Molded article, air conditioner, and method for producing molded article

Abstract

This molded article comprises: a first molded member (1) having a first outer surface (1a) that is the front surface of the molded article (100), and a first joining portion (12) extending along the peripheral edge of a first inner surface (1b), which is located inside the molded article (100); a second molded member (2) having a second outer surface (2a) that is the back surface of the molded article (100), and a second joining portion (22) extending along the peripheral edge of a second inner surface (2b), which is located inside the molded article (100), and abutting against the first joining portion (12); and a joining member (3) located between the first joining portion (12) and the second joining portion (22). At least the joining portion (12) of the first joining portion (12) and the second joining portion (22) has a groove extending in the extension direction of the joining portion (12) on a surface abutting against the other joining portion (22), the second joining portion (22) has an opening leading to the groove, and the joining member (3) joins the first joining portion (12) and the second joining portion (22) in a state of being disposed in the groove from the opening.

Description

Molded product, air conditioning device, and method for manufacturing molded product

[0001] The present disclosure relates to a molded article, an air conditioning device, and a method for manufacturing a molded article.

[0002] Some resin molded products include multiple molded parts. Such molded products are generally produced by molding each molded part and joining the molded parts together. Specifically, each molded part is formed by injecting molding resin into a mold. The injection-molded molded parts are aligned at the joints. The aligned molded parts are then joined together using a joining method to complete the molded product.

[0003] Methods for joining multiple molded parts together include, for example, ultrasonic bonding, adhesive bonding, and thermal melting. These bonding methods are performed after each of the multiple molded parts is removed from the mold. Therefore, producing a molded product requires time and effort.

[0004] Another method for producing a molded product having multiple molded components is the DSI (die slide injection) molding method disclosed in Patent Document 1. In the DSI molding method, the injection molding of each of the multiple molded components, the alignment of the multiple molded components with each other, and the joining of the multiple molded components with each other are all completed inside the mold. Therefore, the time and effort required to produce the molded product is reduced.

[0005] Japanese Patent Application Laid-open No. 62-087315

[0006] The DSI molding method uses a welding resin to join molded parts. The welding resin is injected in a molten state into the mold through the parting line. The injected welding resin joins the outer peripheries of the aligned molded parts.

[0007] The outer periphery of each of the multiple molded members joined together corresponds to the outer periphery of the molded product, and therefore the joints between the multiple molded members are visible on the outside of the molded product, which may impair the appearance of the molded product.

[0008] An object of the present disclosure is to provide a molded product that includes a plurality of molded members and has a good appearance, and a method for manufacturing the molded product.

[0009] In order to achieve the above-mentioned object, the molded product of the present disclosure is a molded product made of resin, and comprises a first molded member having a first outer surface which is the front surface of the molded product, a first inner surface located inside the molded product, and a first joint extending along the periphery of the first inner surface; a second molded member having a second outer surface which is the back surface of the molded product, a second inner surface located inside the molded product, and a second joint extending along the periphery of the second inner surface and abutting the first joint; and a joint member located between the first joint and the second joint, wherein at least one of the first and second joints has a groove on the surface abutting the other joint that extends in the extension direction of the one joint, and the second joint has an opening that leads to the groove, and the joint member joins the first joint and the second joint while being positioned from the opening to the groove.

[0010] According to the above configuration, the first and second molded members are joined by joining members located in the groove space defined between the first and second joining members. Therefore, the joining members are located inside the molded product, and the joined portion between the first and second molded members is not visible from the outside. Therefore, the appearance of the molded product is not impaired.

[0011]

[0012] Hereinafter, with reference to the drawings, an example in which the molded article according to the embodiment is a louver will be described. In the drawings, the same or corresponding parts are designated by the same reference numerals. For ease of understanding, in FIG. 2, a left-handed XYZ Cartesian coordinate system is defined in which the short-side direction of the louver is the X-axis direction, the long-side direction is the Y-axis direction, and the direction perpendicular to the X-axis and Y-axis is the Z-axis direction. This coordinate system is also shown in each of FIGS. 2 to 19.

[0013] [Embodiment 1] As shown in Fig. 1, a louver 100 according to this embodiment is provided in an openable and closable manner at an air outlet AP of an air conditioner AC. As shown in Fig. 2, the louver 100 is a strip-shaped blade member. The air conditioner AC is installed at a position on the ceiling that is higher than the eye level of a user of the air conditioner AC in order to efficiently cool and heat the room.

[0014] 10A and 11A, louver 100 has an airtight internal space S and is formed in an airfoil shape. As shown in Fig. 3, louver 100 has a base member 1, which is a first molded member located on the lower side, and a cover member 2, which is a second molded member located on the upper side.

[0015] The outer surface 1a of the base member 1, which is the first outer surface, faces outward from the air outlet AP of the air conditioner AC when the louver 100 is blocking the air outlet AP. Therefore, the outer surface 1a of the base member 1 becomes the exterior surface of the louver 100 that is easily visible to the user when the user looks up at the air conditioner AC. In other words, the outer surface 1a of the base member 1 functions as the design surface of the louver 100 when viewed from the viewpoint of the user of the air conditioner AC.

[0016] The outer surface 2a of the cover member 2, which is the second outer surface, faces the inside of the air outlet AP when the louver 100 is closing the air outlet AP of the air conditioner AC. Therefore, the outer surface 2a of the cover member 2 is difficult to see from a user looking up at the air conditioner AC, and serves as the external back surface of the louver 100 that is hit by the air blown out from the air outlet AP. In other words, the outer surface 2a of the cover member 2 functions as a control surface of the louver 100 that controls the flow of air blown out from the air outlet AP when viewed from the viewpoint of the user of the air conditioner AC.

[0017] 3, a joining member 3 that joins the base member 1 and the cover member 2 is located between the base member 1 and the cover member 2. The joining member 3 is made of solidified welding resin. The joining member 3 extends in a ring shape in a plan view along the periphery of the surfaces where the base member 1 and the cover member 2 face each other.

[0018] A method for producing a resin molded article having two or more molded components is the DSI molding method, which is suitable for producing a molded article having multiple molded components from the viewpoints of reducing production costs and improving productivity.

[0019] The DSI molding method is a manufacturing method for molded products that includes a primary molding process, a die slide process, and a secondary molding process. In the primary molding process, molten molding resin is injected into a mold and solidified to form multiple molded parts. In the die slide process, the mold is moved to a position where the injection-molded molded parts face each other. Then, in the secondary molding process, the molten resin is extended around the peripheries of the facing molded parts to join the outer peripheries of the multiple molded parts.

