bottom surface of the second groove 27 and connects the fourth surface 34 and the second opposing surface (ninth surface 39).

[0052] As shown in Figures 7 and 8, in the first resin portion 17, the first concave interface 23 and the second concave interface 24 are arranged in close proximity. The first concave interface 23 is formed in an annular shape along the edge region K1 of the first interface 21. The second concave interface 24 is formed in an annular shape along the second interface 22 within the range that overlaps with its edge region K1. The second concave interface 24 is formed within the range that overlaps with the edge region K1 of the first interface 21 in the Z direction, the opposite Z direction, the Y direction, and the opposite Y direction.

[0053] [Regarding the resin molded product 10 having the above configuration] As described above, the resin molded product 10 of this embodiment (see Figure 5) comprises a first molded part 16 and a second molded part 18. The first molded part 16 has a connector terminal 11 as an insert and a first resin part 17 which is integrated with the connector terminal 11. The second molded part 18 has a second resin part 19. The first resin part 17 comprises a first surface 31, a second surface 32, a third surface 33, and a fourth surface 34. The second resin part 19 is in contact with all surfaces of the first resin part 17: the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34.

[0054] According to the resin molded product 10 of this embodiment, even if the shape of the connector terminal 11 of the first molded part 16 or the fitting part 55 of the first resin part 17 varies, only the mold for molding the first molded part 16 needs to be changed. In contrast, the molds 7a and 7b (see Figures 3 and 4) for molding the second molded part 18 can be common. Therefore, mold costs can be reduced compared to the conventional method, which requires multiple molds that are mostly the same shape but have slightly different shapes in some parts.

[0055] When the second molded part 18 is formed by injection molding using the first molded part 16 as an insert, the joint strength between the first molded part 16 and the second molded part 18, and the sealing performance between the two become issues. Therefore, in the resin molded product 10 of this embodiment (see Figure 5), the first surface 31 is annular, the second surface 32 is a surface that includes the normal to the first surface 31, the second surface 32 is annular along the first surface 31, the second surface 32 is positioned adjacent to the first surface 31, the third surface 33 is recessed in the direction normal to the first surface 31 and the third surface 33 is annular along the first surface 31 and the third surface 33 is positioned adjacent to the first surface 31 on the opposite side from the second surface 32, the fourth surface 34 is recessed in the direction normal to the second surface 32 and the fourth surface 34 is annular along the second surface 32 and the fourth surface 34 is positioned adjacent to the second surface 32 on the opposite side from the first surface 31, and the distance between the second surface 32 and the third surface 33 in the direction normal to the second surface 32 of the first surface 31 is defined as the first distance L1, and the second surface 32 The second distance L2 is the distance between the first surface 31 and the fourth surface 34 in the direction normal to the first surface 31 of the third surface 33 and the position on the third surface 33 that is furthest from the first surface 31 of the third surface 33, and the fourth distance L4 is the distance between the second surface 32 and the position on the fourth surface 34 that is furthest from the second surface 32 of the fourth surface 34, and the fourth distance L4 has the relationship 1 / 3 ≤ fourth distance L4 / first distance L1 ≤ 9 / 10 with respect to the first distance L1, the third distance L3 has the relationship 1 / 3 ≤ third distance L3 / second distance L2 ≤ 9 / 10 with respect to the second distance L2, and the first distance L1 has the relationship 2 / 5 ≤ first distance L1 / second distance L2 ≤ 5 / 2 with respect to the second distance L2.

[0056] As shown in Figures 7 and 8, the first surface 31 and the second surface 32 are connected at the corner, the first surface 31 and the third surface 33 are connected at the corner, and the second surface 32 and the fourth surface 34 are connected at the corner. The second resin part 19 covers all surfaces of the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34.

[0057] The second resin part 19 shrinks during molding. Since the first resin part 17 does not shrink, the second resin part 19 tightens the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 of the first resin part 17. Referring to Figure 8, arrows F1 and F2 indicate the tightening force that the second resin part 19 exerts on the first resin part 17 due to the shrinkage of the second resin part 19 during molding. In this embodiment, the shrinkage of the second resin part 19 makes it possible to improve the strength of the joint between the first resin part 17 and the second resin part 19, as well as the sealing performance between them.

[0058] In this embodiment, the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 consist of the first plane 31, the second plane 72, the third plane 73, the fourth plane 74, the fifth plane 75, the sixth plane 76, the seventh plane 77, the eighth plane 78, the ninth plane 79, and the tenth plane 80. Between these planes, any plane is perpendicular to any adjacent plane. Therefore, when the first molded part 16 is manufactured by injection molding, the combination of molds does not need to be complex, and the first molded part 16 is less likely to be forcibly removed from the mold and is easier to remove from the mold.

[0059] [Regarding the specific configuration of the joint]

[0060] The cross-section shown in Figure 8 shows the first distance L1, the second distance L2, the third distance L3, and the fourth distance L4 in this embodiment. As described above, the relationship between the first distance L1, the second distance L2, the third distance L3, and the fourth distance L4 satisfies all of the following equations (1), (2), and (3).

