Resin molded article and method for manufacturing resin molded article

Abstract

Disclosed is a resin molded article that makes it possible to reduce the number of components and assembly man-hours, and that ensures waterproofness between a first component, formed from a synthetic resin, such as a connector mounting part, and a second part, formed from a synthetic resin, such as a case.　A resin molded article 10 comprises: a first component 20 that is formed from a synthetic resin; and a second component 22 that is formed from a synthetic resin. The first component 20 is integrated with the second component 22 as a result of having an embedded section 24 embedded in the second component 22 so as to surround the periphery of a waterproof area 34 of the second component 22. A waterproofing thermoplastic elastomer 26 is disposed and welded between facing surfaces 55, 73, 78, and 82 of the second component 22 and the embedded section 24.

Description

Resin Molded Product and Method for Manufacturing Resin Molded Product

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

[0002] In Patent Document 1, in an electrical connection box which is a kind of resin molded product, there is disclosed a configuration in which a case for housing a circuit component including a circuit board, a lid for closing an opening provided in the case, and a plurality of connector mounting portions protruding through the lid are fixedly provided on the lid.

[0003] Japanese Patent Laid-Open No. 2022-191739

[0004] In the structure of Patent Document 1, a plurality of connector mounting portions are fixed to the lid by means such as bolt tightening, and fastening members are required to hold the connectors on the lid. Further, in order to ensure waterproofness, it is necessary to sandwich a sealing rubber between the lid and the connectors, or to bolt-tighten the lid to the case with a sealing rubber sandwiched between the contact surface of the peripheral edge of the opening of the case and the lid. Therefore, there are many parts and the assembly work is complicated, and there is a limit in coping with miniaturization of the product due to the need to secure a large number of spaces for the fastening members.

[0005] Therefore, a resin molded product and a method for manufacturing a resin molded product are disclosed, which can reduce the number of parts and the number of assembly steps and ensure waterproofness between a first part made of synthetic resin such as a connector mounting portion and a second part made of synthetic resin such as a case.

[0006] The resin molded product of the present disclosure includes a first part made of synthetic resin and a second part made of synthetic resin. The first part has an embedded portion that surrounds the waterproof area of the second part and is embedded in the second part and integrated with the second part. A waterproof thermoplastic elastomer is disposed and welded between the embedded portion and the opposing surface of the second part.

[0007] The method for manufacturing a resin molded article according to the present disclosure is a method for manufacturing a resin molded article according to the present disclosure, comprising: a first part molding step of injection molding the first part; a primary molded article molding step of integrally molding the first part and the waterproof thermoplastic elastomer with the first part molded in the first part molding step as an insert to form a primary molded article; and a second part molding step of injection molding the second part with the primary molded article as an insert such that the thermoplastic elastomer is positioned between the embedded portion of the first part and the opposing surface of the second part.

[0008] A method for manufacturing a resin molded article according to another aspect of the present disclosure is a method for manufacturing a resin molded article according to the present disclosure, comprising: a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; a primary molded article molding step of integrally molding the thermoplastic elastomer and the first part using the thermoplastic elastomer molded in the thermoplastic elastomer molding step as an insert to form a primary molded article; and a second part molding step of injection molding the second part using the primary molded article as an insert such that the thermoplastic elastomer is positioned between the embedded portion of the first part and the opposing surface of the second part.

[0009] A method for manufacturing a resin molded article according to yet another aspect of the present disclosure is a method for manufacturing a resin molded article according to the present disclosure, comprising: a first component molding step of injection molding the first component; a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; an assembly step of assembling the first component and the thermoplastic elastomer such that the thermoplastic elastomer is positioned between the embedded portion of the first component and the opposing surface of the second component; and a second component molding step of injection molding the second component using the assembly of the first component and the thermoplastic elastomer assembled in the assembly step as an insert.

[0010] According to this disclosure, it is possible to provide a resin molded product and a method for manufacturing a resin molded product that can reduce the number of parts and assembly man-hours, and can ensure waterproofness between a first synthetic resin part such as a connector mounting part and a second synthetic resin part such as a case.

[0011] Figure 1 is a plan view showing an electrical junction box, which is a resin molded product according to Embodiment 1. Figure 2 is a longitudinal cross-sectional view showing an enlarged view of the main part of the II-II cross-section in Figure 1. Figure 3 is a longitudinal cross-sectional view showing an enlarged view of the main part of the III-III cross-section in Figure 1. Figure 4 is a perspective view showing the first component constituting the resin molded product shown in Figure 1 from the bottom side, with connection terminals attached. Figure 5 is a perspective view showing the first component shown in Figure 4 from the bottom side, with the thermoplastic elastomer integrally formed. Figure 6 is a longitudinal cross-sectional view showing an enlarged view of the main part of an electrical junction box comprising a resin molded product according to Embodiment 2, and corresponds to Figure 2.

[0012] <Description of Embodiments of the Disclosure> First, embodiments of the Disclosure will be listed and described. The resin molded product of the Disclosure comprises (1) a first component made of synthetic resin and a second component made of synthetic resin, wherein the first component is integrated with the second component and has an embedded portion that surrounds the periphery of the waterproof area of ​​the second component and is embedded in the second component, and a waterproof thermoplastic elastomer is placed and welded between the embedded portion and the opposing surface of the second component.

[0013] According to the resin molded product of this embodiment, the first component is integrated with the second component, having an embedded portion that surrounds the waterproof area of ​​the second component and is embedded in the second component. Furthermore, a waterproof thermoplastic elastomer is placed and welded between the embedded portion of the first component embedded in the second component and the opposing surface of the second component. As a result, after molding the first component, the thermoplastic elastomer can be integrally molded using the first component as an insert, or after molding the thermoplastic elastomer, the first component can be integrally molded using the thermoplastic elastomer as an insert to form a primary molded product, and the second component can be secondary molded using this primary molded product as an insert to ensure the waterproofing of the waterproof area of ​​the second component. This allows for a simple and reliable production of a resin molded product in which the first component and the second component are integrated. Alternatively, the first component and the thermoplastic elastomer may be formed separately, and the second component may be integrally molded using the assembled first component as an insert.

[0014] For example, if the second component is the case of an electrical junction box and the first component is, for example, a component mounting part that protrudes through the opening of the case, the conventional structure requires the placement of a sealing rubber between the first and second components and the subsequent fixing of the two components by bolting, eliminating the need for this process and simplifying assembly. Furthermore, separate fastening components and sealing rubber can be eliminated, reducing the number of parts and lowering the cost of the product. In addition, since the location and structure for fastening components are no longer required, the resin molded product can be made smaller.