[0020] In the secondary molding process, molten welding resin is injected into the mold through the parting line, where it welds the outer peripheries of the multiple molded parts together and solidifies to form a joined part.

[0021] In other words, when a molded product is produced using a conventional DSI molding method, the welded portions that connect the molded components and the solidified welded resin are exposed to the outside, which can impair the appearance of the molded product as seen by the user.

[0022] To address this concern, it is conceivable to position the welding resin inside the outer periphery of the multiple molded components, so that the joints between the multiple molded components are located inside the molded product, and the welded parts and joint members are not exposed to the outside.

[0023] However, when the joints between multiple molded components are located inside the molded product, the state of the joints formed by the welding resin at the joints cannot be visually confirmed. If the welding resin is not sufficiently filled at the joints between multiple molded components, poor bonding occurs at the insufficiently filled areas. Poor bonding can weaken the adhesion between the multiple molded components, potentially compromising the mechanical strength of the molded product.

[0024] In particular, when the molded article is a louver 100 having an airtight internal space S, the internal space S communicates with the outside at the joint failure portion, thereby compromising the airtightness of the internal space S of the louver 100.

[0025] When a louver 100 whose airtightness has been compromised is cleaned, water will enter the internal space S of the louver 100 through the poorly joined portions. The water that has entered the internal space S of the louver 100 will promote the growth of mold and bacteria. As a result, there is a concern that the louver 100 may emit an unpleasant odor or foreign matter.

[0026] Furthermore, in order to check the state of bonding between the multiple molded members, the louver 100 must be destroyed to expose the bonded portions to the outside, which is time-consuming.

[0027] Louver 100, which is a molded product according to this embodiment, has a structure in which the joint portion between base member 1 and cover member 2 is not visible from the outside, and the state in which joint member 3 joins base member 1 and cover member 2 can be confirmed non-destructively. These will be described below.

[0028] First, we will explain the base member 1, which is the first molded member. As shown in Figure 6, the base member 1 is formed in a long, narrow box shape with an upper opening 1c. The base member 1 has a first plate-like portion 11 that corresponds to the bottom plate of the louver 100 and a first joint portion 12 that corresponds to the side plate of the louver 100.

[0029] The base member 1 is made of virgin resin, which is a synthetic resin, from the viewpoint of ensuring the aesthetic appearance of the outer surface 1a. More specifically, the base member 1 is made of virgin ABS (acrylonitrile butadiene styrene) resin, which has durability and heat resistance.

[0030] As shown in Fig. 4, the outer surface 1a of the base member 1, which is the first outer surface, includes the outer surface 11a of the first plate-shaped portion 11 and the outer surface 12a of the first joint portion 12. Also, as shown in Fig. 6, the inner surface 1b of the base member 1, which is the first inner surface, includes the inner surface 11b of the first plate-shaped portion 11 and the inner surface 12b of the first joint portion 12.

[0031] The first plate-shaped portion 11 is rectangular when viewed in the minus Z-axis direction, and its cross-sectional shape in the XZ plane shown in FIG. 10A is formed into an arc shape that is convex in the minus Z-axis direction at the center.

[0032] The first joint portion 12 is a portion that is joined to the second joint portion 22 of the cover member 2 by the joining member 3. The first joint portion 12 extends in an annular shape along the periphery of the inner surface 11b of the first plate-shaped portion 11 when viewed in the negative Z-axis direction, and also extends in the positive Z-axis direction.

[0033] The first joint portion 12 has a groove portion 4 on its end surface, which is the surface that abuts against a second joint portion 22 of the cover member 2 described later. The groove portion 4 extends annularly in the extension direction of the first joint portion 12 when viewed in the negative Z-axis direction as shown in Fig. 6, and is recessed in the negative Z-axis direction as shown in Figs. 10B and 10C.

[0034] Specifically, the first joint portion 12 has an outer peripheral wall 41 and an inner peripheral wall 42 disposed inside the outer peripheral wall 41 and parallel to the outer peripheral wall 41. The groove portion 4 is located between the outer peripheral wall 41 and the inner peripheral wall 42.

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

[0036] 5A and 5B, the base member 1 has mold engaging portions 5 on the outer surface 12a at both ends in the Y-axis direction. The mold engaging portions 5 have a first engaging portion 51 and a second engaging portion 52 on the outer surface 12a of the first outer wall portion 41L and the second outer wall portion 41R at both ends in the Y-axis direction of the outer peripheral wall 41 of the first joint portion 12.

[0037] The first engaging portion 51 and the second engaging portion 52 each extend in the X-axis direction and are grooves whose cross sections in the YZ plane are recessed inward of the base member 1. The first engaging portion 51 and the second engaging portion 52 engage with the mold to prevent the base member 1 from shrinking and deforming in the primary molding process, and also function to hold the base member 1 in the moving mold in the die slide process.

[0038] 6, the inner surface 1b of the base member 1, i.e., the inner surface 11b of the first plate-shaped portion 11, does not have, for example, ribs or recesses for reinforcement or fitting purposes. This makes it difficult for molding defects such as weld lines and sink marks to occur during the primary molding process. This allows for good design of the outer surface 1a of the base member 1.

[0039] Next, the cover member 2, which is the second molded member, will be described. As shown in Figure 7, the cover member 2 is formed in the shape of an elongated lid. The shape of the cover member 2 in a plan view is the same as the shape of the opening surface of the upper opening 1c of the base member 1. In detail, the cover member 2 is shaped to fit onto the opening edge of the base member 1 and close the upper opening 1c. The cover member 2 has a second plate-shaped portion 21 and a second joint portion 22.

[0040] The cover member 2 is made of recycled resin, which is used resin, from the viewpoints of reducing manufacturing costs and being environmentally friendly. Specifically, the cover member 2 is made of recycled ABS resin, which has durability and heat resistance.

[0041] The outer surface 2 a of the cover member 2, which is the second outer surface, corresponds to the outer surface 21 a of the second plate-shaped portion 21. The inner surface 2 b of the cover member 2, which is the second inner surface, includes the inner surface 21 b of the second plate-shaped portion 21 and the inner surface 22 b of the second joint portion 22.

[0042] The second plate-shaped portion 21 corresponds to the top plate of the louver 100. The second plate-shaped portion 21 is rectangular when viewed in the negative Z-axis direction, and has a cross-sectional shape in the XZ plane in which the front end is bent downward.

