JP2023157304A - Air conditioner case for vehicle - Google Patents

Abstract

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

Description

The present invention relates to a case for an air conditioner mounted on a vehicle.

Traditionally, in vehicle air conditioner cases, support was provided inside the case to prevent poor fitting between products due to sinkage and warpage of resin products, as well as increase in noise and pressure loss due to changes in airflow within the case. Providing ribs and filling resin with filler have been implemented. However, if support ribs are provided within the case, the support ribs may cause changes in air flow, generation of abnormal noise, increase in pressure loss, etc. Furthermore, filling the resin with filler increases the weight of the case, which may lead to deterioration of fuel efficiency.

Therefore, it is possible to improve the sink marks and warpage of resin products by foam molding the vehicle air conditioner case. However, in foam molding, the foam distribution may be uneven within the product, or the foam distribution may occur at unintended locations within the product. In that case, physical properties change in unintended locations within the product, and if the desired physical properties of the material cannot be obtained, this may affect product functions such as structural design and vibration transmission for vehicle air conditioners. .

Patent Document 1 describes a foam molding method that is applied to vehicle air conditioner cases and the like. In the foam molding method described in Patent Document 1, when there are a plurality of resin filling parts with different resin flow distances in the mold, a plurality of gates are opened to supply molten resin to each of the plurality of resin filling parts. It is described that control is performed to vary the timing. Specifically, a first gate is opened to supply molten resin to a resin filled part having a long distance, and after a predetermined time has elapsed, a second gate is opened to supply molten resin to a resin filled part having a short distance. This controls the opening of the gate. As a result, in Patent Document 1, the pressure of the molten resin supplied to each of the plurality of resin filling sections is made uniform, thereby improving the problem that foaming does not progress in the resin filling sections having a short distance.

Patent No. 4269879

However, even with the foam molding method described in Patent Document 1, it is difficult to control variations in foam distribution in each region within a product by simply controlling the timing of opening a plurality of gates, and the cost of introducing equipment is also high. Furthermore, only by controlling the opening and closing of a plurality of gates as in the foam molding method described in Patent Document 1, it is not possible to achieve high foaming at an intended location within the product.

In view of the above-mentioned points, an object of the present invention is to provide a vehicle air conditioner case that has a simple configuration and is capable of achieving high foaming at intended locations at low cost.

In order to achieve the above object, the invention according to claim 1 provides a vehicle air conditioner case formed by foam molding, in which a gate part (10), a first resin part (11) and a second resin part (12) Be prepared. The gate portion is a portion into which molten resin containing a foaming agent is injected during foam molding. A portion of the first resin portion connected to the gate portion extends in a direction intersecting the direction in which molten resin is injected into the gate portion. The part of the second resin part connected to the first resin part extends in a direction intersecting the direction in which the first resin part extends. In this vehicle air conditioner case, the thickness (T2) of the second resin part is larger than the thickness (T1) of the first resin part, and the total volume occupied by air bubbles per unit volume in the first resin part is larger than the thickness (T1) of the first resin part. Also, the total volume occupied by the bubbles per unit volume in the second resin part is large.

According to this, the molten resin containing the foaming agent injected from the gate part into the first resin part in the mold during foam molding flows into the second resin part from the first resin part. The sudden expansion of the space causes a sudden pressure reduction, which promotes foaming of the blowing agent contained in the molten resin in the second resin section. Therefore, the total volume occupied by the bubbles per unit volume in the second resin part is larger than the total volume occupied by the bubbles per unit volume in the first resin part. Therefore, this vehicle air conditioner case has a simple structure in which the thickness of the second resin part is larger than that of the first resin part, so that the intended location (i.e., the second resin part) can be easily installed at low cost. Can be highly foamed. As a result, it is possible to suppress sink marks and warpage at the intended location (i.e., the second resin portion) and to improve heat insulation.

Note that the reference numerals in parentheses attached to each component etc. indicate an example of the correspondence between the component etc. and specific components etc. described in the embodiments to be described later.

