Resin molded article and method for producing resin molded article

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

Resin molded product and method for manufacturing the same

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

[0002] For example, resin molded products including connectors are known. The resin molded product disclosed in Patent Document 1 includes components such as connector terminals and a resin housing that is integrated with the connector terminals. The housing has a mating portion for connecting the connector terminals to a mating connector. Such resin molded products are manufactured by injection molding using components such as connector terminals as inserts.

[0003] Japanese Patent Application Laid-Open No. 2022-51061

[0004] Among the resin molded products described above, there are multiple resin molded products with different connector terminal shapes but the same other parts, or multiple resin molded products with different mating part shapes but the same other parts. To manufacture these, multiple molds are required for each resin molded product. Each of the multiple molds has a slightly different shape in only one part, but most of the shape is the same. When there are many types of parts such as connector terminals or mating parts, it is very expensive to manufacture and manage a large number of molds.

[0005] Therefore, an object of the present disclosure is to provide a resin molded product that enables reduction in mold costs, and to provide a method for manufacturing such a resin molded product.

[0006] A resin molded product according to the present disclosure has a first molded portion and a second molded portion, wherein the first molded portion has a part as an insert and a first resin portion integral with the part, wherein the second molded portion has a second resin portion, wherein the first resin portion has a first surface, a second surface, a third surface, and a fourth surface, wherein the first surface is annular, wherein the second surface is a surface including a normal to the first surface, wherein the second surface is annular along the first surface, wherein the second surface is disposed adjacent to the first surface, wherein the third surface is recessed in a direction normal to the first surface, wherein the third surface is annular along the first surface, wherein the third surface is disposed adjacent to the first surface on the opposite side to the second surface, wherein the fourth surface is recessed in a direction normal to the second surface, wherein the fourth surface is annular along the second surface, and wherein the fourth surface is disposed adjacent to the second surface on the opposite side to the first surface, a first distance is a distance between the second surface and the third surface in a normal direction of the second surface of the first surface; a second distance is a distance between the first surface and the fourth surface of the second surface in a normal direction of the first surface of the second surface; a third distance is a distance between the first surface and a position on the third surface that is furthest from the first surface in a normal direction of the first surface of the third surface; a fourth distance is a distance between the second surface and a position on the fourth surface that is furthest from the second surface in a normal direction of the second surface of the fourth surface; the fourth distance has a relationship with the first distance of 1 / 3≦the fourth distance / the first distance≦9 / 10; the third distance has a relationship with the second distance of 1 / 3≦the third distance / the second distance≦9 / 10; and the first distance has a relationship with the second distance of 2 / 5≦the first distance / the second distance≦5 / 2; 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.

[0007] The method for manufacturing a resin molded product disclosed herein is a method for manufacturing the resin molded product, and includes a preparation step of placing the first molded portion in a mold, a molding step of supplying molten resin to the mold to mold the second molded portion, and a demolding step of removing the resin molded product, in which the first molded portion and the second molded portion are integrated, from the mold when the molten resin solidifies.

[0008] According to the resin molded product and manufacturing method thereof disclosed herein, it is possible to significantly reduce costs associated with manufacturing and managing a large number of molds, even when there are many different types of resin molded products. According to the resin molded product disclosed herein, the sealing performance between the first resin part and the second resin part is good, and moisture is less likely to penetrate into the gap between the first resin part and the second resin part from the external space.

[0009] FIG. 1 is a perspective view showing an example of a resin molded product. FIG. 2 is an explanatory diagram of a manufacturing method for a resin molded product. FIG. 3 is an explanatory diagram of a preparation process for secondary injection molding. FIG. 4 is an explanatory diagram of a molding process for secondary injection molding. FIG. 5 is a cross-sectional view of a part of the resin molded product. FIG. 6 is an explanatory diagram of a resin molded product after secondary injection molding. FIG. 7 is a perspective view of a first molding part. FIG. 8 is an enlarged cross-sectional view of a part of FIG. 5.

[0010] <Outline of Embodiments of the Invention of the Present Disclosure> Below, outlines of embodiments of the invention of the present disclosure will be listed and described.