[0043] Furthermore, as will be described in detail below, the cover member 2 has a shrinkage prevention groove 6 on its outer surface 2a. The shrinkage prevention groove 6 extends along the periphery of the outer surface 2a of the second plate-shaped portion 21 and is recessed in the negative Z-axis direction of the cover member 2. In a plan view of the cover member 2, the shrinkage prevention groove 6 extends parallel to a first edge of the second plate-shaped portion 21 in the negative X-axis direction and to second and third edges at both ends in the Y-axis direction. The shrinkage prevention groove 6 serves the function of preventing the cover member 2 from shrinking and deforming in the primary molding step and the function of holding the cover member 2 in the mold in the die slide step.

[0044] 8A and 8B , the cover member 2 has a bearing portion 7 that is rotatably supported on an opening / closing shaft provided at the opening edge of the air outlet AP of the air conditioner AC. In detail, the bearing portion 7 has a first bearing portion 71 and a second bearing portion 72 on the second plate-shaped portion 21.

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

[0046] The first bearing portion 71 and the second bearing portion 72 have shaft holes 71a and 72a, respectively, that penetrate the louver 100 in the Y-axis direction. An opening / closing shaft provided at the air outlet AP of the air conditioner AC is inserted into the shaft holes 71a and 72a. In addition to their bearing function, these bearing portions 71 and 72 also serve the functions of preventing the cover member 2 from shrinking and deforming in the primary molding process and of holding the cover member 2 in the mold in the die slide process.

[0047] 9 , the second joint portion 22 is a portion joined to the first joint portion 12 of the base member 1 by the joining member 3. The second joint portion 22 has a flange 81 which is the periphery of the second plate-shaped portion 21, and an abutment wall 82 which is located inside the flange 81.

[0048] 10A to 10C , when the cover member 2 is fitted onto the opening edge of the base member 1, the flange 81 closes the groove 4 of the first joint portion 12 and abuts against the end face of the inner peripheral wall 42 of the first joint portion 12. In addition, the flange 81 is located inside the outer peripheral wall 41 of the first joint portion 12.

[0049] That is, when the cover member 2 is fitted onto the opening edge of the base member 1, a space is defined between the first joint portion 12 and the second joint portion 22 by the groove portion 4 and the flange 81. This space is filled with the joint member 3. Hereinafter, the space formed between the first joint portion 12 and the second joint portion 22 will be referred to as the groove space 4S.

[0050] The abutment wall 82 extends parallel to the flange 81 on the inner surface 21b of the second plate-shaped portion 21 and also extends downward perpendicular to the longitudinal direction of the cover member 2. The abutment wall 82 is also located directly below the shrinkage prevention groove 6.

[0051] The abutting wall 82 abuts against the inner peripheral wall 42 of the first joint portion 12 from the inside when the cover member 2 is fitted onto the opening edge portion of the base member 1. The abutting wall 82 is located inside the inner peripheral wall 42 of the first joint portion 12. An internal space S of the louver 100 is defined inside the abutting wall 82.

[0052] In other words, the interior of the louver 100 is divided by the first joint 12 and the second joint 22 into an internal space S, which is the majority of the space in the center of the louver 100, and a groove space 4S that extends to the inner edge of the louver 100 and surrounds the internal space S on the outer periphery.

[0053] The abutment wall 82 serves to prevent deformation and collapse of the inner peripheral wall 42 due to the pressure of the welding resin when the welding resin is injected into the groove space 4S in the secondary molding process, and to prevent the welding resin from leaking from the groove space 4S into the internal space S.

[0054] 11B and 11C , the second joint portion 22 has a gate 91, which is an opening that leads to the groove portion 4 when the cover member 2 is fitted to the edge of the opening of the base member 1. The gate 91 is formed by cutting out part of the outer peripheral edge of the flange 81 of the second joint portion 22 in a rectangular shape, for example, a square shape.

[0055] More specifically, a plurality of gates 91 are formed at regular intervals in the extension direction of the flange 81 along which the groove space 4S extends. The gates 91 function as injection ports through which molten welding resin is injected into the groove space 4S in the secondary molding process.

[0056] The second joint portion 22 has a window portion 92 that communicates with the groove space 4S when the cover member 2 is fitted to the opening edge portion of the base member 1. The window portion 92 is a rectangular, for example, square, opening that penetrates the flange 81, which is the periphery of the second plate-shaped portion 21, in the Z-axis direction.

[0057] More specifically, a plurality of window portions 92 are formed at equal distances from adjacent gates 91 in a plan view of the cover member 2 and at regular intervals in the extension direction of the flange 81. The window portions 92 function as confirmation windows for visually confirming that the welding resin injected from the gates 91 into the groove space 4S has filled the groove space 4S between the adjacent gates 91 in the secondary molding process.

[0058] Next, the joining member 3 will be described. The joining member 3 is formed by cooling and solidifying the welding resin molten in the groove space 4S. The joining member 3 extends around the peripheries of the base member 1 and the cover member 2, thereby joining the base member 1 and the cover member 2. Specifically, the joining member 3 joins the first joining portion 12 of the base member 1 and the second joining portion 22 of the cover member 2. In more detail, the joining member 3 is formed by filling the groove space 4S from the gate 91 with welding resin, which solidifies in a state where it is integrated with the outer peripheral wall 41 and inner peripheral wall 42 of the first joining portion 12 and the flange 81 of the second joining portion 22.

[0059] The joint portion between the base member 1 and the cover member 2, formed by the joint member 3, extends to the inner periphery of the louver 100. This prevents the joint portion between the base member 1 and the cover member 2, formed by the joint member 33, from appearing on the exterior of the louver 100. This ensures the aesthetic appeal of the louver 100. Furthermore, the interior space S of the louver 100 is airtightly defined within the louver 100. Because the interior space S is airtightly defined, there is no risk of moisture entering the interior space S. This prevents the louver 100 from emitting unpleasant odors or contaminants. Furthermore, the interior space S provides insulation, preventing condensation on the louver 100 due to cold air when the air conditioning unit AC is in use. Furthermore, because the interior space S is airtightly defined, it can be filled with an insulating gas. For example, argon gas can be used as the insulating gas. Filling the interior space S with an insulating gas further improves the insulating performance. The internal space S may also be filled with a heat insulating material such as urethane resin.

[0060] The joining members 3 are made of recycled resin, which is a used resin, from the viewpoints of reducing manufacturing costs and being environmentally friendly. More specifically, the joining members 3 are made of recycled ABS resin, which has durability and heat resistance.

[0061] The joining member 3, which is the welding resin that has filled and solidified in the groove space 4S, is exposed in a window portion 92 on the periphery of the outer surface 2a of the cover member 2. This makes it possible to determine whether the welding resin has filled the groove space 4S between the adjacent gates 91, simply by visually checking whether the joining member 3 is exposed in the window portion 92.