[0015] In particular, a thermoplastic elastomer is positioned and welded between the embedded portion of the first component and the opposing surface of the second component. Therefore, even if a gap occurs between the opposing surfaces of the first and second components due to different resin materials or relatively hard resin materials such as glass fiber reinforced resin, the waterproof area is surrounded by the welded portion of the thermoplastic elastomer, thus advantageously preventing water from entering the waterproof area through the gap.

[0016] (2) In (1) above, it is preferable that an annular groove surrounding the waterproof area is formed on the surface of the embedded portion facing the second component, and that the thermoplastic elastomer is arranged in the groove. Since the embedded portion of the first component is provided with a groove that opens on the surface facing the second component, the thermoplastic elastomer can be arranged in the groove. This makes it possible to second-mold the second component using a primary molded product made of the first component and the thermoplastic elastomer, or an assembly thereof, as an insert, with the thermoplastic elastomer positioned and arranged on the surface of the embedded portion facing the second component. As a result, it is possible to easily and stably embed and weld the thermoplastic elastomer between the surface of the embedded portion and the second component, and to further improve the waterproofness of the waterproof area of ​​the resin molded product.

[0017] (3) In the above (2), it is preferable that the second component includes a case for housing a circuit board, and the first component includes a connector mounting portion provided in the opening of the case which serves as the waterproof area, the connector mounting portion having a hood portion that protrudes above the case and an embedded portion that extends in a flange shape on the base end side of the hood portion, and the thermoplastic elastomer filled in the annular groove provided in the embedded portion is arranged to surround the periphery of the opening. When the second component of the resin molded product is a case for housing a circuit board, and the first component is a connector mounting portion provided in the opening of the case, the resin molded product with waterproof function according to this embodiment can be applied to an electrical junction box. In this case, by using the flange-shaped portion on the base end side which bears the load applied to the connector mounting portion as the embedded portion, an annular groove surrounding the periphery of the opening can be advantageously provided. Furthermore, by filling the grooves surrounding the opening with thermoplastic elastomer, waterproof performance can be reliably and stably achieved around the entire circumference of the opening by the thermoplastic elastomer welded between the opposing surfaces of the case and the embedded part.

[0018] (4) In (3) above, it is preferable that the connector mounting portion has a terminal retaining wall that divides the hood portion into an inner side and an outer side of the case, and includes a connecting terminal that penetrates the terminal retaining wall and protrudes to the inner side and the outer side of the case, and that the connecting terminal is fixedly held by the terminal retaining wall. Since the connecting terminal is fixedly held by the terminal retaining wall provided in the hood portion of the connector mounting portion, the case can be secondary molded with the connector mounting portion holding the connecting terminal as an insert. This makes it possible to further improve assembly workability and to make it easier to adjust the alignment of the connecting terminal. Fixed holding of the connecting terminal to the terminal retaining wall can be achieved by press-fitting and fixing the connecting terminal to the terminal retaining wall, or by integrally molding the connector mounting portion with the connecting terminal as an insert.

[0019] (5) In (3) above, it is preferable that the connector mounting portion has a terminal retaining wall that divides the hood portion into an inner side and an outer side of the case, and that the terminal retaining wall is provided with through holes that allow insertion of connection terminals protruding to the inner side and the outer side of the case. Since the terminal retaining wall provided in the hood portion of the connector mounting portion is provided with through holes that allow insertion of connection terminals, the connector mounting portion can be configured by inserting connection terminals protruding from a circuit board that constitutes an electrical circuit housed in the case. Furthermore, if there are unused through holes in the terminal retaining wall, the through holes can be used to extract electrical signals from the circuit board as needed, thereby improving the versatility of the connector mounting portion. In addition, to prevent water from entering the case through the through holes, a sealing rubber may be sandwiched between the hood portion and the mating connector.

[0020] (6) In the above (2), it is preferable that the second component includes a case that houses a circuit board inside, the first component includes a terminal block having a connecting terminal having one end connected to the circuit board and the other end having a terminal fastening portion, and a terminal base that holds the connecting terminal with the terminal fastening portion exposed above the waterproof area, the waterproof area includes a through portion through which the middle portion of the connecting terminal passes, the embedded portion is formed by the peripheral edge of the base end of the terminal base, and the thermoplastic elastomer filled in the annular groove provided in the embedded portion is arranged to surround the through portion. When the first component is a terminal block and the second component is a case that houses a circuit board inside, the case includes a through portion through which the middle portion of a connecting terminal having one end connected to the circuit board and the other end having a terminal fastening portion to which the terminal portion of an external wire harness etc. is fastened is passed, and the through portion becomes the waterproof area. In this case, by utilizing the peripheral edge of the terminal base that bears the load applied to the terminal block, an annular groove surrounding the penetration can be advantageously created. Then, by filling the groove surrounding the penetration with thermoplastic elastomer, waterproofing can be reliably and stably ensured around the entire circumference of the penetration by the thermoplastic elastomer welded between the opposing surfaces of the case and the embedded portion.

[0021] The method for manufacturing a resin molded article according to the present disclosure includes: (7) a method for manufacturing a resin molded article according to the embodiment of (1) above, comprising: a first part molding step of injection molding the first part; a primary molded article molding step of integrally molding the first part and the waterproof thermoplastic elastomer with the first part molded in the first part molding step as an insert to form a primary molded article; and a second part molding step of injection molding the second part with the primary molded article as an insert such that the thermoplastic elastomer is positioned between the embedded portion of the first part and the opposing surface of the second part.

[0022] According to this embodiment, the resin molded product described in embodiment (1) above can be manufactured advantageously, and a resin molded product that can achieve the same effects as in embodiment (1) above can be provided.

[0023] Another method for manufacturing a resin molded article of the present disclosure is (8) a method for manufacturing a resin molded article as described in the embodiment of (1) above, comprising: a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; a primary molded article molding step of integrally molding the thermoplastic elastomer and the first part using the thermoplastic elastomer molded in the thermoplastic elastomer molding step as an insert to form a primary molded article; and a second part molding step of injection molding the second part using the primary molded article as an insert so that the thermoplastic elastomer is positioned between the embedded portion of the first part and the opposing surface of the second part.

[0024] According to this embodiment, the resin molded product described in embodiment (1) above can be manufactured advantageously, and a resin molded product that can achieve the same effects as in embodiment (1) above can be provided.

[0025] A further method for manufacturing a resin molded article of the present disclosure is (9) a method for manufacturing a resin molded article according to the embodiment of (1) above, comprising: a first component molding step of injection molding the first component; a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; an assembly step of assembling the first component and the thermoplastic elastomer such that the thermoplastic elastomer is positioned between the embedded portion of the first component and the opposing surface of the second component; and a second component molding step of injection molding the second component using the assembly of the first component and the thermoplastic elastomer assembled in the assembly step as an insert.

[0026] According to this embodiment, the resin molded product described in embodiment (1) above can be manufactured advantageously, and a resin molded product that can achieve the same effects as in embodiment (1) above can be provided.