[0011] (1A) A resin molded product according to the present disclosure has a first molded portion and a second molded portion, wherein the first molded portion has a part as an insert and a first resin portion integral with the part, wherein the second molded portion has a second resin portion, wherein the first resin portion has a first surface, a second surface, a third surface, and a fourth surface, wherein the first surface is annular, wherein the second surface is a surface including a normal to the first surface, wherein the second surface is annular along the first surface, wherein the second surface is disposed adjacent to the first surface, wherein the third surface is recessed in a direction normal to the first surface, wherein the third surface is annular along the first surface, wherein the third surface is disposed adjacent to the first surface on the opposite side to the second surface, wherein the fourth surface is recessed in a direction normal to the second surface, wherein the fourth surface is annular along the second surface, and wherein the fourth surface is disposed adjacent to the second surface on the opposite side to the first surface, a first distance is a distance between the second surface and the third surface in a normal direction of the second surface of the first surface; a second distance is a distance between the first surface and the fourth surface of the second surface in a normal direction of the first surface of the second surface; a third distance is a distance between the first surface and a position on the third surface that is furthest from the first surface in a normal direction of the first surface of the third surface; a fourth distance is a distance between the second surface and a position on the fourth surface that is furthest from the second surface in a normal direction of the second surface of the fourth surface; the fourth distance has a relationship with the first distance of 1 / 3≦the fourth distance / the first distance≦9 / 10; the third distance has a relationship with the second distance of 1 / 3≦the third distance / the second distance≦9 / 10; and the first distance has a relationship with the second distance of 2 / 5≦the first distance / the second distance≦5 / 2; 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.

[0012] According to the resin molded product of the present disclosure, even when there are many types of resin molded products, it is possible to significantly reduce costs associated with manufacturing and managing a large number of molds. According to the resin molded product of the present disclosure, the sealing performance between the first resin part and the second resin part is good, and moisture is less likely to penetrate into the gap between the first resin part and the second resin part from the external space.

[0013] When the second molded part is formed by injection molding using the first molded part as an insert, the bond strength between the first molded part and the second molded part and the sealing ability between them become issues. The infiltration 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 product of the present disclosure can solve these issues.

[0014] (2A) The manufacturing method of a resin molded product of the present disclosure is the manufacturing method of a resin molded product described in (1A) above, and includes a preparation step of arranging the first molded portion in a mold, a molding step of supplying molten resin to the mold to mold the second molded portion, and a demolding step of removing the resin molded product, in which the first molded portion and the second molded portion are integrated, from the mold when the molten resin solidifies.

[0015] According to the manufacturing method of the resin molded product disclosed herein, when the shape of the part of the first molded portion or the part of the first resin portion surrounding the part varies, it is only necessary to change the mold for molding the first molded portion. A common mold can be used for molding the second molded portion. This reduces mold costs. It is also possible to increase the strength between the first resin portion and the second resin portion and the sealing performance between them.

[0016] (1B) A resin molded product of the present disclosure from another viewpoint comprises: a first molded portion having a part as an insert and a first resin part integral with the part; and a second molded portion integral with the first molded portion as an insert, wherein the second molded portion has a second resin part covering at least a peripheral portion of the first resin part, and the first resin part has, as a joining interface with the second resin part, a first interface, a ring-shaped second interface having a surface that is continuous from the edge of the entire periphery of the first interface and intersects with the first interface, a first concave interface recessed from the first interface, and a second concave interface recessed from the second interface, wherein the first concave interface is formed in a ring shape along an edge region of the first interface, and the second concave interface is formed in a ring shape along the second interface within a range that overlaps with the edge region.

[0017] According to the resin molded product, when the shape of the part of the first molded portion or the part of the first resin portion surrounding the part varies, it is only necessary to change the mold for molding the first molded portion. A common mold can be used for molding the second molded portion. This makes it possible to reduce mold costs compared to conventional methods.

[0018] When the second molded part is molded by injection molding using the first molded part as an insert, the bond strength between the first molded part and the second molded part and the sealability between them become issues. Therefore, according to the resin molded product of the present 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 a range overlapping the edge region, so the first concave interface and the second concave interface are close to each other. The resin of the second resin part penetrates and contacts these first and second concave interfaces. Therefore, shrinkage during molding of the second resin part can increase the strength of the bond between the first resin part and the second resin part and the airtightness between them.