FIG. 1 is a perspective view of a vehicle air conditioner case according to the first embodiment. It is a perspective view of one component which constitutes a vehicle air conditioner case concerning a 1st embodiment. FIG. 1 is a cross-sectional view of a portion of the vehicle air conditioner case according to the first embodiment. FIG. 1 is a cross-sectional view schematically showing a part of the vehicle air conditioner case according to the first embodiment. 5 is a cross-sectional view schematically showing a mold for foam-molding the portion shown in FIG. 4. FIG. FIG. 2 is a cross-sectional view schematically showing a part of a vehicle air conditioner case of a first comparative example. FIG. 3 is a cross-sectional view schematically showing a part of a vehicle air conditioner case of a second comparative example. FIG. 3 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a modification of the first embodiment. FIG. 2 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a second embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a modification of the second embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a third embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a fourth embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a fifth embodiment. FIG. 7 is a perspective view of the bottom of a vehicle air conditioner case of a third comparative example. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case of a third comparative example. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a sixth embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a modification of the sixth embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a seventh embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case of a fourth comparative example. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to a modification of the seventh embodiment. FIG. 7 is a cross-sectional view schematically showing a part of a vehicle air conditioner case according to an eighth embodiment.

Embodiments of the present invention will be described below with reference to the drawings. In each of the following embodiments, modifications, and comparative examples, parts that are the same or equivalent to each other are given the same reference numerals, and their explanations will be omitted.

(First embodiment)
A first embodiment will be described with reference to the drawings. As shown in FIG. 1, a vehicle air conditioner case 1 (hereinafter simply referred to as "air conditioner case 1") of the present embodiment is a housing for an air conditioner mounted on a vehicle. The air conditioning case 1 includes a blower unit case 2 and an air conditioning unit case 3. The air conditioner blows air sucked in by driving a blower (not shown) provided inside the blower unit case 2 to a ventilation path in the air conditioning unit case 3, and It is configured to blow out conditioned air into the vehicle interior, with the temperature and humidity adjusted using a heat exchanger.

The air conditioning unit case 3 is constructed by fitting each component, such as a right case 4, a center case 5, and a left case 6, to each other. FIG. 2 is a perspective view of the right case 4 viewed from inside the air conditioning unit case 3. As shown in FIG. 2, the right case 4 is provided with ribs 7, 8, 9, etc. for supporting an air cooling heat exchanger (not shown) and an air heating heat exchanger (not shown), respectively. . The ribs at various locations in the air conditioning case 1, including the ribs 7, 8, and 9, provided in the ventilation passages are required to have high dimensional accuracy to prevent abnormal noise from occurring due to changes in air flow and poor assembly of the heat exchanger. . Therefore, the air conditioning case 1 of this embodiment includes the ribs 7, 8, and 9, and furthermore, the foam molding prevents shrinkage and warpage in all the ribs, which may lead to abnormal noise or poor assembly of the air conditioning case 1. It is something.

Foam molding is a method of molding a foam by injecting molten resin containing a foaming agent into a mold. As the foam molding, for example, a supercritical foam molding method can be employed. In the supercritical foam molding method, supercritical carbon dioxide gas is injected as a foaming agent into a heated and molten thermoplastic resin material to dissolve it, and then it is injected into a mold to form a resin product with bubbles. It's a method. Note that as the thermoplastic resin material, a resin material (for example, polypropylene) that has a certain degree of elasticity and is excellent in strength is used.

FIG. 3 is a sectional view of a part of the air conditioning case 1, and FIG. 4 is a sectional view schematically showing a part of the air conditioning case 1. In addition, in FIG. 4, in order to make the figure easier to read, hatching indicating the cross section is omitted. This also applies to FIGS. 5 to 13 and 15 to 21, which will be referred to in each embodiment, each modified example, and each comparative example, which will be described later.