[0027] (10) In any one of (7) to (9) above, it is preferable that the first component has an annular groove opening on the surface of the embedded portion facing the second component, surrounding the periphery of the waterproof area, and that the primary molded product, in which the thermoplastic elastomer is placed in the groove of the embedded portion, is used as an insert product when the second component molding process is carried out. According to this embodiment, the resin molded product described in embodiment (2) above can be manufactured advantageously, and a resin molded product that can achieve the same effects as in embodiment (2) above can be provided.

[0028] <Details of Embodiments of the Disclosure> Specific examples of the resin molded articles of the Disclosure will be described below with reference to the drawings. However, the Disclosure is not limited to these examples and is intended to include all modifications within the meaning and scope of the Claims as indicated by the Claims.

[0029] <Embodiment 1> Hereinafter, an electrical junction box 10, which is a resin molded product of Embodiment 1 of the present disclosure, will be described with reference to Figures 1 to 5. This electrical junction box 10 includes a case 14 in which a circuit board 12 is housed. Specifically, the case 14 is composed of an upper case 16 and a lower case 18, and the case 14 is formed by the upper opening 19 of the lower case 18 being covered by the upper case 16. The electrical junction box 10 can be positioned in any orientation, but in the following description, "upper" refers to the upper part in Figure 2, "lower" refers to the lower part in Figure 2, "front" refers to the left in Figure 1, "rear" refers to the right in Figure 1, "left" refers to the upper part in Figure 1, and "right" refers to the lower part in Figure 1. In addition, for multiple identical components, reference numerals may be assigned to only some of the components, while the reference numerals for other components may be omitted.

[0030] <Resin molded product (electrical junction box 10)> The electrical junction box 10 comprises a first component 20 made of synthetic resin and a second component 22 made of synthetic resin. The first component 20 has an embedded portion 24 that surrounds the waterproof area 23 (opening 40 and through portion 42 described later) of the second component 22 and is embedded in the second component 22. With this embedded portion 24 embedded in the second component 22, the first component 20 and the second component 22 are integrated. A waterproof thermoplastic elastomer 26 is placed and welded between the opposing surfaces of the embedded portion 24 and the second component 22 (outer surfaces 55, 73 and inner surfaces 78, 82 described later). That is, the embedded portion 24 and the thermoplastic elastomer 26 are fused together at their contact surfaces, and the second component 22 and the thermoplastic elastomer 26 are fused together at their contact surfaces. Furthermore, the embedded portion 24 of the first component 20 does not need to be embedded in the second component 22 as a whole; a portion of the embedded portion 24 may be exposed to the outside from the second component 22.

[0031] In particular, in Embodiment 1, the electrical connection box 10 (especially the upper case 16) comprises a plurality of first components 20, each of which includes a plurality of connector mounting portions 32 (described later) and a terminal block 34. The second component 22 includes a case 14 that houses the circuit board 12, and specifically includes an upper bottom wall portion 36 and a lower case 18 in the upper case 16 (described later). Therefore, in Embodiment 1, the second component 22 is composed of a plurality of members.

[0032] The circuit board 12 housed in the electrical connection box 10 (case 14) is not limited to any particular type, but a known circuit board such as a rigid printed circuit board or a flexible printed circuit board (FPC) may be used, and an electrical circuit (not shown) is printed on at least one surface of the circuit board 12 in the thickness direction. Furthermore, through-holes 28 that penetrate the circuit board 12 in the thickness direction are formed at predetermined locations on the circuit board 12. The method of fixing the circuit board 12 to the case 14 is not limited to any particular type.

[0033] <Upper Case 16> The upper case 16 comprises a plurality of connector mounting portions 32 and one terminal block 34, which are first components 20. The upper case 16 also includes an upper bottom wall portion 36 that is substantially flat in shape as a whole, and as described above, the second component 22 is formed including the upper bottom wall portion 36. Each first component 20 (each connector mounting portion 32 and terminal block 34) is fixed to the upper bottom wall portion 36. That is, the upper bottom wall portion 36 has a plurality of waterproof areas 23 on which each first component 20 is provided. Specifically, the waterproof areas 23 are composed of openings 40 to which each connector mounting portion 32 is fixed and through portions 42 to which the terminal block 34 is fixed.

[0034] <Lower Case 18> The lower case 18 is generally box-shaped with an upward opening (having an upper opening 19), and comprises a generally flat bottom wall portion 44 that extends horizontally (in a direction perpendicular to the vertical direction), and a lower peripheral wall portion 46 that protrudes upward from the outer peripheral edge of the bottom wall portion 44. Therefore, the upper opening 19 is formed by the upper end of the lower peripheral wall portion 46. The method of fixing the upper case 16 and the lower case 18 is not limited.

[0035] The lower case 18 can be formed from a rigid material such as metal or synthetic resin. When the lower case 18 is made of synthetic resin, materials such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) are preferably used. Furthermore, when the lower case 18 is made of synthetic resin, it may be reinforced with glass fibers or the like.

[0036] <First Component 20 (Connector Mounting Section 32)> In Embodiment 1, as described above, some of the first component 20 are made up of connector mounting sections 32. Each connector mounting section 32, as shown in Figures 2 and 4, includes a hood section 52 that protrudes upward from the case 14 (particularly the upper bottom wall section 36 of the upper case 16) and an embedded section 24 that spreads out in a flange-like manner at the base end (lower end) of the hood section 52. In Embodiment 1, the hood section 52 is substantially cylindrical and continuous around the entire circumference, and the embedded section 24 at the base end (lower end) of the hood section 52 is formed as a substantially annular portion that protrudes outward around the entire circumference. In particular, in Embodiment 1, each hood section 52 is formed in a substantially rectangular annular shape in plan view, and each embedded section 24 is also formed in a substantially rectangular annular shape in plan view. A groove 54 that opens downward is formed on the lower surface of the embedded section 24, which is thus substantially rectangular annular. As will be described later, in the connector mounting portion 32, the outer surface 55 of the embedded portion 24, including the inner circumferential surface, lower surface, and outer circumferential surface of the embedded portion 24, forms the opposing surface between the embedded portion 24 and the second component 22. Therefore, the groove 54 opens onto the surface of the embedded portion 24 that faces the second component 22.

[0037] Each groove 54 is an annular groove that extends continuously around the entire circumference in the circumferential direction. In Embodiment 1, each groove 54 is formed in the radially intermediate portion of the lower surface of each embedded portion 24. As mentioned above, each embedded portion 24 is provided surrounding the periphery of the waterproof area 23, and therefore each groove 54 is provided surrounding the periphery of each waterproof area 23. In particular, in Embodiment 1, each groove 54 has a rectangular cross-sectional shape with an inner surface consisting of an upper bottom wall and both side surfaces.