[0019] (2B) Preferably, the first interface has a planar first surface, the second interface has a planar second surface perpendicular to the first surface, the first concave interface has a third surface located opposite the second surface and perpendicular to the first surface, and the second concave interface has a fourth surface located opposite the first surface and perpendicular to the second surface. According to this configuration, the first surface and the second surface are perpendicular to each other. The third surface is a surface perpendicular to the first surface, and the fourth surface is a surface perpendicular to the second surface. When the first molded portion is manufactured by injection molding, the mold is less likely to be forcibly removed, and the mold has high release performance.

[0020] (3B) Preferably, when a first distance is a distance between the second surface and the third surface along the first surface, a second distance is a distance between the first surface and the fourth surface along the second surface, a third distance is a distance between the first surface and a position of the third surface that is farthest from the first surface along the third surface, and a fourth distance is a distance between the second surface and a position of the fourth surface that is farthest from the second surface along the fourth surface, the following relational expressions are satisfied: 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, and 0.4≦the first distance / the second distance≦2.5.

[0021] This configuration can further improve the strength of the joint between the first molded portion and the second molded portion, suppress a decrease in strength of the resin portion of the first molded portion, including the edge region of the first interface, and more reliably ensure the strength of the joint due to shrinkage during molding of the second resin portion.

[0022] (4B) From another perspective, the method for manufacturing a resin molded product of the present disclosure is a method for manufacturing a resin molded product described in any one of (1B) to (3B) above, and includes: a preparation step of arranging the first molded portion in a mold; a molding step of supplying molten resin to the mold to mold the second molded portion; and a demolding step of removing the resin molded product, in which the first molded portion and the second molded portion are integrated, from the mold when the molten resin hardens.

[0023] According to the manufacturing method of the resin molded product disclosed herein, when the shape of the component of the first molded portion or the part of the first resin portion surrounding the component varies, it is only necessary to change the mold for molding the first molded portion. A common mold can be used for molding the second molded portion. This reduces mold costs. It is possible to increase the strength of the joint between the first resin portion and the second resin portion and the airtightness between them.

[0024] <Details of the embodiment of the invention of the present disclosure> Hereinafter, an embodiment of the invention of the present disclosure will be described. [Resin molded product and manufacturing method thereof] Fig. 1 is a perspective view showing an example of a product. The product 1 shown in Fig. 1 includes a resin molded product 10, a substrate 14, and a lid 15. The resin molded product 10 includes a connector terminal 11 as a first component, a sensor 12 as 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 attached to the housing 13. The lid 15 is fixed to the housing 13. Fig. 1 shows the product 1 in which the substrate 14, the lid 15, and the resin molded product 10 are separate. The product 1 is a sensor device.

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

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

[0027] 3 and 4 are explanatory diagrams of the secondary injection molding. Fig. 3 shows a preparation step of placing the first molded part 16 in the molds 7a and 7b. The first molded part 16 and the sensor 12 (not shown in Fig. 3) are placed at predetermined positions in the molds 7a and 7b.

[0028] FIG. 4 shows a molding process in which the first molded portion 16 and the sensor 12 are inserted into the cavity 8 of the molds 7a and 7b, and then molten resin 19a is supplied to integrally mold the second molded portion 19. Secondary injection molding is an injection molding process in which the molten resin 19a supplied into the cavity 8 solidifies. The first molded portion 16 and the second molded portion 18 are integrated by the solidification of the molten resin 19a. FIG. 5 is a cross-sectional view of a portion of the resin molded product 10 obtained after removal from the molds 7a and 7b. FIG. 5 is a cross-sectional view taken along arrow V in FIG. 1 , taken along a plane including the center reference line C of the first molded portion 16. The resin molded product 10, in which the first molded portion 16 and the second molded portion 18 are integrated, is removed from the molds 7a and 7b. The removal process is a process in which the resin molded product 10, in which the first molded portion 16 and the second molded portion 18 are integrated, is removed from the molds 7a and 7b. The solidified portion of the molten resin 19a is the second resin portion 19. The second resin portion 19 covers a part of the first resin portion 17.