[0062] That is, it is possible to visually confirm that the joining member 3 joins the base member 1 and the cover member 2 without breaking the louver 100. Therefore, it is possible to save the effort of checking the joining state of the base member 1 and the cover member 2.

[0063] Furthermore, the connecting members 3 exposed at the gates 91 and the windows 92 are molded flush with the outer surface 2a of the cover member 2. In other words, the connecting members 3 exposed at the gates 91 and the windows 92 form part of the outer surface 2a of the cover member 2. Therefore, the design of the louver 100 is not impaired.

[0064] Next, a description will be given of a manufacturing method for the molded product, the louver 100. The manufacturing method for the louver 100 according to this embodiment is a manufacturing method that utilizes a DSI molding method using a two-color molding machine and that continuously performs a primary molding process, a die slide process, and a secondary molding process.

[0065] 12A , in the primary molding process, the base member 1 and the cover member 2 are each injection-molded with a molding resin inside a closed mold M. The mold M has a first mold M1 that is movable in the Z-axis direction and a second mold M2 that is movable in the Z-axis direction and the Y-axis direction.

[0066] The first mold M1 is provided with a first cavity M11 for forming the outside of the base member 1 and a second core M22 for molding the inside of the cover member 2. The first cavity M11 and the second core M22 are provided adjacent to each other on the parting surface of the first mold M1 with the second mold M2.

[0067] The second mold M2 is provided with a first core M12 for molding the inside of the base member 1 and a second cavity M21 for molding the outside of the cover member 2. The first core M12 and the second cavity M21 are provided adjacent to the parting surface of the second mold M2 with the first mold M1, and are opposed to the first cavity M11 and the second core M22 of the first mold M1, respectively.

[0068] The first cavity M11 has an engagement mold portion M5 for molding the mold engagement portion 5 of the base member 1. The first core M12 has a groove mold portion M4 for molding the groove portion 4 of the base member 1.

[0069] The second cavity M21 has a groove mold portion (not shown) that molds the shrinkage prevention groove 6 of the cover member 2, and a bearing mold portion M7 that forms the bearing portion 7 of the cover member 2. The second core M22 has an abutment wall mold portion (not shown) that molds the abutment wall 82, a gate mold portion (not shown) that molds the gate 91, and a window mold portion (not shown) that molds the window portion 92.

[0070] When such a mold M is closed, a first hollow portion MS1 ​​is defined between the first cavity M11 and the first core M12, and a second hollow portion MS2 is defined between the second cavity M21 and the second core M22.

[0071] The second mold M2 has a first spool SP1 and a second spool SP2. The first spool SP1 communicates with the first cavity MS1 and an injection port of a first injection molding machine (not shown) that injects virgin resin molding resin. The second spool SP2 communicates with the second cavity MS2 and an injection port of a second injection molding machine (not shown) that injects recycled resin molding resin.

[0072] The molten molding resin injected into the first cavity MS1 and the second cavity MS2 is cooled and solidified, and the base member 1 having the first plate-like portion 11 and the first joint portion 12, and the cover member 2 having the second plate-like portion 21 and the second joint portion 22 are molded.

[0073] There is a concern that the volume of the molding resin will shrink as it cools, causing deformation of the base member 1 and the cover member 2. Specifically, as the base member 1 in the first hollow portion MS1 ​​cools, it tends to shrink and deform from the first cavity M11 toward the first core M12. Meanwhile, the cover member 2 in the second hollow portion MS2 tends to shrink and deform from the second cavity M21 toward the second core M22.

[0074] To counter such molding shrinkage, the base member 1 is molded to have a first engaging portion 51 and a second engaging portion 52 on the outer surface 12 a of the first joint portion 12 .

[0075] As the base member 1 cools, the first engaging portion 51 and the second engaging portion 52 each engage with the engaging mold portion M5 of the first cavity M11. This allows the base member 1 to be held at both longitudinal ends in the first cavity M11, i.e., the first mold M1. The base member 1 held in the first mold M1 is prevented from shrinking toward the second mold M2. As a result, the base member 1 does not deform.

[0076] Similarly, the cover member 2 is molded with a shrinkage prevention groove 6 and a bearing portion 7 on the outer surface 2a. As the cover member 2 cools, the shrinkage prevention groove 6 and the bearing portion 7 engage with a groove portion and a bearing portion M7 (not shown) of the second cavity M21, respectively. This holds the cover member 2 in the second cavity M21, i.e., the second mold M2. The cover member 2 held in the second mold M2 is prevented from shrinking toward the first mold M1. As a result, the cover member 2 does not deform.

[0077] 12B and 12C, in the die sliding process, the second mold M2 and the first mold M1 are moved to positions where the cover member 2 and the base member 1 face each other and fit together.

[0078] In detail, as shown in Figure 12C, the second mold M2 moves parallel to the parting surface with the first mold M1, and the cover member 2 held in the second cavity M21 is positioned above the base member 1 held in the first cavity M11.

[0079] 12D , the first mold M1 moves perpendicularly to the parting plane with the second mold M2, and the molds are closed. This fits the cover member 2 and the base member 1 together. The groove 4 of the first joint 12 of the base member 1 is then closed by the second joint 22 of the cover member 2.

[0080] As a result, a groove space 4S is defined between the first joint portion 12 and the second joint portion 22. Furthermore, an internal space S is defined inside each of the first joint portion 12 and the second joint portion 22. The gate 91 and the window portion 92 of the cover member 2 are disposed at the position of the groove portion 4 of the base member 1, as shown in FIG.

[0081] Next, the secondary molding process will be described. As shown in Fig. 13, in the secondary molding process, molten joining material 3 is injected into the groove space 4S from multiple gates 91 using a pinpoint gate method to join the first joining portion 12 and the second joining portion 22, i.e., the base member 1 and the cover member 2. Note that a mold is omitted from Fig. 13 for ease of understanding.

[0082] The mold further includes a third mold having a welding spool (not shown) into which the joining member 3, which is a recycled resin, is poured. The second mold M2 is connected to the welding spool of the third mold and has a plurality of welding runners M30 through which the welding resin flows.

[0083] The welding resin that has passed through the welding spool and the welding runner M30 from the injection molding machine is injected into the groove space 4S from each of the multiple gates 91 of the cover member 2. The welding resin injected into the groove space 4S from the gates 91 flows in the extension direction of the first bonding portion 12 and the second bonding portion 22.

[0084] The welding resin flowing through the groove space 4S is welded to the first bonding portion 12 and the second bonding portion 22 and solidifies to become the bonding member 3. Furthermore, as the welding resin passes through the window portion 92, it comes into contact with the second mold M2 and is cooled and solidified. Therefore, the portion of the bonding member 3 exposed by the window portion 92 is molded flush with the outer surface 2 a of the cover member 2.