[0038] In Embodiment 1, the connector mounting portion 32 has a terminal retaining wall 58 that divides the hood portion 52 into an inward (downward) side and an outward (upward) side of the case 14. The connector mounting portion 32 also includes connection terminals 60 that penetrate the terminal retaining wall 58 and protrude to the inward (downward) side and outward (upward) side of the case 14. In Embodiment 1, a plurality of connection terminals 60 are provided, and each connection terminal 60 is fixedly held by the terminal retaining wall 58. Each connection terminal 60 is arranged in alignment in the front-to-back and left-to-right directions on the inner circumference of the hood portion 52.

[0039] Specifically, in the vertically intermediate portion of the hood portion 52, a terminal retaining wall 58 is provided that extends horizontally on the inner circumference side of the hood portion 52. The intermediate portion of each connection terminal 60 in the vertical direction is embedded in the terminal retaining wall 58, with one end (lower end) of each connection terminal 60 protruding downward from the terminal retaining wall 58 and the other end (upper end) of each connection terminal 60 protruding upward from the terminal retaining wall 58. In other words, when the upper case 16, which includes each connector mounting portion 32, is fixed to the lower case 18 to form the case 14 (electrical connection box 10), one end (lower end) of each connection terminal 60 protrudes inward from the case 14, and the other end (upper end) of each connection terminal 60 protrudes outward from the case 14.

[0040] In Embodiment 1, as shown in Figure 4, the connector mounting portion 32 is formed as an integrally molded product equipped with each connection terminal 60. Specifically, when molding the connector mounting portion 32, injection molding is performed with each connection terminal 60 set as an insert in the molding cavity of the connector mounting portion 32, thereby forming the connector mounting portion 32 as an integrally molded product equipped with each connection terminal 60. As a result, each connection terminal 60 is fixedly held against the terminal holding wall 58. The resin material constituting the connector mounting portion 32 (hood portion 52 and embedded portion 24) is not limited as long as it is rigid, but materials such as PPS and PBT are preferably used, similar to the lower case 18, and may be reinforced with, for example, glass fiber.

[0041] Furthermore, the other end (upper end) of each connection terminal 60 is located on the inner circumference side of the hood portion 52 and protrudes upward. As a result, each connector mounting portion 32 constitutes a male connector, and each connection terminal 60 and the connection terminal of the female connector are electrically connected when a female connector (not shown), which is the mating connector, is attached to each connector mounting portion 32.

[0042] <First component 20 (terminal block 34)> In Embodiment 1, as described above, one of the first components 20 is composed of a terminal block 34. This terminal block 34 has a connecting terminal 66 having one end connected to the circuit board 12 and the other end having a terminal fastening portion 64, and a terminal base 68 that holds the connecting terminal 66 with the terminal fastening portion 64 exposed above the through portion 42 which is the waterproof area 23.

[0043] Specifically, in Embodiment 1, the connection terminal 66 is bent in a substantially L shape, and one end portion extends downward and is configured to be connected to the circuit board 12. Further, the other end portion of the connection terminal 66 extends horizontally and constitutes a terminal fastening portion 64 that is substantially rectangular in plan view. A bolt insertion hole 70 penetrating in the thickness direction (vertical direction) is formed in the central portion of the terminal fastening portion 64, and the shaft portion of the stud bolt 72 disposed below the terminal fastening portion 64 protrudes upward through the bolt insertion hole 70. Thus, when a mating terminal (not shown) is connected to the connection terminal 66, the shaft portion of the stud bolt 72 is inserted into the bolt insertion hole provided in the mating terminal, and a nut is fastened to the stud bolt 72, so that the mating terminal and the terminal fastening portion 64 are overlapped and electrically connected to each other.

[0044] The terminal fastening portion 64 and the stud bolt 72 are supported on the terminal pedestal 68. As described above, the terminal fastening portion 64 is exposed upward, and the shaft portion of the stud bolt 72 protrudes upward. The terminal pedestal 68 is substantially rectangular in plan view and has a predetermined thickness dimension. The buried portion 24 is formed by the peripheral edge portion of the base end portion (lower end portion) of the terminal pedestal 68. Specifically, the base end portion (lower end portion) of the terminal pedestal 68 protrudes to the outer peripheral side compared to the upper portion, and the buried portion 24 is formed by the portion protruding to the outer peripheral side. The buried portion 24 is continuously formed in an annular shape over the entire circumference in the circumferential direction.

[0045] Furthermore, a concave groove 54 opening downward is formed on the lower surface of the terminal pedestal 68. The concave groove 54 has the same shape as the concave groove 54 in the connector mounting portion 32 and is an annular groove continuous over the entire circumference in the circumferential direction. Note that the concave groove 54 may be provided in the buried portion 24 or may be provided on the inner peripheral side of the buried portion 24. As will be described later, also in the terminal block 34, since the outer surface 73 of the buried portion 24 including the inner peripheral surface, the lower surface, and the outer peripheral surface of the buried portion 24 constitutes the opposing surface between the buried portion 24 and the second component 22, the concave groove 54 opens to the opposing surface between the buried portion 24 and the second component 22.

[0046] In Embodiment 1, the terminal block 34 is formed as an integrally molded product equipped with connection terminals 66 and stud bolts 72. Specifically, when molding the terminal block 34, the connection terminals 66 and stud bolts 72 are inserted into the molding cavity of the terminal block 34 during injection molding, thereby forming the terminal block 34 as an integrally molded product equipped with connection terminals 66 and stud bolts 72. As a result, the connection terminals 66 and stud bolts 72 are fixedly held to the terminal base 68. The resin material constituting the terminal base 68 is not limited as long as it is rigid, but materials such as PPS or PBT are preferably used, similar to the connector mounting portion 32, and it may be reinforced with, for example, glass fiber.

[0047] <Second Component 22> As described above, the second component 22 is composed of an upper bottom wall portion 36 of the upper case 16 and a lower case 18. In the upper bottom wall portion 36, an opening 40 is formed as a waterproof area 23 that penetrates the upper bottom wall portion 36 in the vertical direction at the location where the connector mounting portion 32, which is a first component 20, is fixed. Also, in the upper bottom wall portion 36, a penetration portion 42 is formed as a waterproof area 23 that penetrates the upper bottom wall portion 36 in the vertical direction at the location where the terminal block 34, which is a first component 20, is fixed.