As shown in FIGS. 3 and 4, the air conditioning case 1 includes a gate portion 10, a first resin portion 11, and a second resin portion 12. Note that the first resin part 11 and the second resin part 12 schematically shown in FIG. 4 may have a curved part and a bent part in the middle, as shown in FIGS. 2 and 3. This also applies to each embodiment, each modified example, and each comparative example described below.

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

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

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

Here, as shown in FIGS. 3 and 4, the thickness of the gate portion 10 is assumed to be Tg. The plate thickness of the first resin portion 11 is assumed to be T1. The plate thickness of the second resin portion 12 is assumed to be T2. At this time, in this embodiment, there is a relationship of Tg>T1 and T1<T2. That is, the thickness T1 of the first resin portion 11 is smaller than the thickness Tg of the gate portion 10. Further, the plate thickness T2 of the second resin part 12 is larger than the plate thickness T1 of the first resin part 11. In this specification, the relationship Tg>T1 and T1<T2 means that the difference between the plate thickness Tg of the gate part 10, the plate thickness T1 of the first resin part 11, and the plate thickness T2 of the second resin part 12 is determined by the manufacturing process. It means that it is larger than the tolerance. Note that, as will be described later, in order to cause rapid depressurization of the molten resin in the second resin part 12 during foam molding, the plate thickness T2 of the second resin part 12 is 1.5 of the plate thickness T1 of the first resin part 11. It is preferably twice or more, more preferably twice or more. Further, in order to suppress pressure reduction of the molten resin in the first resin part 11 during foam molding, the plate thickness Tg of the gate part 10 is preferably 1.5 times or more the plate thickness T1 of the first resin part 11. More preferably, it is twice or more.

In the configuration of the air conditioning case 1 of this embodiment, the plate thickness Tg of the gate part 10, the plate thickness T1 of the first resin part 11, and the plate thickness T2 of the second resin part 12 are such that Tg>T1 and T1<T2. I will explain the reason why.

FIG. 5 is a cross-sectional view schematically showing molds 20 and 21 for foam-molding a part of the air conditioning case 1 shown in FIG. In addition, in FIG. 5, the dividing surfaces 23 of the molds 20 and 21 are shown as an example.

In foam molding, molten resin containing a foaming agent is injected from the gate portion 10 into a space (ie, cavity) 24 within the mold. The molten resin flows from the gate section 10 through the first resin section 11 as shown by arrow A. At this time, in this embodiment, since the plate thickness T1 of the first resin part 11 is smaller than the plate thickness Tg of the gate part 10, the pressure reduction of the molten resin flowing from the gate part 10 through the first resin part 11 is suppressed, Foaming in the first resin portion 11 is suppressed. Subsequently, the molten resin flows from the first resin section 11 to the second resin section 12 as shown by arrow B. At this time, in this embodiment, since the plate thickness T2 of the second resin part 12 is larger than the plate thickness T1 of the first resin part 11, when the molten resin flows from the first resin part 11 to the second resin part 12, Since the space 24 within the mold rapidly expands, a sudden pressure reduction occurs in the molten resin, and foaming in the second resin portion 12 is promoted. As described above, in this embodiment, the relationship between the thickness Tg of the gate portion 10, the thickness T1 of the first resin portion 11, and the thickness T2 of the second resin portion 12 is such that Tg>T1 and T1<T2. By doing so, the second resin part 12 can be highly foamed, and shrinkage and warpage of the second resin part 12 can be prevented.

Next, in order to compare with the first embodiment described above, air conditioning cases 1 of a first comparative example and a second comparative example will be described.

FIG. 6 is a cross-sectional view schematically showing a part of the air conditioning case 101 of the first comparative example. The air conditioning case 101 of the first comparative example is not formed by foam molding, but is made of resin that does not contain bubbles (ie, solid). Further, in the first comparative example, the plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 are the same. In this case, in the first comparative example, as indicated by the broken line C, the second resin portion 12 may warp or shrink.