[0029] As shown in FIG. 1 , a resin molded product 10 manufactured by secondary injection molding has an accommodation space 20. A substrate 14 is attached to the accommodation space 20. The substrate 14 is electrically connected to a connector terminal 11. The substrate 14 is electrically connected to a sensor 12. A lid 15 closes the accommodation space 20. The lid 15, which is made of resin, is fixed to the resin molded product 10 by, for example, laser welding. The accommodation space 20 becomes a closed space. The process of attaching 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 preparation process (see FIG. 3), molding process (see FIG. 4), removal process (see FIG. 5), and assembly process (see FIG. 1) are performed in this order. The preparation process (see FIG. 3) is a process of placing the first molded portion 16 manufactured by primary injection molding in the molds 7a and 7b. The molding process is a process of supplying molten resin 19a to the molds 7a and 7b and solidifying the molten resin 19a to form the second molded portion 18. The removal process is a process of removing the resin molded product 10, in which the first molded portion 16 and the second molded portion 18 are integrated, from the molds 7a and 7b. The assembly process is a process of assembling the substrate 14 and the lid 15 to the resin molded product 10. The product 1 is completed through these four processes.

[0031] As shown in FIG. 1 , a portion of the connector terminal 11 is exposed from the housing 13 within the accommodating space 20 within a rectangular area. The X direction is a direction perpendicular to a plane including the rectangle. The Y direction is a direction perpendicular to the X direction and along the long side of the rectangle. The Z direction is a direction perpendicular to the X direction and along the short side of the rectangle. Each figure shows the X direction, the Y direction, and the Z direction. The arrowhead side of the X-direction arrow in each figure is the first side in the X direction, and the side opposite the arrowhead is the second side in the X direction. The arrowhead side of the Y-direction arrow in each figure is the first side in the Y direction, and the side opposite the arrowhead is the second side in the Y direction. The arrowhead side of the Z-direction arrow in each figure is the first side in the Z direction, and the side opposite the arrowhead is the second side in the Z direction.

[0032] 1 and 2 , the first molded portion 16 of the resin molded product 10 includes a connector terminal 11 as a first component, and the second molded portion 18 includes a sensor 12 as a second component, but the second component may be omitted. The first component may be a component other than the connector terminal 11. When 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 Molded Portion 16 and the Second Molded Portion 18] As described with reference to Fig. 2, the first molded portion 16 is manufactured by primary injection molding. The first molded portion 16 has a connector terminal 11 as an insert and a first resin portion 17 that is integral with the connector terminal 11. The second molded portion 18 is manufactured by secondary injection molding. The second molded portion 18 has a second resin portion 19 that is integral with the first molded portion 16 as an insert. Fig. 6 is an explanatory diagram of the resin molded product 10 after secondary injection molding has been completed. Fig. 6 is an image diagram in which the first molded portion 16 is separated from the second molded portion 18 in order to distinguish and explain the first molded portion 16.

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

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

[0036] The first resin portion 17 includes a first surface 31, a second surface 32, a third surface 33, and a fourth surface 34. The third surface 33 is adjacent to the first surface 31 of the first groove 26. The fourth surface 34 is adjacent to the second surface 32 of the second groove 27. The first resin portion 17 further includes 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 opposite the first surface 31 of the first groove 26. The fifth surface 35 and the first surface 31 are on the same plane. Each surface of the sixth surface 36 is 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 are on the same plane. The seventh surface 37 is a surface adjacent to the fifth surface 35 of the first groove 26. The eighth surface 38 is a surface between the third surface 33 and the fifth surface 35. Each surface of the ninth surface 39 is a surface adjacent to each surface of the sixth surface 36 of the second groove 27. Each surface of the tenth surface 40 is a 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 plane perpendicular to the X-axis and annular. The first surface 31 is parallel to the Y-axis and the Z-axis. The first surface 31 is an annular surface between a first periphery 61 and a second periphery 62. The first periphery 61 has a rectangular first long side 61a, a second long side 61b, a first short side 61c, and a second short side 61d. The second periphery 62 has a rectangular third long side 62a, a fourth long side 62b, a third short side 62c, and a fourth short side 62d. 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 on the same plane and parallel to each other. 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 on the same plane and parallel to each other.