[0048] <Waterproof Area 23 (Opening 40)> The opening 40 as the waterproof area 23 has a shape that substantially corresponds to the connector mounting portion 32 in plan view and is substantially rectangular. The opening 40 is formed by penetrating the upper bottom wall portion 36 in the vertical direction, and a housing recess 76 for housing the embedded portion 24 provided at the lower end portion of the connector mounting portion 32 is formed at the peripheral edge of the opening 40. As shown also in FIG. 2, the housing recess 76 has a rectangular cross-sectional shape that substantially corresponds to the embedded portion 24 and is an annular recess that is continuous over the entire circumference in the circumferential direction around the opening 40. In short, when the first component (connector mounting portion 32) and the second component (upper bottom wall portion 36) are fixed, each embedded portion 24 is housed in each housing recess 76, and the outer surface 55 of each embedded portion 24 (including the inner peripheral surface, lower surface, and outer peripheral surface of the embedded portion 24) and the inner surface 78 of each housing recess 76 (including the inner peripheral side surface, bottom surface, and outer peripheral side surface of the housing recess 76) are the opposing surfaces of the embedded portion 24 and the second component 22. Note that in the state where the first component 20 and the second component 22 are fixed and each embedded portion 24 is housed in the housing recess 76, the upper surfaces of each embedded portion 24 are exposed to the outside.

[0049] <Waterproof Area 23 (Through-Hole Portion 42)> The through-hole portion 42 as the waterproof area 23 is a portion through which the middle portion in the length direction of the connection terminal 66 provided on the terminal block 34 penetrates in the upper bottom wall portion 36 and is formed in a rectangular shape corresponding to the connection terminal 66 in plan view. A housing recess 80 for housing the terminal pedestal 68 and the embedded portion 24 is formed around the through-hole portion 42. In short, when the first component (terminal block 34) and the second component (upper bottom wall portion 36) are fixed, the terminal pedestal 68 and the embedded portion 24 are housed in the housing recess 80, and the outer surface 73 of the terminal pedestal 68 and the embedded portion 24 (including the lower surface of the terminal pedestal 68 and the outer peripheral surface of the embedded portion 24) and the inner surface 82 of the housing recess 80 (including the inner peripheral side surface, bottom surface, and outer peripheral side surface of the housing recess 80) are the opposing surfaces of the embedded portion 24 and the second component 22. Note that in the state where the first component 20 and the second component 22 are fixed and the terminal pedestal 68 and the embedded portion 24 are housed in the housing recess 80, the upper portion of the terminal pedestal 68 and the upper surface of the embedded portion 24 are exposed to the outside.

[0050] <Thermoplastic Elastomer 26> The thermoplastic elastomers 26 provided in each connector mounting portion 32 and each embedded portion 24 in the terminal block 34 each have a substantially rectangular cross-section and are formed in an annular shape continuously around the entire circumference in the circumferential direction. Known materials can be used for the thermoplastic elastomer 26. In Embodiment 1, each groove 54 is opened on the lower surface of each embedded portion 24, and each thermoplastic elastomer 26 is filled and arranged in each groove 54. As a result, each thermoplastic elastomer 26 filled in each groove 54 in each connector mounting portion 32 is arranged to surround the periphery of the opening 40. Also, the thermoplastic elastomer 26 filled in the groove 54 in the terminal block 34 is arranged to surround the periphery of the through portion 42.

[0051] <Manufacturing Method for Resin Molded Product (Electrical Connection Box 10)> The following describes a specific example of the manufacturing method for the electrical connection box 10. However, the manufacturing method for the electrical connection box 10 is not limited to the description below.

[0052] First, in the first component molding process, the first component 20, namely the connector mounting portion 32 and the terminal block 34, is formed by injection molding. In Embodiment 1, since the connector mounting portion 32 is formed integrally with each connection terminal 60, the connector mounting portion 32 shown in Figure 4 is obtained by the first component molding process. Also, since the terminal block 34 is formed integrally with the connection terminals 66, the terminal block 34 equipped with the connection terminals 66 is obtained by the first component molding process.

[0053] Subsequently, in the primary molded product molding process, the first components 20 (connector mounting portion 32 and terminal block 34) are set as inserts in the molding cavity of the thermoplastic elastomer 26, and the resin material of the thermoplastic elastomer 26 is filled into the grooves 54 in the embedded portion 24 of each first component 20, and molded. This results in a primary molded product 84 in which the thermoplastic elastomer 26 is integrally molded into the grooves 54 of each first component 20. Figure 5 shows a primary molded product 84 consisting of a connector mounting portion 32 and a thermoplastic elastomer 26. When manufacturing this primary molded product 84, since molten thermoplastic elastomer 26 is filled into the grooves 54 in the embedded portion 24 of each first component 20, the heat of the molten thermoplastic elastomer 26 melts the inner surface of the grooves 54, causing these embedded portions 24 and the thermoplastic elastomer 26 to melt and adhere to each other. During the manufacturing of each primary molded product 84, the lower surface of each thermoplastic elastomer 26 is exposed to the outside at the outer surfaces 55, 73 of each embedded portion 24.

[0054] Next, in the second part molding process, a plurality of primary molded products 84 manufactured in the primary molded product molding process are set as inserts in the molding cavity of the upper bottom wall portion 36 which constitutes a part of the second part 22, and the upper bottom wall portion 36 is formed by injection molding. As a result, a receiving recess 76 is formed to cover the area around the embedded portion 24 in each connector mounting portion 32, and a receiving recess 80 is formed to cover the area around the terminal base 68 and the embedded portion 24 in the terminal block 34, thereby forming a second part 22 (upper bottom wall portion 36) that integrally includes each primary molded product 84. When forming the upper bottom wall portion 36, the molten upper bottom wall portion 36 is filled into the molding cavity into which each primary molded product 84 is inserted. As a result, the heat of the molten upper bottom wall portion 36 melts the outer surfaces 55, 73 of each embedded portion 24, including the lower surface of the thermoplastic elastomer 26, causing these embedded portions 24 and the thermoplastic elastomer 26 to fuse tightly with the upper bottom wall portion 36. This completes the upper case 16.

[0055] Alternatively, the following embodiment may also be adopted as another embodiment of the manufacturing method of the upper case 16. First, in the thermoplastic elastomer molding process, the thermoplastic elastomer 26 is formed by injection molding.

[0056] Subsequently, in the primary molded product molding process, the thermoplastic elastomer 26 is set in the molding cavity of the first part 20, and then the resin material of the first part 20 is filled and molded. Specifically, in each connector mounting section 32, the thermoplastic elastomer 26 and each connection terminal 60 are set in the molding cavity of each connector mounting section 32, and then the resin material of each connector mounting section 32 is filled and molded. Similarly, in the terminal block 34, the thermoplastic elastomer 26 and the connection terminal 66 are set in the molding cavity of the terminal block 34, and then the resin material of the terminal block 34 is filled and molded. This results in a primary molded product 84 (each connector mounting section 32) having the thermoplastic elastomer 26 and each connection terminal 60 integrally, as shown in Figure 5, and a primary molded product 84 (terminal block 34) having the thermoplastic elastomer 26 and the connection terminal 66 integrally. In this process as well, since the molten first part 20 is filled into the molding cavity of the first part 20 in which the thermoplastic elastomer 26 is set, the heat of the molten first part 20 melts the surface of the thermoplastic elastomer 26, causing the first part 20 (embedded portion 24) and the thermoplastic elastomer 26 to fuse together.