On the other hand, FIG. 7 is a cross-sectional view schematically showing a part of the air conditioning case 102 of the second comparative example. The air conditioning case 102 of the second comparative example is formed by foam molding. Similarly to the first comparative example, in the second comparative example, the plate thickness T1 of the first resin part 11 and the plate thickness T2 of the second resin part 12 are the same. Therefore, in the second comparative example, as shown by the bubbles 100 inside the product shown in FIG. 7, variations in the foaming distribution occur inside the product. Therefore, in the second comparative example, the physical properties may change in unintended locations of the product, and the physical properties originally desired for the material may not be obtained.

Compared to the first comparative example and the second comparative example described above, the air conditioning case 1 of this embodiment has the following effects.
(1) The air conditioning case 1 of this embodiment has a configuration in which the thickness T2 of the second resin part 12 is larger than the thickness T1 of the first resin part 11, and the first resin part 11 has air bubbles per unit volume. The total volume occupied by the bubbles per unit volume in the second resin part 12 is larger than the total volume occupied by the bubbles.
According to this, the molten resin injected from the gate part 10 into the first resin part 11 in the mold during foam molding flows into the second resin part 12 from the first resin part 11 into the mold. The sudden expansion of the space causes a sudden pressure reduction, and the foaming of the blowing agent contained in the molten resin in the second resin section 12 is promoted. Therefore, this air conditioning case 1 has a simple configuration in which the plate thickness T2 of the second resin part 12 is made larger than the plate thickness T1 of the first resin part 11, so that the intended location (i.e., the second resin part 12) can be highly foamed. Therefore, sink marks and warpage in the second resin portion 12, which requires high dimensional accuracy, can be suppressed.

(2) In the air conditioning case 1 of this embodiment, the plate thickness T1 of the first resin part 11 is smaller than the plate thickness Tg of the gate part 10.
According to this, during foam molding, by preventing the pressure of the molten resin injected from the gate part 10 into the first resin part 11 in the mold from increasing rapidly, the first resin part 11 can be made to have low foaming. It is possible to do so. Then, by generating a sudden pressure reduction when the molten resin flows from the first resin part 11 to the second resin part 12, it is possible to make the second resin part 12 more foamed than the first resin part 11. It is. Therefore, the first resin part 11 can be made into a product having the physical properties of a resin close to a solid, and the second resin part 12 can be made to have the physical properties of a highly foamed resin.

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

The second resin part 12 is connected to the middle of the first part 11a of the first resin part 11, and is arranged in a direction that intersects with the extending direction of the first part 11a (in this modified example, a substantially perpendicular direction). It extends to In FIG. 8, an arrow D indicates the direction in which the molten resin flows from the gate part 10 to the first resin part 11 and the second resin part 12 during foam molding. This also applies to each embodiment, each modified example, and each comparative example described below.

Also in the modification of the first embodiment, the thickness T1 of the first resin part 11 and the thickness T2 of the second resin part 12 have the relationship T1<T2. Therefore, also in this modification, it is possible to highly foam the intended location (that is, the second resin part 12) and suppress sink marks and warpage in the second resin part 12.

Also in this modification, the thickness Tg of the gate portion 10 and the thickness T1 of the first resin portion 11 have a relationship of Tg>T1. Therefore, it is possible to make the first resin part 11 have low foaming, and to make the second resin part 12 have high foaming compared to the first resin part 11. Therefore, the first resin part 11 can be made into a product having the physical properties of a resin close to a solid, and the second resin part 12 can be made to have the physical properties of a highly foamed resin.

(Second embodiment)
A second embodiment will be described. The second embodiment has a part of the configuration of the air conditioning case 1 changed from the first embodiment, and is otherwise the same as the first embodiment, so only the parts that differ from the first embodiment are the same. explain.