[0038] The second surface 32 is a surface having a normal perpendicular to the X-axis. The second surface 32 is a surface including the normal to the first surface 31. The second surface 32 is an annular surface along the first surface 31. The second surface 32 is an annular surface between the first periphery 61 and the third periphery 63. The third periphery 63 coincides with the periphery obtained by moving the first periphery 61 toward the second side in the X direction. The third periphery 63 includes a fifth long side 63a, a sixth long side 63b, a fifth short side 63c, and a 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. A second plane 72 is formed between the first long side 61a and the fifth long side 63a. A third plane 73 is formed between the second long side 61b and the sixth long side 63b. A fourth plane 74 is formed between the first short side 61c and the fifth short side 63c. A fifth plane 75 is formed between the second short side 61d and the sixth short side 63d. The second surface 32 has the second plane 72, the third plane 73, the fourth plane 74, and the fifth plane 75.

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

[0040] The fourth surface 34 is located on the opposite side of the second surface 32 from the first surface 31. The fourth surface 34 is recessed in a direction normal to the second surface. The fourth surface 34 is a side surface of the second groove 27. The fourth surface 34 is an annular tenth plane 80 along the second surface 32. The fourth surface 34 is an annular surface between the third periphery 63 and the fifth periphery 65. The fifth periphery 65 includes a ninth long side 65a, a tenth long side 65b, a ninth short side 65c, and a tenth short side 65d of the rectangle. The ninth long side 65a is located on a first side in the Z direction of the fifth long side 63a. The tenth long side 65b is located on a second side in the Z direction of the sixth long side 63b. The ninth short side 65c is located on a 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, the ninth long side 65a and the tenth long side 65b are on the same plane and are parallel to each other. 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, the third short side 65c and the fourth short side 65d are on the same plane and are parallel to each other.

[0041] The first distance L1 is the distance on the first plane 31 in the normal direction of the second plane 32 at any point on the first circumference 61, and is the distance between the second plane 32 and the third plane 33. The first distance L1 is the distance on the first plane 31 in the normal direction of the second plane 72 at any point on the first long side 61a, and includes the distance between the first long side 61a and the third long side 62a. The first distance L1 is the distance on the first plane 31 in the normal direction of the third plane 73 at any point on the second long side 61b, and includes the distance between the second long side 61b and the fourth long side 62b. The first distance L1 is the distance on the first plane 31 in the normal direction of the fourth plane 74 at any point on the first short side 61c, and includes the distance between the first short side 61c and the third short side 62c. The first distance L1 is the distance on the first plane 31 in the normal direction of the fifth plane 75 at any point on the second short side 61d, 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 surface 32 in the normal direction of the first surface 31 at any point on the first circumference 61, and is the distance between the first surface 31 and the fourth surface 34. The second distance L2 is the distance on the second plane 72 in the normal direction of the first plane 31 at any point on the first long side 61a, and includes the distance between the first long side 61a and the fifth long side 63a. The second distance L2 is the distance on the third plane 73 in the normal direction of the first plane 31 at any point on the second long side 61b, and includes the distance between the second long side 61b and the sixth long side 63b. The second distance L2 is the distance on the fourth plane 74 in the normal direction of the first plane 31 at any point on the first short side 61c, and includes the distance between the first short side 61c and the fifth short side 63c. The second distance L2 is the distance on the fifth plane 75 in the normal direction of the first plane 31 at any point on the second short side 61d, 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 surface 33 in the normal direction to the first surface 31 at any point on the second circumference 62, and is the distance between the first surface 31 and the farthest point from the first surface 31. The third distance L3 is the distance on the sixth plane 76 in the normal direction to the first plane 31 at any point on the third long side 62a, and includes the distance between the third long side 62a and the seventh long side 64a. The third distance L3 is the distance on the seventh plane 77 in the normal direction to the first plane 31 at any point on the fourth long side 62b, and includes the distance between the fourth long side 62b and the eighth long side 64b. The third distance L3 is the distance on the eighth plane 78 in the normal direction to the first plane 31 at any point on the third short side 62c, and includes the distance between the third short side 62c and the seventh short side 64c. The third distance L3 is the distance on the ninth plane 79 in the normal direction of the first plane 31 of any point on the fourth short side 62d, 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 normal direction to the second plane 32 at any point on the third circumference 63, and is the distance between the second plane 32 and the farthest point from the second plane 32. The fourth distance L4 is the distance on the tenth plane 80 in the normal direction to the second plane 72 at 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 normal direction to the third plane 73 at 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 normal direction to the fourth plane 74 at 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 the distance on the tenth plane 80 in the normal direction of the fifth plane 75 at any point on the fifth short side 63d, and includes the distance between the sixth short side 63d and the tenth short side 65d.