[0057] Next, in the second component molding process, a plurality of primary molded products 84 manufactured in the primary molded product molding process are set as inserts in the molding cavity of the second component 22 (upper bottom wall portion 36), and the upper bottom wall portion 36 is formed by injection molding. This process is the same as described in the second component molding process above. The upper case 16 can also be obtained by this manufacturing method.

[0058] Alternatively, the following embodiment may also be adopted as another embodiment of the manufacturing method of the upper case 16. First, in the first component molding step, the first component 20, that is, each connector mounting portion 32 and the terminal block 34, are formed by injection molding. In Embodiment 1, the first component molding step provides a connector mounting portion 32 integrally equipped with each connection terminal 60, as shown in Figure 4. The first component molding step also provides a terminal block 34 integrally equipped with connection terminals 66. Furthermore, in the thermoplastic elastomer molding step, the thermoplastic elastomer 26 is formed by injection molding.

[0059] Subsequently, in the assembly process, the thermoplastic elastomer 26 is assembled to the first component 20 (each connector mounting portion 32 and terminal 34) such that the thermoplastic elastomer 26 is positioned between the opposing surfaces (outer surfaces 55, 73 and inner surfaces 78, 82) of the second component 22 (upper bottom wall portion 36) and the embedded portions 24 of each connector mounting portion 32 and terminal block 34 formed in the first component molding process. Specifically, the thermoplastic elastomer 26 is inserted and fitted into the grooves 54 provided in each connector mounting portion 32 and each embedded portion 24 of the terminal block 34. This completes the assembly 86 of the first component 20 (connector mounting portion 32) and thermoplastic elastomer 26 as shown in Figure 5. Similarly, the assembly of the terminal block 34 and thermoplastic elastomer 26 is also completed, but it is not shown in the illustration.

[0060] Next, in the second component molding process, the multiple assembled parts 86 manufactured in the assembly process are set as inserts in the molding cavity of the second component 22 (upper bottom wall portion 36), and the upper bottom wall portion 36 is formed by injection molding. This process is the same as described in the second component molding process above. The upper case 16 can also be obtained by this manufacturing method.

[0061] Then, for example, the circuit board 12 is brought close to the upper case 16 manufactured as described above from below and fixed with screws. As a result, one end (lower end) of each connection terminal 60 and connection terminal 66 that protrudes downward from the upper case 16 is inserted into each through-hole 28 in the circuit board 12. Each connection terminal 60 and connection terminal 66 inserted into each through-hole 28 may be electrically connected to the circuit board 12 by solder or the like (not shown). Furthermore, the upper case 16 with the circuit board 12 assembled is brought close to the separately formed lower case 18 from above, and with the upper case 16 covering the upper opening 19 of the lower case 18, the upper case 16 and the lower case 18 are fixed together with screws, for example. As a result, the entire second component 22 is formed by the upper bottom wall portion 36 and the lower case 18, and a case 14 containing the circuit board 12 is formed inside, completing the electrical connection box 10.

[0062] In the resin molded product (electrical connection box 10) of Embodiment 1, which has the structure described above, a thermoplastic elastomer 26 is provided between a first component 20 made of synthetic resin and a second component 22 made of synthetic resin. This configuration not only welds the first component 20 and the second component 22 together, but also welds the first component 20 to the thermoplastic elastomer 26 and the second component 22 to the thermoplastic elastomer 26. More specifically, the first component 20 has an embedded portion 24 that is embedded in the second component 22, and a thermoplastic elastomer 26 is placed between the opposing surfaces (outer surfaces 55, 73 and inner surfaces 78, 82) of the embedded portion 24 and the second component 22, thereby welding not only the embedded portion 24 to the second component 22, but also the embedded portion 24 to the thermoplastic elastomer 26 and the second component 22 to the thermoplastic elastomer 26. As a result, the first component 20 and the thermoplastic elastomer 26, and the second component 22 and the thermoplastic elastomer 26 are fused together, and water intrusion from between them can be prevented more reliably than when the first component 20 and the second component 22 are simply welded together. In other words, when fixing the first component and the second component, if the second component is integrally molded with the first component as an insert, the interfaces between them will not be completely welded together, and there is a risk of water intrusion from their opposing surfaces. However, by adopting the above configuration, water intrusion through the opposing surfaces can be prevented, and problems such as an increase in the number of parts and assembly steps, as in conventional structures, can also be eliminated. Note that the first component 20 and the thermoplastic elastomer 26 do not necessarily have to be welded together; they may be formed separately and assembled later.

[0063] An annular groove 54 surrounding the waterproof area 23 is formed on the surface (outer surface 55, 73) facing the second part 22 in each embedded portion 24, and thermoplastic elastomer 26 is filled into each groove 54. As a result, in the primary molded product 84 in which the first part 20 and the thermoplastic elastomer 26 are integrally formed, the thermoplastic elastomer 26 does not protrude significantly to the outside, making it easier to handle the primary molded product 84 when molding the second part 22 using the primary molded product 84 as an insert, and enabling stable molding of the second part 22.

[0064] In Embodiment 1, a plurality of first components 20 are provided, some of which are connector mounting portions 32, and the second component 22 is the upper bottom wall portion 36 of the upper case 16 and the lower case 18 that constitute the case 14. Thus, an electrical connection box 10 equipped with a plurality of connector mounting portions 32 is constructed as a resin molded product comprising the first component 20 and the second component 22. That is, when providing the connector mounting portions 32 in the electrical connection box 10, an opening 40 that penetrates in the thickness direction is formed in the upper bottom wall portion 36, but by fixing the connector mounting portion 32 (embedded portion 24) to this opening 40 which is a waterproof area 23, the intrusion of water through the opening 40 can be effectively prevented.

[0065] Furthermore, in Embodiment 1, the connector mounting portion 32 has a terminal holding wall 58, and a plurality of connection terminals 60 are fixedly held in the terminal holding wall 58. In particular, in Embodiment 1, each connection terminal 60 is integrally molded with the connector mounting portion 32 as an insert. This makes it possible to form the connector mounting portion 32 having each connection terminal 60 inside in a single molding process. Therefore, by molding the second component 22 with this connector mounting portion 32 as an insert, the upper case 16, and thus the electrical connection box 10, which has each connection terminal 60 in the connector mounting portion 32, can be easily manufactured.