[0085] When the welding resin flows through the groove space 4S in this way, the internal pressure in the groove space 4S increases. This internal pressure is applied to the inner peripheral wall 42 of the first joint portion 12 that forms the groove space 4S. This may cause deformation or collapse of the inner peripheral wall 42, or leakage of the welding resin from the groove space 4S into the internal space S.

[0086] 10A to 11C, the second joint portion 22 of the cover member 2 has a contact wall 82 that contacts the inner peripheral wall 42 of the first joint portion 12 from the inside, improving the rigidity of the inner peripheral wall 42. This prevents deformation and collapse of the inner peripheral wall 42, and prevents leakage of the welding resin from the groove space 4S into the internal space S. As a result, the welding resin can be stably distributed throughout the entire groove space 4S.

[0087] Finally, the first mold M1 and the second mold M2 are separated to open the mold M, and the louver 100, which is the molded product shown in Fig. 2, is released. Then, it is visually confirmed whether the joining member 3, which is the solidified welded resin, is exposed in the window portion 92 of the cover member 2 of the louver 100, and it is determined whether the welded resin fills the groove space 4S without any gaps.

[0088] If the joining member 3 is exposed in all of the plurality of window portions 92, it can be evaluated that the base member 1 and the cover member 2 are joined without gaps by the joining member 3. On the other hand, if there is a window portion among the plurality of welded window portions 92 where the joining member 3 is not exposed, it can be evaluated that there is a poor joint between that window portion and an adjacent window portion where the joining member is exposed. In this way, according to the manufacturing method of the molded product according to this embodiment, it is possible to manufacture a louver 100 in which the airtightness of the internal space S is ensured and no joints are visible on the exterior.

[0089] 10B and 10C illustrate a configuration in which the base member 1, which is the first molded member, has a groove portion 4, and the cover member 2, which is the second molded member, has an abutting wall 82. However, the configuration in which the groove portion 4 and the abutting wall 82 are respectively arranged is not limited to this. Specific examples will be described below.

[0090] 14A and 14B , the cover member 2 has a long, narrow box shape with an opening. The second joint portion 22 of the cover member 2 has a groove portion 4 on the end surface that abuts against the first joint portion 12 of the base member 1.

[0091] The outer surface 2a of the cover member 2, which is the second outer surface, has the outer surface 21a of the second plate-shaped portion 21 and the outer surface 22a of the second joint portion 22. The inner surface 2b of the cover member 2, which is the second inner surface, has the inner surface 21b of the second plate-shaped portion 21 and the inner surface 22b of the second joint portion 22.

[0092] The second joint portion 22 extends annularly along the periphery of the inner surface 21 b of the second plate-shaped portion 21 in a bottom view and in the negative Z-axis direction. The groove portion 4 extends annularly in the extension direction of the second joint portion 22 in a positive Z-axis view and is a groove recessed in the positive Z-axis direction at the second joint portion 22.

[0093] More specifically, the second joint portion 22 has an outer peripheral wall 41 and an inner peripheral wall 42 disposed inside the outer peripheral wall 41 and parallel to the outer peripheral wall 41. The groove portion 4 is located between the outer peripheral wall 41 and the inner peripheral wall 42.

[0094] The outer peripheral wall 41 extends slightly further in the negative Z-axis direction of the cover member 2 than the inner peripheral wall 42 around the periphery of the inner surface 21b of the second plate-shaped portion 21. That is, the opening edge of the cover member 2 is formed by the Z-axis direction end of the outer peripheral wall 41 and the Z-axis direction end of the inner peripheral wall 42. The base member 1 is fitted into this opening edge of the cover member 2.

[0095] The outer surface 1a of the base member 1, which is the first outer surface, corresponds to the outer surface 11a of the first plate-shaped portion 11. The inner surface 1b of the base member 1, which is the first inner surface, includes the inner surface 11b of the first plate-shaped portion 11 and the inner surface 12b of the first joining portion 12.

[0096] The first joint portion 12 of the base member 1 has a flange 81 which is the periphery of the first plate-shaped portion 11 , and an abutment wall 82 which is located inside the flange 81 .

[0097] When the base member 1 is fitted onto the opening edge of the cover member 2, the flange 81 closes the groove 4 of the second joint portion 22 and abuts against the end face of the inner peripheral wall 42 of the second joint portion 22. The flange 81 is also located inside the outer peripheral wall 41 of the first joint portion 12. This defines a groove space 4S between the first joint portion 12 and the second joint portion 22.

[0098] The abutment wall 82 extends parallel to the flange 81 and in the positive Z-axis direction on the inner surface 11b of the first plate-shaped portion 11. The abutment wall 82 abuts against the inner circumferential wall 42 of the second joint portion 22 from the inside.

[0099] 7, the second joint portion 22 has a plurality of gates 91, which are openings that lead to the groove space 4S. The gates 91 are formed at regular intervals in the direction in which the groove space 4S extends, i.e., in the direction in which the flange 81 extends.

[0100] The second joint portion 22 also has a window portion 92 that communicates with the groove space 4S. The window portions 92 are formed at equal distances from adjacent gates 91 in a plan view of the cover member 2 and at regular intervals in the extension direction of the flange 81.

[0101] The method for manufacturing louver 100 having base member 1 and cover member 2 differs from the method for manufacturing louver 100 according to the first embodiment in the mold used in the primary molding step.

[0102] That is, a groove mold portion (not shown) for molding the groove portion 4 is provided on the second core M22 for molding the inner surface 2b of the cover member 2 of the first mold M1. Also, a contact wall mold portion (not shown) for molding the contact wall 82 is provided on the first core M12 for molding the inner surface 1b of the base member 1 of the second mold M2.

[0103] In this embodiment, as in the first embodiment, the first joint portion 12 and the second joint portion 22 are joined to each other by the welding resin filled into the groove space 4S through the gate 91. In this case, the joint portion of the joint member 3 joining the base member 1 and the cover member 2 extends along the inner periphery of the louver 100. Therefore, the joint portion of the base member 1 and the cover member 2 is not visible from the outside of the louver 100. This ensures the aesthetic appearance of the louver 100. Furthermore, the internal space S is airtightly defined. This prevents the louver 100 from emitting unpleasant odors or foreign matter. Furthermore, the internal space S provides thermal insulation, preventing condensation on the louver 100 due to cold air when the air conditioning unit AC is in use. Furthermore, filling the internal space S with a thermal insulating gas such as argon gas or a thermal insulating material such as urethane resin further improves the thermal insulation performance.