As shown in FIG. 9, the air conditioning case 1 of the second embodiment also includes a first resin part 11 and a second resin part 12. The thickness T1 of the first resin part 11 and the thickness T2 of the second resin part 12 have a relationship of T1<T2. In addition, in FIG. 9 as well, arrow D indicates the direction in which the molten resin flows with respect to the first resin part 11 and the second resin part 12 during foam molding. Therefore, although not shown, the gate part 10 that supplies molten resin to the first resin part 11 and the second resin part 12 during foam molding is arranged on the left side of the paper in FIG.

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

Here, it is assumed that the thickness of the portion of the first resin portion 11 where the adjacent recessed portion 13 is provided is T3. The thickness of a portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13 is T1. At this time, in the second embodiment, there is a relationship of T1>T3. That is, the thickness T3 of the portion of the first resin portion 11 where the adjacent recess 13 is provided is smaller than the thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13. In the second embodiment, the relationship T1>T3 is the thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13, and the thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13. This means that the difference between the plate thickness T3 and the plate thickness T3 at the part where the plate is attached is larger than the manufacturing tolerance.

As a result, in the second embodiment, during foam molding, compared to a configuration in which the molten resin directly flows from the first resin part 11 to the second resin part 12, the molten resin flows through the narrow channel in the mold of the adjacent recess 13. The configuration is such that when the molten resin flows into the second resin part 12, the space within the mold expands more rapidly. Therefore, according to the configuration of the second embodiment, the pressure fluctuation (that is, the degree of pressure reduction) of the molten resin when the molten resin flows into the second resin part 12 from the narrow in-mold channel of the adjacent recess 13 can be increased. However, foaming of the foaming agent contained in the molten resin in the second resin portion 12 can be further promoted.

The air conditioning case 1 of the second embodiment described above has a simple configuration in which the adjacent recess 13 is provided on the side closer to the gate portion 10 among the portions of the first resin portion 11 adjacent to the second resin portion 12, resulting in low cost. The intended location (ie, the second resin portion 12) can be more reliably foamed to a high degree.

(Modified example of second embodiment)
A modification of the second embodiment will be described. As shown in FIG. 10, also in the modification of the second embodiment, the air conditioning case 1 includes a gate portion 10, a first resin portion 11, and a second resin portion 12. Furthermore, the air conditioning case 1 includes an adjacent recessed portion 13 on the side of the first resin portion 11 adjacent to the second resin portion 12 and closer to the gate portion 10 .

In a modification of the second embodiment, the first resin part 11 includes a first part 11a connected to the gate part 10, and a second part 11b and a third part 11c provided at both ends of the first part 11a, respectively. have. Note that the first portion 11a extends in a direction intersecting the direction in which the molten resin is injected into the gate portion 10 (in this modification, a substantially perpendicular direction). The second portion 11b and the third portion 11c extend in a direction crossing the first portion 11a. The second resin part 12 is connected to the middle of the first part 11a of the first resin part 11, and is arranged in a direction that intersects with the extending direction of the first part 11a (in this modified example, a substantially perpendicular direction). It extends to

Also in the modification of the second embodiment, the thickness T1 of the first resin part 11 and the thickness T2 of the second resin part 12 have the relationship T1<T2. Therefore, also in this modification, it is possible to highly foam the intended location (that is, the second resin part 12) and suppress sink marks and warpage in the second resin part 12.

Also, in the modification of the second embodiment, the thickness Tg of the gate portion 10 and the thickness T1 of the first resin portion 11 have a relationship of Tg>T1. Therefore, it is possible to make the first resin part 11 have low foaming, and to make the second resin part 12 have high foaming compared to the first resin part 11. Therefore, the first resin part 11 can be made into a product having the physical properties of a resin close to a solid, and the second resin part 12 can be made to have the physical properties of a highly foamed resin.