[0045] After the secondary injection molding, the second resin portion 19 contacts all of the first resin portion 17's surfaces, including the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34. After the secondary injection molding, the first resin portion 17's surfaces, including the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34, form interfaces with the second resin portion 19. After the secondary injection molding, the second resin portion 19 contacts all of the first resin portion 17's surfaces, including the first groove 26 and the second groove 27. The first surface 31 and the second surface 32 are connected by a corner. The path of this corner is a first perimeter 61. The first surface 31 and the third surface 33 are connected by a corner. The path of this corner is a second perimeter 62. The second surface 32 and the fourth surface 34 are connected by a corner. The locus of this corner is the third periphery 63 .

[0046] [Regarding the resin molded product 10] Because the second molded portion 18 is injection molded using the first molded portion 16 as an insert (insert product), a bonding interface 25 is obtained between the first resin portion 17 and the second resin portion 19 (see FIG. 5 ). The bonding interface 25 between the first resin portion 17 and the second resin portion 19 includes a first interface 21, a second interface 22, a first concave interface 23, and a second concave interface 24. The second resin portion 19 covers the entire surface of the first interface 21 and also the entire surface of the second interface 22. The second resin portion 19 covers the entire surface of the first concave interface 23 and also the entire surface of the second concave interface 24.

[0047] In the embodiment shown in Fig. 5, the first interface 21 is part of an upper surface 29 of the first molded portion 16 facing the X direction. The second resin portion 19 has an annular portion that covers the peripheral edge portion 17a of the first resin portion 17 (see Figs. 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 planar first surface 31. Furthermore, the first interface 21 has a fifth surface 35 on the opposite side of the first surface 31 with the first concave interface 23 in between.

[0048] The second interface 22 has side surfaces facing the Y direction, the direction opposite the Y direction, the Z direction, and the direction opposite the Z direction. In other words, the second interface 22 has an annular (cylindrical) surface. The second interface 22 has a second surface 32. The second surface 32 is continuous with the edge 21a of the entire periphery 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 across the second concave interface 24.

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

[0050] FIG. 7 is a perspective view of the first molding portion 16. The first concave interface 23 is a surface recessed from the first interface 21. The first concave interface 23 is continuous along the annular first interface 21. When the first molding portion 16 is viewed alone, the first concave interface 23 forms an annular first groove 26. FIG. 8 is an enlarged cross-sectional view of a portion of FIG. 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 opposite the second surface 32 and is perpendicular to the first surface 31. The first opposing surface (seventh surface 37) is a surface opposing 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 FIG. 7 , the second concave interface 24 is a surface recessed from the second interface 22. The second concave interface 24 is continuous along the annular second interface 22. When the first molding portion 16 is viewed alone, the second concave interface 24 forms an annular second groove 27. As shown in FIG. 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 opposite the first surface 31 and is perpendicular to the second surface 32. The second opposing surface (ninth surface 39) is a surface opposite 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] 7 and 8 , the first concave interface 23 and the second concave interface 24 are disposed close to each other in the first resin portion 17. 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 a range overlapping with the edge region K1. The second concave interface 24 is formed within a range overlapping with the edge region K1 of the first interface 21 in the Z direction, the direction opposite the Z direction, the Y direction, and the direction opposite the Y direction.