[0104] Furthermore, the joining member 3 is exposed in a window portion 92 on the periphery of the outer surface 2a of the cover member 2. By simply visually checking whether the joining member 3 is exposed in this window portion 92, it is possible to determine whether the welding resin filled from the gate 91 has filled the groove space 4S between the adjacent gates 91.

[0105] That is, it is possible to visually confirm the state in which the joining member 3 joins the base member 1 and the cover member 2 without destroying the louver 100. This facilitates the task of checking the joining state of the base member 1 and the cover member 2 to ensure the airtightness of the internal space S of the manufactured louver 100.

[0106] 5A and 5B show an example of a configuration in which the mold engagement portion 5 is formed on both longitudinal end surfaces of the base member 1. However, the position at which the mold engagement portion 5 of the base member 1 is formed is not limited to this. Specific examples will be described below.

[0107] As shown in FIG. 15, the mold engaging portion 5 of this embodiment has a first engaging portion 53 and a second engaging portion 54 on each of the outer surfaces 12a at both ends of the base member 1 in the X-axis direction.

[0108] The first engaging portion 53 and the second engaging portion 54 are grooves formed on the outer surface 12a of the third outer wall portion 41F and the fourth outer wall portion 41B at both ends in the X-axis direction of the outer peripheral wall 41 of the first joint portion 12. Furthermore, the first engaging portion 53 and the second engaging portion 54 each extend in the Y-axis direction of the base member 1 and are recessed inward of the base member 1 when viewed in a cross section of the base member 1 on the XZ plane.

[0109] The manufacturing method of louver 100 including base member 1 having such mold engagement portion 5 on its outer surface 1a differs from the manufacturing method of louver 100 according to the above-described embodiment 1 in the mold used in the primary molding process. That is, first cavity M11, which molds outer surface 1a of base member 1, has engagement mold portions (not shown) on its front and rear sides, which mold mold engagement portion 5 of base member 1.

[0110] In this embodiment, as in the first embodiment, the mold engagement portion 5 engages with an engagement mold portion (not shown) of the first cavity M11 as the mold is cooled during the primary molding step. That is, the base member 1 is held in the first cavity M11 by the first engagement portion 53 and the second engagement portion 54 of the third outer wall portion 41F and the fourth outer wall portion 41B of the outer peripheral wall 41, respectively.

[0111] In particular, the mold engagement portion 5 of this embodiment is formed longer than the mold engagement portion 5 of the first embodiment. This increases the contact area between the base member 1 and the first mold. This further suppresses the contraction of the base member 1 toward the second mold M2. As a result, the base member 1 does not deform.

[0112] 5A and 5B show an example in which the mold engagement portion 5 is a groove recessed inward in the longitudinal direction of the base member 1. However, the mold engagement portion 5 is not limited to a groove. Specific examples thereof will be described below.

[0113] As shown in Figures 16A and 16B, the mold engagement portion 5 of this embodiment has a convex first engagement portion 55 and a convex second engagement portion 56 on each of the outer surfaces of the base member 1 at both ends in the Y-axis direction.

[0114] More specifically, the first engaging portion 55 and the second engaging portion 56 are protrusions that protrude outward from the outer surfaces of the first outer wall portion 41L and the second outer wall portion 41R at both ends in the Y-axis direction of the outer peripheral wall 41 of the first joint portion 12. The first engaging portion 55 and the second engaging portion 56 extend in the X-axis direction of the base member 1, and extend in a convex shape outward from the base member 1 when viewed in a cross section of the base member 1 in the YZ plane.

[0115] The manufacturing method for louver 100 including base member 1 having such mold engagement portion 5 on its outer surface 1a differs from the manufacturing method for louver 100 according to the above-described embodiment 1 in the mold used in the primary molding process. That is, the engagement mold portion (not shown) in first cavity M11 that molds outer surface 2a of base member 1 is formed in a groove recessed inward in the first mold.

[0116] In this embodiment, as in the first embodiment, the mold engagement portion 5 engages with an engagement mold portion (not shown) of the first cavity M11 during the primary molding process. That is, the base member 1 is held in the first mold M1 by the first engagement portion 55 and the second engagement portion 56 of the first outer wall portion 41L and the second outer wall portion 41R of the outer peripheral wall 41, respectively. The base member 1 held in the first mold M1 is suppressed from shrinking toward the second mold M2. As a result, the base member 1 does not deform.

[0117] Although the embodiments have been described above, the present disclosure is not limited to these, and modifications as described below are also possible.

[0118] 2 and 3 illustrate an example of a configuration in which the molded article according to this embodiment is a louver 100 including a base member 1, a cover member 2, and a joining member 3. However, the molded article is not limited to the louver 100, as long as it is a resin molded article including a first molded member having an outer surface 1a that is the front surface of the molded article, a second molded member having an outer surface 2a that is the back surface of the molded article, and a joining member 3 that joins the inner peripheral edges of the first molded member and the second molded member together. The molded article may also be, for example, a drainage pipe that forms a flow path, a toner container used in a printing machine, or a figurine such as a character or vehicle. In other words, the molded article does not necessarily have to have an internal space S, and the internal space S may not be airtight but open to the outside.

[0119] The molded article may have at least a first molding member and a second molding member, and may have three or more molding members. The molded article may be produced by joining multiple molding members, such as a third molding member joined to the second molding member, a fourth molding member joined to the third molding member, etc.

[0120] In this embodiment, the base member 1, which is the first molded member, is made of virgin resin, which is unused synthetic resin, and the cover member 2 and the joining member 3, which are the second molded members, are made of recycled resin, which is used resin. However, the materials of the base member 1, the cover member 2, and the joining member 3 are not limited to these.

[0121] For example, the material of the base member 1 may be a recycled resin that is cheaper than virgin resin or a bioresin, which is a resin derived from living organisms, as long as the aesthetic appearance of the outer surface 1a, which is the exterior surface, is maintained. The cover member 2 and the connecting members 3 may be formed from virgin resin, or alternatively, from a bioresin, which is a resin derived from living organisms. Bioresin is a resin made from plant-derived carbon sources, such as sugars or starches extracted from plants such as corn, sugarcane, and sugarbeets. Therefore, forming the cover member 2 and the connecting members 3 from bioresin can contribute to environmental considerations, such as reducing carbon dioxide emissions and the use of synthetic resins derived from fossil fuels.

[0122] Although the base member 1, cover member 2, and joining member 3 in this embodiment are made of ABS resin, they may be made of nylon or polypropylene, for example. However, from the viewpoints of heat resistance and durability, it is preferable that the base member 1, cover member 2, and joining member 3 are made of ABS resin.