[0061] Equation (1): 1 / 3 ≤ fourth distance L4 / first distance L1 ≤ 9 / 10 Equation (2): 1 / 3 ≤ third distance L3 / second distance L2 ≤ 9 / 10 Equation (3): 2 / 5 ≤ first distance L1 / second distance L2 ≤ 5 / 2

[0062] According to the formula (1) above, "1 / 3 ≤ fourth distance L4 / first distance L1", the depth of the fourth surface 34 in the Z direction is 1 / 3 or more of the first distance L1. The depth of the second resin part 19 in the Z direction that contacts the fourth surface 34 becomes sufficient, and the tension force due to the contraction of the second resin part 19 (arrow F1 in Figure 8) is effectively transmitted to the fourth surface 34. The seal formed by the first resin part 17 and the second resin part 19 has good sealing properties, and moisture is less likely to penetrate from the outside space into the gap between the first resin part 17 and the second resin part 19. According to equation (2) above, "1 / 3 ≤ third distance L3 / second distance L2", the depth of the third surface 33 in the X direction is 1 / 3 or more of the second distance L2. The depth of the second resin part 19 in the X direction that contacts the third surface 33 becomes sufficient, and the tension force due to the contraction of the second resin part 19 (arrow F2 in Figure 8) is effectively transmitted to the third surface 33. The seal formed by the first resin part 17 and the second resin part 19 has good sealing properties, and moisture does not easily penetrate from the outside space into the gap between the first resin part 17 and the second resin part 19.

[0063] According to equation (1) above, "fourth distance L4 / first distance L1 ≤ 9 / 10" and equation (2) above, "third distance L3 / second distance L2 ≤ 9 / 10" , position Place P1 and position The position P2 is not too close. In other words, when the first molded part 16 is considered as a single unit, the corner block portion 54 of the first resin part 17, which has a first surface 31, a second surface 32, a third surface 33, and a fourth surface 34, is prevented from being cut from the other central block portion 53. The first molded part 16 is less likely to detach from the second molded part 18.

[0064] According to equation (3) above, neither the first distance L1 nor the second distance L2 is excessively large compared to the other. With respect to either the first distance L1 or the second distance L2, if the distance of the first distance L1 to the third distance L3 is extremely small, or if the distance of the second distance L2 to the fourth distance L4 is extremely small, the second resin part 19 does not tightly press against the third surface 33 or the fourth surface 34, making it difficult to improve the sealing performance of the seal formed by the first resin part 17 and the second resin part 19.

[0065] [Regarding other matters] In the above embodiment, the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 were each a plane or a combination of planes, and were each orthogonal surfaces. On the other hand, in the present invention, the shapes of the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 may be partially convex or concave, as long as they do not become forcibly removed when the mold is removed or the first resin part 17 does not undergo plastic deformation. Also, for example, the first surface 31 and the second surface 32 are orthogonal, but they may intersect at other angles as long as they do not become forcibly removed. Similarly, for the other surfaces, the angles formed by adjacent surfaces do not have to be right angles.

[0066] The embodiments described above are illustrative and not restrictive in all respects. The scope of the present invention is indicated by the claims rather than by the embodiments, and includes all modifications within the scope of equivalence to the configurations described in the claims. [Explanation of symbols]

[0067] 7a,7b Mold 10 Resin molded products 11. Connector terminals (components) 16 First molding section 17 First resin department 17a Peripheral area 18 Second molding section 19a Molten resin 19 Second resin part 31 First side 32 The second side 33 The Third Side 34. The Fourth Face L1 First distance L2 Second distance L3 Third distance L4 Fourth distance

Claims

1. It has a first molding section and a second molding section, The first molded part has a component as an insert and a first resin part that is integrated with the component. The second molded part has a second resin part, The first resin part comprises a first surface, a second surface, a third surface, and a fourth surface. The first surface is an annular plane between the first and second perimeters, The second surface is an annular surface between the first and third perimeters, comprising four planes including the normal to the first surface, and is positioned adjacent to the first perimeter of the first surface. The third surface is an annular plane between the second and fourth perimeters, which forms the side surface of the first groove that is recessed in the direction normal to the first surface, and is located on the side opposite to the second surface of the first surface and adjacent to the second perimeter of the first surface. The fourth surface is an annular plane between the third and fifth perimeters, which forms the side surface of the second groove that is recessed in the direction normal to the second surface, and is located on the side opposite to the first surface relative to the second surface, adjacent to the third perimeter of the second surface. The distance between the second surface and the third surface in the direction normal to the first surface is defined as the first distance. The distance between the first and fourth surfaces in the direction normal to the first surface of the second surface is defined as the second distance. The third distance is defined as the distance between the first surface and the position on the third surface that is furthest from the first surface, in the direction normal to the first surface of the third surface. The distance between the second surface and the position on the fourth surface furthest from the second surface in the direction normal to the second surface is defined as the fourth distance. The fourth distance has the relationship 1 / 3 ≤ fourth distance / first distance ≤ 9 / 10 with respect to the first distance. The third distance has the relationship 1 / 3 ≤ the third distance / the second distance ≤ 9 / 10 with respect to the second distance. The first distance has the relationship 2 / 5 ≤ the first distance / the second distance ≤ 5 / 2 with respect to the second distance, The second resin portion is in contact with all surfaces of the first resin portion, including the first surface, the second surface, the third surface, and the fourth surface. Resin molded product.

2. A method for manufacturing a resin molded article according to claim 1, A preparation step for placing the first molding section into the mold, A molding step of supplying molten resin to the mold to form the second molding section, Once the molten resin has solidified, a demolding step is performed to remove the resin molded product, in which the first molded part and the second molded part are integrated, from the mold. A method for manufacturing a resin molded product having the following characteristics.

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