[0053] [Regarding the resin molded product 10 having the above-described configuration] As described above, the resin molded product 10 of this embodiment (see FIG. 5) includes the first molded portion 16 and the second molded portion 18. The first molded portion 16 includes the connector terminal 11 as an insert and the first resin portion 17 that is integral with the connector terminal 11. The second molded portion 18 includes the second resin portion 19. The first resin portion 17 includes a first surface 31, a second surface 32, a third surface 33, and a fourth surface 34. The second resin portion 19 contacts all of the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 of the first resin portion 17.

[0054] According to the resin molded product 10 of this embodiment, even if the shapes of the connector terminal 11 of the first molded portion 16 or the fitting portion 55 of the first resin portion 17 vary, it is only necessary to change the mold for molding the first molded portion 16. In contrast, the molds 7a, 7b (see FIGS. 3 and 4) for molding the second molded portion 18 can be the same. This makes it possible to reduce mold costs compared to the conventional method, which requires multiple molds that are mostly the same in shape but have only slight differences in some parts.

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

[0056] 7 and 8 , the first surface 31 and the second surface 32 are connected at a corner, the first surface 31 and the third surface 33 are connected at a corner, and the second surface 32 and the fourth surface 34 are connected at a corner. The second resin portion 19 covers all of the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34.

[0057] The second resin portion 19 shrinks during molding. Because the first resin portion 17 does not shrink, the second resin portion 19 presses against the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 of the first resin portion 17. Referring to Figure 8, arrows F1 and F2 indicate the pressing force with which the second resin portion 19 tightens against the first resin portion 17 due to the shrinkage of the second resin portion 19 during molding. In the resin molded product 10 of this embodiment, the shrinkage of the second resin portion 19 makes it possible to increase the strength of the joint between the first resin portion 17 and the second resin portion 19 and 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 are made up of a first plane 31, a second plane 72, a third plane 73, a fourth plane 74, a fifth plane 75, a sixth plane 76, a seventh plane 77, an eighth plane 78, a ninth plane 79, and a tenth plane 80. Among these planes, any plane is perpendicular to any adjacent plane. Therefore, when manufacturing the first molded portion 16 by injection molding, the combination of molds does not need to be complex, and the first molded portion 16 is less likely to be forcibly removed from the mold, making it easier to remove from the mold.

[0059] [Specific configuration of the joint]

[0060] 8 shows the first distance L1, the second distance L2, the third distance L3, and the fourth distance L4 of this embodiment. As described above, the relationships between the first distance L1, the second distance L2, the third distance L3, and the fourth distance L4 satisfy all of the following formulas (1), (2), and (3).

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

[0062] According to the formula (1) where "1 / 3≦fourth distance L4 / first distance L1," the depth of the fourth surface 34 in the Z direction is equal to or greater than 1 / 3 of the first distance L1. The Z direction depth of the second resin portion 19 in contact with the fourth surface 34 is sufficient, and the tension force (arrow F1 in FIG. 8 ) caused by contraction of the second resin portion 19 is effectively transmitted to the fourth surface 34. The seal formed between the first resin portion 17 and the second resin portion 19 has good sealing properties, and moisture is less likely to penetrate into the gap between the first resin portion 17 and the second resin portion 19 from the external space. According to the formula (2) where "1 / 3≦third distance L3 / second distance L2," the depth of the third surface 33 in the X direction is equal to or greater than 1 / 3 of the second distance L2. The depth in the X direction of the second resin part 19 that contacts the third surface 33 is sufficient, and the tension force (arrow F2 in FIG. 8 ) caused by the contraction of the second resin part 19 is effectively transmitted to the third surface 33. The seal formed between the first resin part 17 and the second resin part 19 has good sealing properties, and moisture is unlikely to penetrate into the gap between the first resin part 17 and the second resin part 19 from the external space.

[0063] According to the formula (1) of "fourth distance L4 / first distance L1≦9 / 10" and the formula (2) of "third distance L3 / second distance L2≦9 / 10," the positions P1 and P2 are not too close to each other. In other words, when the first molded portion 16 is considered as a single unit, the corner block portions 54 of the first resin portion 17, which will have the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34, are prevented from being cut off from the remaining central block portion 53. The first molded portion 16 is unlikely to come off the second molded portion 18.