[0066] Furthermore, in Embodiment 1, one of the first components 20 is a terminal block 34. As a result, an electrical connection box 10 equipped with a terminal block 34 is constructed as a resin molded product comprising the first component 20 and the second component 22. That is, when providing the terminal block 34 to the electrical connection box 10, a through-hole 42 through which the connection terminal 66 is inserted is formed in the upper bottom wall portion 36. By fixing the terminal block 34 (embedded portion 24) to this through-hole 42 which is a waterproof area 23, the intrusion of water through the through-hole 42 can be effectively prevented.

[0067] In the manufacturing of the primary molded product 84 which integrally comprises the first component 20 and the thermoplastic elastomer 26, the first component 20 may be made as an insert part using insert molding, or the thermoplastic elastomer 26 may be made as an insert part using insert molding.

[0068] <Embodiment 2> Next, an electrical junction box 90, which is a resin molded product of Embodiment 2 of the present disclosure, will be described with reference to Figure 6. The basic structure of the electrical junction box 90 in Embodiment 2 is the same as that of the electrical junction box 10 in Embodiment 1. However, in Embodiment 1, the connector mounting portion 32 as the first component 20 was formed as an integrally molded product equipped with each connection terminal 60, whereas in Embodiment 2, the connector mounting portion 92 as the first component 20 is formed separately from each connection terminal 60. In the following, mainly the differences from Embodiment 1 will be described, and detailed explanations of components or parts that are substantially the same as those in Embodiment 1 will be omitted by denoting them with the same reference numerals in the figures as in Embodiment 1.

[0069] The connector mounting portion 92 of Embodiment 2 is provided with a hood portion 52 that protrudes upward from the electrical connection box 90 (upper case 93). The hood portion 52 is provided with a terminal retaining wall 58 that divides the case 14 into an inward side (downward side) and an outward side (upward side). This terminal retaining wall 58 widens horizontally in the vertical intermediate portion on the inner circumference side of the hood portion 52. The terminal retaining wall 58 is provided with a plurality of insertion holes 94 that allow insertion of each connection terminal 60 protruding to the inward side (downward side) and outward side (upward side) of the case 14. In a plan view, each insertion hole 94 is, for example, rectangular in shape and is larger than the planar shape (for example, rectangular) of each connection terminal 60. As a result, as shown in Figure 6, when each connection terminal 60 is inserted into each insertion hole 94, each connection terminal 60 does not come into contact with the inner surface of each insertion hole 94.

[0070] In manufacturing the electrical junction box 90 with the structure described above, first, the connector mounting portion 92 as the first component 20 is formed by injection molding. Then, using the connector mounting portion 92 as an insert, thermoplastic elastomer 26 is filled into the groove 54 provided in the embedded portion 24 of the first component 20 and molded. This gives a primary molded product 84 in which the connector mounting portion 92 and the thermoplastic elastomer 26 are integrally molded. Furthermore, by molding the second component 22 (upper bottom wall portion 36) using this primary molded product 84 as an insert, the upper case 93 in Embodiment 2 is obtained. The terminal block 34 is formed in the same manner as in Embodiment 1, and when manufacturing the upper case 93, one end of the connection terminal 66 protrudes downward from the upper case 83.

[0071] Furthermore, when manufacturing the electrical junction box 90 using the upper case 93 in Embodiment 2, first, a circuit board 12 equipped with connection terminals 60 protruding upward is prepared. Specifically, one end (lower end) of each connection terminal 60 is inserted from above into each through-hole 28 of the circuit board 12, and each connection terminal 60 is fixed to the circuit board 12 with solder or the like (not shown), and the electrical circuit on the circuit board 12 and each connection terminal 60 are electrically connected. After that, the circuit board 12 equipped with each connection terminal 60 is brought close to the upper case 93 manufactured as described above from below, and the other end (upper end) of each connection terminal 60 is inserted into each insertion hole 94 in the terminal holding wall 58. Also, the connection terminals 66 protruding downward from the upper case 93 are inserted into the through-hole 28 of the circuit board 12 and fixed and electrically connected with solder or the like. Then, the circuit board 12 is fixed to the upper bottom wall 36, for example, with screws.

[0072] As a result, the other end (upper end) of each connection terminal 60 protrudes above the terminal holding wall 58 on the inner circumference side of the hood portion 52 and is exposed to the outside. Furthermore, the upper case 93, to which the circuit board 12 is assembled as described above, is brought closer from above to the separately formed lower case 18, and with the upper case 93 covering the upper opening 19 of the lower case 18, the upper case 93 and the lower case 18 are fixed together, for example, with screws. This provides the electrical connection box 90 using the upper case 93 in Embodiment 2.

[0073] As in Embodiment 1, a female connector (not shown) can be connected to each connector mounting portion 92 having the structure described above. Furthermore, since the electrical connection box 90 of Embodiment 2 differs from the electrical connection box 10 of Embodiment 1 only in the way in which each connection terminal 60 is held, the same effects as in Embodiment 1 can be achieved.

[0074] <Modifications> Although Embodiments 1 and 2 have been described in detail above as specific examples of the present disclosure, the present disclosure is not limited by these specific descriptions. Modifications, improvements, etc., to the extent that they can achieve the objectives of the present disclosure are included in the present disclosure. For example, the following modifications of embodiments are also included in the technical scope of the present disclosure.

[0075] (1) In the embodiments 1 and 2 described above, the first component 20 was made up of connector mounting parts 32 and 92 and terminal blocks 34, and the second component 22 was made up of an upper bottom wall 36 and a lower case 18, and the resin molded product comprising these first component 20 and second component 22 was made up of electrical connection boxes 10 and 90, but the invention is not limited to this embodiment. Also, in the embodiments 1 and 2 described above, the second component 22 (upper bottom wall 36) was integrally molded with a primary molded product 84 (first component 20 and thermoplastic elastomer 26) as an insert, but the invention is not limited to this embodiment. Furthermore, in the embodiments 1 and 2 described above, the first component 20 was made up of connector mounting parts 32 and 92 and terminal blocks 34, but the invention is not limited to this embodiment, and the specific embodiments of the first component and the second component are not limited as long as the embedded portion of the first component surrounds the periphery of the waterproof area of ​​the second component.

[0076] For example, the second component may consist only of the upper bottom wall portion, and the upper case may be a resin molded product comprising the first component (each connector mounting portion and terminal block) and the second component. Alternatively, the upper bottom wall portion may be the first component. That is, the upper bottom wall portion may be the first component, and a primary molded product may be manufactured by integrally molding the first component (upper bottom wall portion) and a thermoplastic elastomer. Subsequently, the upper case may be manufactured as a resin molded product by molding the connector mounting portion, which is the second component, using the primary molded product and connection terminals as inserts. In that case, in the connector mounting portion, for example, the lower opening of the hood portion, which is roughly cylindrical, is made into a waterproof area. The upper bottom wall portion, which is the first component, is provided with an embedded portion surrounding the waterproof area, and a receiving recess is formed in the connector mounting portion, which is the second component, to accommodate the embedded portion, and the thermoplastic elastomer may be provided so as to be located between the opposing surfaces of the embedded portion and the receiving recess.