[0123] 6 , 11B, and 11C illustrate a configuration in which only the first bonding portion 12 of the base member 1 has a groove 4, and the second bonding portion 22 of the cover member 2 does not have a groove 4. Also, FIGS. 14A and 14B illustrate a configuration in which only the second bonding portion 22 of the cover member 2 has a groove 4, and the first bonding portion 12 of the base member 1 does not have a groove 4. However, as shown in FIG. 17 , both the first bonding portion 12 and the second bonding portion 22 may have a groove 4 as long as a groove space 4S is defined between the first bonding portion 12 and the second bonding portion 22 when they are in contact, in which the bonding member 3 is located. When the groove 4 is formed in both the base member 1 and the cover member 2, leakage of the welding resin can be more effectively suppressed than when the groove 4 is formed in only one of them.

[0124] 7 shows an example of a configuration in which gates 91, which are openings through which molten welding resin is injected, are formed by cutting out part of the outer peripheral edge of flange 81 in a square shape in a plan view, and a plurality of gates are formed at equal intervals in the extension direction of flange 81. However, the shape, number, and distance between gates 91 are arbitrary as long as they communicate with groove portion 4 and maintain a distance between them that allows the welding resin in groove space 4S to flow.

[0125] FIG. 7 also shows an example of a configuration in which the second bonding portion 22 of the cover member 2 has a window portion 92 through which the bonding member 3 is exposed. When the molded product is made of a transparent resin, the state of the bonding member 3 in the groove space 4S can be seen, so the window portion 92 is not necessarily a required configuration.

[0126] 7 illustrates a configuration in which the window portions 92 are square-shaped openings in a plan view that penetrate the periphery of the second plate-shaped portion 21 in the Z-axis direction, and are formed in multiple positions equidistant from adjacent gates 91. However, the number and shape of the window portions 92 are not limited as long as they are formed in positions between adjacent gates 91 that take into consideration the fluidity of the molten welding resin that flows from the position of each gate 91 to the depth of the groove space 4S. Two or more window portions 92 may be formed between adjacent gates 91, and the window portions 92 may be circular or elliptical openings in a plan view, or rectangular openings as shown in FIGS. 18 and 19 .

[0127] 3 illustrates an example configuration in which the joining member 3 joining the first joining portion 12 of the base member 1 and the second joining portion 22 of the cover member 2 is made of solidified welded resin. However, the joining member 3 is not limited to being made of resin, as long as it joins the first joining portion 12 and the second joining portion 22 together when placed in the groove space 4S, and may be made of an inorganic silicone material.

[0128] 7 illustrates a configuration in which the shrinkage prevention groove 6 is formed on the outer surface 2a of the cover member 2, which is the second molded member. However, the shrinkage prevention groove 6 may also be formed on the outer surface 1a of the base member 1, which is the first molded member, as long as the aesthetic appearance is not impaired.

[0129] Furthermore, the louvers, which are the molded articles in the above-mentioned embodiments, are not limited to those installed in the air outlets of air conditioning units, but also include those used in objects that block light from outside and conceal the interior while ensuring breathability, such as blinds installed on windows and the front part of a shelf with storage space inside.

[0130] In the above embodiment, a configuration has been described in which a plurality of gates 91 are formed at regular intervals in the extending direction of the flange 81. However, the intervals between adjacent gates 91 do not need to be regular and may be different.

[0131] In the above embodiment, a configuration has been exemplified in which a plurality of window portions 92 are formed at positions equidistant from adjacent gates 91 and at regular intervals in the extension direction of the flange 81. However, the intervals between adjacent window portions 92 do not need to be regular and may be different.

[0132] This application is based on Japanese Patent Application No. 2023-122846 filed on July 27, 2023. The entire specification, claims, and drawings of Japanese Patent Application No. 2023-122846 are incorporated herein by reference.

[0133] Various aspects of the present disclosure are described below.

[0134] (Note 1) A molded product made of resin, comprising: a first molded member having a first outer surface which is the front surface of the molded product, a first inner surface located inside the molded product, and a first joint portion extending along the periphery of the first inner surface; a second molded member having a second outer surface which is the back surface of the molded product, a second inner surface located inside the molded product, and a second joint portion which extends along the periphery of the second inner surface and abuts against the first joint portion; and a joint member located between the first joint portion and the second joint portion, wherein at least one of the first joint portion and the second joint portion has a groove portion on the surface that abuts against the other joint portion, extending in the extension direction of the one joint portion, and the second joint portion has an opening that leads to the groove portion, and the joint member joins the first joint portion and the second joint portion while being positioned from the opening to the groove portion.

[0135] (Supplementary Note 2) The molded article according to Supplementary Note 1, wherein the molded article is a louver for opening and closing an air outlet of an air conditioning device, and the first outer surface faces outward from the air outlet when the louver closes the air outlet.

[0136] (Supplementary Note 3) The molded product according to Supplementary Note 1 or Supplementary Note 2, wherein at least one of the first and second joints has an outer peripheral wall and an inner peripheral wall positioned more inward than the outer peripheral wall, and the groove is formed between the outer peripheral wall and the inner peripheral wall.

[0137] (Appendix 4) The molded product according to Appendix 3, wherein the other joint portion has an abutment wall that abuts against the inner peripheral wall from inside the one joint portion when the first joint portion and the second joint portion abut against each other.

[0138] (Supplementary Note 5) The molded article according to any one of Supplementary Notes 1 to 4, wherein the second joint portion has a plurality of the openings in an extending direction of the groove portion.

[0139] (Supplementary Note 6) The molded article according to any one of Supplementary Notes 1 to 5, wherein the second bonding portion has a window portion through which the bonding member disposed in the groove portion is exposed.

[0140] (Appendix 7) The molded product according to any one of Appendices 1 to 6, wherein the first molded member is formed from virgin resin, which is an unused synthetic resin, and the second molded member and the joining member are formed from recycled resin, which is a used resin, or bio-resin, which is a resin derived from living organisms.

[0141] (Appendix 8) The molded product described in any one of Appendices 1 to 7 is a louver for opening and closing an air outlet of an air conditioning device, wherein the first molded member is a base member whose first outer surface faces outward from the air outlet when the louver is blocking the air outlet, and the second molded member is a cover member whose second outer surface faces inward from the air outlet when the louver is blocking the air outlet, and the cover member has a bearing portion on its second outer surface that is rotatably supported on an opening / closing shaft provided at the opening edge of the air outlet.

[0142] (Supplementary Note 9) The molded article according to any one of Supplementary Notes 1 to 8, wherein the molded article has an internal space defined by the first joint portion and the second joint portion, and the internal space is formed airtight by the joint members.