[0064] According to the formula (3), one of the first distance L1 and the second distance L2 is not extremely large compared to the other. With regard to one of the first distance L1 and the second distance L2, if the first distance L1 is extremely small relative to the third distance L3 or the second distance L2 is extremely small relative to the fourth distance L4, the second resin portion 19 does not strongly press against the third surface 33 or the fourth surface 34, and therefore it is difficult to improve the sealing performance of the seal formed between the first resin portion 17 and the second resin portion 19.

[0065] [Others] In the above embodiment, the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 are each a flat surface or a combination of flat surfaces, and are perpendicular to each other. However, the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 of the present invention may have a partially convex or concave surface shape as long as the first surface 31, the second surface 32, the third surface 33, and the fourth surface 34 are not forced to be removed from the mold or the first resin portion 17 is not plastically deformed when removed from the mold. Furthermore, for example, the first surface 31 and the second surface 32 are perpendicular to each other, but may intersect at another angle as long as the first surface 31 and the second surface 32 are not forced to be removed. Similarly, the angle between adjacent surfaces of the other surfaces does not have to be a right angle.

[0066] The above-described embodiments are illustrative in all respects and are not limiting. The scope of the present invention is defined by the claims rather than the above-described embodiments, and includes all modifications within the scope equivalent to the configurations described in the claims.

[0067] 7a, 7b Mold 10 Resin molded product 11 Connector terminal (component) 16 First molded portion 17 First resin portion 17a Peripheral edge portion 18 Second molded portion 19a Molten resin 19 Second resin portion 31 First surface 32 Second surface 33 Third surface 34 Fourth surface L1 First distance L2 Second distance L3 Third distance L4 Fourth distance

Claims

1. having a first molding portion and a second molding portion; the first molding portion having a component as an insert and a first resin portion integral with the component; the second molding portion having a second resin portion; the first resin portion including a first surface, a second surface, a third surface, and a fourth surface; the first surface being an annular flat surface; the second surface being four planes including the normal line of the first surface; the second surface being annular along the first surface; the second surface being disposed adjacent to the first surface; the third surface being recessed in the normal direction of the first surface; the third surface being four annular planes along the first surface; the third surface being disposed adjacent to the first surface on the side opposite to the second surface; the fourth surface being recessed in the normal direction of the second surface; the fourth surface being an annular plane along the second surface; the fourth surface being disposed adjacent to the second surface on the side opposite to the first surface; the first resin portion; a first groove recessed in the normal direction of the first surface and having the third surface as a groove side surface; a second groove recessed in a direction perpendicular to the normal direction of the first surface and having the fourth surface as a groove side surface; defining a first distance as the distance between the second surface and the third surface in the normal direction of the first surface of the first surface; defining a second distance as the distance between the first surface and the fourth surface in the normal direction of the first surface of the second surface; defining a third distance as the distance between the first surface and the position of the third surface farthest from the first surface in the normal direction of the first surface of the third surface; defining a fourth distance as the distance between the second surface and the position of the fourth surface farthest from the second surface in the normal direction of the second surface of the fourth surface; the fourth distance having a relationship of 1 / 3 ≤ the fourth distance / the first distance ≤ 9 / 10 with respect to the first distance; the third distance having a relationship of 1 / 3 ≤ the third distance / the second distance ≤ 9 / 10 with respect to the second distance; the first distance having a relationship of 2 / 5 ≤ the first distance / the second distance ≤ 5 / 2 with respect to the second distance; the second resin portion being in contact with all surfaces of the first resin portion, namely the first surface, the second surface, the third surface, and the fourth surface; a resin molded product.

2. A method for manufacturing the resin molded product according to Claim 1, comprising: a preparation step of disposing the first molding portion in a mold; a molding step of supplying molten resin to the mold to mold the second molding portion; When the molten resin solidifies, a demolding step of removing a resin molded product in which the first molded portion and the second molded portion are integrated from the mold, A method for manufacturing a resin molded product having the above.