[0077] Furthermore, the upper bottom wall and the lower case may be integrated into a single first component. For example, a circuit board with protruding connection terminals may be fixed to the lower part of the upper bottom wall with screws, and the upper bottom wall and the lower case may be fixed together with screws or the like. Then, a primary molded product is manufactured by integrally molding this first component (upper bottom wall and lower case) with a thermoplastic elastomer. Subsequently, as described above, the connector mounting portion, which is the second component, may be molded using the primary molded product as an insert, thereby forming an electrical connection box as a resin molded product.

[0078] (2) In the embodiment 1 described above, each connection terminal 60 and each connector mounting portion 32 were integrally molded so that each connection terminal 60 was fixedly held by the terminal holding wall 58 of each connector mounting portion 32. However, each connection terminal and each connector mounting portion may be formed separately, and each connection terminal may be press-fitted into a through hole provided in the terminal holding wall of each connector mounting portion so that each connection terminal is fixedly held by the terminal holding wall of each connector mounting portion.

[0079] (3) In the embodiments 1 and 2 described above, each groove 54 and the thermoplastic elastomer 26 placed within each groove 54 were provided in the radial central portion of each embedded portion 24, but the embodiment is not limited to this. Each groove and thermoplastic elastomer only needs to be provided between the opposing surfaces of the embedded portion and the second component (retaining recess). For example, the groove and thermoplastic elastomer may be provided on the inner circumferential surface of the embedded portion, or on the outer circumferential surface of the embedded portion.

[0080] (4) The circuit board is not limited to being fixed to the upper case, but may also be fixed to the lower case. Furthermore, the upper case and the lower case are not limited to being fixed together by screws, but may also be fixed together by, for example, a known locking mechanism.

[0081] 10 Electrical junction box (resin molded product in Embodiment 1) 12 Circuit board 14 Case 16 Upper case 18 Lower case 19 Upper opening 20 First component 22 Second component 23 Waterproof area 24 Embedded portion 26 Thermoplastic elastomer 28 Through hole 32 Connector mounting portion 34 Terminal block 36 Upper bottom wall portion 40 Opening 42 Through portion 44 Bottom wall portion 46 Lower peripheral wall portion 52 Hood portion 54 Groove 55 Outer surface (opposing surface) 58 Terminal retaining wall 60 Connection terminal 64 Terminal fastening portion 66 Connection terminal 68 Terminal base 70 Bolt insertion hole 72 Stud bolt 73 Outer surface (opposing surface) 76 Retaining recess 78 Inner surface (opposing surface) 80 Retaining recess 82 Inner surface (opposing surface) 84 Primary molded product 86 Assembly 90 Electrical connection box (resin molded product in Embodiment 2) 92 Connector mounting part 93 Upper case 94 Through hole

Claims

1. A resin molded product comprising a first component made of synthetic resin and a second component made of synthetic resin, wherein the first component is integrated with the second component and has an embedded portion that surrounds the periphery of the waterproof area of ​​the second component and is embedded in the second component, and a waterproof thermoplastic elastomer is placed and welded between the embedded portion and the opposing surface of the second component.

2. The resin molded product according to claim 1, wherein an annular groove surrounding the waterproof area is formed on the surface of the embedded portion facing the second component, and the thermoplastic elastomer is disposed in the groove.

3. The resin molded product according to claim 2, wherein the second component includes a case for housing a circuit board inside, the first component includes a connector mounting portion provided in an opening of the case which serves as a waterproof area, the connector mounting portion having a hood portion that protrudes above the case and an embedded portion that extends in a flange-like manner toward the base end of the hood portion, and the thermoplastic elastomer filled in the annular groove provided in the embedded portion is arranged to surround the periphery of the opening.

4. The resin molded product according to claim 3, wherein the connector mounting portion has a terminal retaining wall that divides the hood portion into an inner side and an outer side of the case, and includes a connecting terminal that penetrates the terminal retaining wall and protrudes to the inner side and the outer side of the case, and the connecting terminal is fixedly held by the terminal retaining wall.

5. The resin molded product according to claim 3, wherein the connector mounting portion has a terminal retaining wall that divides the hood portion into an inward side and an outward side of the case, and the terminal retaining wall is provided with an insertion hole that allows the insertion of a connecting terminal protruding to the inward side and the outward side of the case.

6. The resin molded product according to claim 2, wherein the second component includes a case for housing a circuit board, the first component includes a terminal block having a connecting terminal having one end connected to the circuit board and the other end having a terminal fastening portion, and a terminal base for holding the connecting terminal with the terminal fastening portion exposed above the waterproof area, the waterproof area includes a through portion through which the intermediate portion of the connecting terminal passes, the embedded portion is formed by the peripheral edge of the base end of the terminal base, and the thermoplastic elastomer filled in the annular groove provided in the embedded portion is arranged to surround the through portion.

7. A method for manufacturing a resin molded article according to claim 1, comprising: a first component molding step of injection molding the first component; a primary molded article molding step of integrally molding the first component and the waterproof thermoplastic elastomer using the first component molded in the first component molding step as an insert to form a primary molded article; and a second component molding step of injection molding the second component using the primary molded article as an insert such that the thermoplastic elastomer is positioned between the embedded portion of the first component and the opposing surface of the second component.

8. A method for manufacturing a resin molded article according to claim 1, comprising: a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; a primary molded article molding step of integrally molding the thermoplastic elastomer and the first part using the thermoplastic elastomer molded in the thermoplastic elastomer molding step as an insert to form a primary molded article; and a second part molding step of injection molding the second part using the primary molded article as an insert so that the thermoplastic elastomer is positioned between the embedded portion of the first part and the opposing surface of the second part.

9. A method for manufacturing a resin molded article according to claim 1, comprising: a first component molding step of injection molding the first component; a thermoplastic elastomer molding step of injection molding the thermoplastic elastomer; an assembly step of assembling the first component and the thermoplastic elastomer such that the thermoplastic elastomer is positioned between the embedded portion of the first component and the opposing surface of the second component; and a second component molding step of injection molding the second component using the assembly of the first component and the thermoplastic elastomer assembled in the assembly step as an insert.

10. The method for manufacturing a resin molded product according to any one of claims 7 to 9, wherein the first part has an annular groove formed on the surface of the embedded part facing the second part, surrounding the periphery of the waterproof area, and the second part molding step is performed using the primary molded product or the assembly in which the thermoplastic elastomer is placed in the groove of the embedded part as an insert product.

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