[0143] (Supplementary Note 10) The molded article according to Supplementary Note 9, wherein the molded article contains a heat insulating gas in the internal space.

[0144] (Supplementary Note 11) An air conditioning device comprising the louver which is the molded article according to Supplementary Note 8.

[0145] (Appendix 12) A method for manufacturing a molded product, comprising: a primary molding step of injecting molten molding resin into a mold having a first mold and a second mold and solidifying it to mold a first molded member having a first joint portion and a second molded member having a second joint portion, wherein at least one of the first joint portion and the second joint portion has a groove portion on a surface facing the other joint portion and the second joint portion has an opening, and holding the first molded member in the first mold and holding the second molded member in the second mold; a die slide step of moving either the first mold or the second mold to a position where the first molded member held in the first mold and the second molded member held in the second mold face each other, thereby fitting the first molded member and the second molded member together and connecting the groove portion with the opening; and a secondary molding step of filling the groove portion with molten welding resin from the opening and solidifying it, thereby joining the first joint portion and the second joint portion.

[0146] (Appendix 13) In the primary molding step, the first molded member is molded with a mold engagement portion on its outer surface that engages with the first mold, and the first molded member is held in the first mold by the mold engagement portion. This is the method for manufacturing a molded product described in Appendix 12.

[0147] (Supplementary Note 14) The method for producing a molded product according to Supplementary Note 12 or Supplementary Note 13, wherein in the primary molding step, the second molded member is molded to have a shrinkage prevention groove on an outer surface thereof for preventing molding shrinkage.

[0148] 100... louver (molded article), 1... base member (first molded member), 1a... outer surface (first outer surface), 1b... inner surface (first inner surface), 1c... upper opening, 11... first plate-shaped portion, 11a... outer surface, 11b... inner surface, 12... first joint portion, 12a... outer surface, 12b... inner surface, 2... cover member (second molded member), 2a... outer surface (second outer surface), 2b... inner surface (second inner surface), 21... second plate-shaped portion, 21a... outer surface, 21b... inner surface, 22... second joint portion, 22a... outer surface, 22b... inner surface, 3... joint member, 4... groove portion, 41... outer peripheral wall, 41L... first outer wall portion, 41R... second outer wall portion, 41F... third outer wall portion, 41B... fourth outer wall portion, 42...inner peripheral wall, 4S...groove space, 5...mold engagement portion, 51, 53, 55...first engagement portion, 52, 54, 56...second engagement portion, 6...shrinkage prevention groove, 7...bearing portion, 71...first bearing portion, 72...second bearing portion, 71a, 72a...shaft hole, 81...flange, 82...abutment wall, 91...gate (opening), 92...window portion, M...mold, M1...first mold, M2...second mold, M11...first cavity, M12...first core, M21...second cavity, M22...second core, M30...welding runner, M4...groove portion, M5...engagement portion, M7...bearing portion, S...internal space, AC...air conditioning unit, AP...air outlet

Claims

1. A resin molded product comprising: a first molded member having a first outer surface which is the front surface of the molded product, a first inner surface which is located inside the molded product, and a first joint portion which extends along the periphery of the first inner surface; a second molded member having a second outer surface which is the back surface of the molded product, a second inner surface which is located inside the molded product, and a second joint portion which extends along the periphery of the second inner surface and abuts against the first joint portion; and a joint member located between the first joint portion and the second joint portion, wherein at least one of the first joint portion and the second joint portion has a groove portion which extends in the extension direction of the one joint portion on the surface which abuts against the other joint portion, the second joint portion has an opening which leads to the groove portion, and the joint member joins the first joint portion and the second joint portion while being disposed from the opening to the groove portion.

2. The molded article according to claim 1, wherein the molded article is a louver for opening and closing an air outlet of an air conditioning device, and the first outer surface faces outward from the air outlet when the louver is blocking the air outlet.

3. A molded product as described in claim 1 or claim 2, wherein at least one of the first and second joints has an outer peripheral wall and an inner peripheral wall located more inward than the outer peripheral wall, and the groove portion is formed between the outer peripheral wall and the inner peripheral wall.

4. A molded product as described in claim 3, wherein the other joint has an abutment wall that abuts against the inner peripheral wall from the inside of the one joint when the first joint and the second joint are in abutment with each other.

5. A molded product as claimed in any one of claims 1 to 4, wherein the second joint portion has a plurality of the openings in the extending direction of the groove portion.

6. A molded product as claimed in any one of claims 1 to 5, wherein the second joint portion has a window portion through which the joint member arranged in the groove portion is exposed.

7. A molded product as claimed in any one of claims 1 to 6, wherein the first molded member is formed from virgin resin, which is an unused synthetic resin, and the second molded member and the joining member are formed from recycled resin, which is a used resin, or bio-resin, which is a resin derived from living organisms.

8. The molded product described in any one of claims 1 to 7 is a louver for opening and closing an air outlet of an air conditioning unit, wherein the first molded member is a base member whose first outer surface faces outward from the air outlet when the louver is blocking the air outlet, and the second molded member is a cover member whose second outer surface faces inward from the air outlet when the louver is blocking the air outlet, and the cover member has a bearing portion on its second outer surface that is rotatably supported on an opening / closing shaft provided on the opening edge of the air outlet.

9. A molded article according to any one of claims 1 to 8, wherein the molded article has an internal space defined by the first joint portion and the second joint portion, and the internal space is formed airtight by the joint members.

10. The molded article according to claim 9, wherein the molded article contains an insulating gas in the internal space.

11. An air conditioning device comprising the louver which is the molded article according to claim 8.

12. A method for manufacturing a molded product, comprising: a primary molding process in which a molten molding resin is injected into a mold having a first die and a second die, and solidified to mold a first molded member having a first joint portion and a second molded member having a second joint portion, wherein at least one of the first joint portion and the second joint portion has a groove portion on a surface facing the other joint portion and the second joint portion has an opening, and the first molded member is held in the first die and the second molded member is held in the second die; a die slide process in which either the first die or the second die is moved to a position where the first molded member held in the first die and the second molded member held in the second die face each other, thereby fitting the first molded member and the second molded member together and communicating the groove portion with the opening; and a secondary molding process in which molten welding resin is filled into the groove portion from the opening and solidified to join the first joint portion and the second joint portion.

13. A method for manufacturing a molded product as described in claim 12, wherein in the primary molding step, the first molded member is molded with a mold engagement portion on its outer surface that engages with the first mold, and the first molded member is held in the first mold by the mold engagement portion.

14. A method for producing a molded product according to claim 12 or 13, wherein in the primary molding step, the second molded member is molded with a shrinkage prevention groove on its outer surface for preventing molding shrinkage.

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