Furthermore, in the modified example of the second embodiment, the plate thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13 and the thickness T1 of the portion of the first resin portion 11 that is closer to the gate portion 10 than the adjacent recess 13 are provided. The plate thickness T3 of the portion has a relationship of T1>T3. Therefore, during foam molding, when the molten resin flows into the second resin part 12 from the narrow channel in the mold of the adjacent recess 13, the pressure fluctuation of the molten resin (that is, the degree of pressure reduction) is made larger, and the second resin The portion 12 can be more reliably foamed.

(Third embodiment)
A third embodiment will be described. The third embodiment also differs from the first embodiment, etc. because a part of the configuration of the air conditioning case 1 is changed from the first embodiment etc., and the other aspects are the same as the first embodiment etc. Only parts will be explained.

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

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

Here, the distance between the surface 11d of the first resin portion 11 on the side where the second resin portion 12 is provided and the surface of the opposite surface recess 14 is defined as T4. At this time, in the third embodiment, there is a relationship of T1>T4. That is, the distance T4 between the surface 11d of the first resin part 11 on which the second resin part 12 is provided and the surface of the opposite recess 14 is smaller than the thickness T1 of the first resin part 11. In the third embodiment, the relationship T1>T4 is determined by the distance T4 between the surface 11d of the first resin portion 11 on which the second resin portion 12 is provided and the surface of the opposite surface concave portion 14, and This means that the difference between the thickness T1 of the portion 11 and the thickness T1 is larger than the manufacturing tolerance.

As a result, in the third embodiment, during foam molding, a narrow space is formed between the surface 11d of the first resin section 11 on the side where the second resin section 12 is provided and the surface of the opposite surface recess 14. The configuration is such that when the molten resin flows into the second resin portion 12 through the channel within the mold, the space within the mold expands more rapidly. Therefore, according to the configuration of the third embodiment, when the molten resin flows into the second resin part 12 from the narrow channel in the mold, the pressure fluctuation (i.e., the degree of pressure reduction) of the molten resin is made larger. In the second resin part 12, foaming of the foaming agent contained in the molten resin can be further promoted.

The air conditioning case 1 of the third embodiment described above has a simple configuration in which the opposite surface recess 14 is provided at the connection point between the first resin part 11 and the second resin part 12, so that the intended location (i.e., The second resin part 12) can be reliably foamed to a high degree.

(Fourth embodiment)
A fourth embodiment will be described. The fourth embodiment is also different from the first embodiment, etc. because a part of the configuration of the air conditioning case 1 is changed from the first embodiment etc., and the other aspects are the same as the first embodiment etc. Only parts will be explained.

As shown in FIG. 12, the air conditioning case 1 of the fourth embodiment also includes a first resin part 11 and a second resin part 12. The thickness T1 of the first resin part 11 and the thickness T2 of the second resin part 12 have a relationship of T1<T2. Although not shown, the gate part 10 that supplies molten resin to the first resin part 11 and the second resin part 12 during foam molding is arranged on the left side of the paper in FIG.

Furthermore, the air conditioning case 1 of the fourth embodiment has a first curved surface portion 15 provided on the side closer to the gate portion 10 of the corner portion where the first resin portion 11 and the second resin portion 12 connect, and a first resin portion 15 that is provided on the side closer to the gate portion 10. A second curved surface portion 16 is provided on the side far from the gate portion 10 of the corner portion where the portion 11 and the second resin portion 12 are connected.

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

By the way, if the radius of curvature R1 of the first curved surface section 15 is increased, the pressure of the molten resin will gradually decrease as the molten resin passes from the first resin section 11 through the first curved surface section 15 during foam molding. Therefore, the promotion of foaming of the foaming agent contained in the molten resin in the second resin portion 12 is reduced.

On the other hand, in the fourth embodiment, the radius of curvature R1 of the first curved surface part 15 is made as small as possible, so that it passes from the first resin part 11 through the first curved part 15 to the second resin part 12 during foam molding. When the molten resin flows in, the space inside the mold rapidly expands. Therefore, according to the configuration of the fourth embodiment, the pressure fluctuation (that is, the degree of pressure reduction) of the molten resin when the molten resin flows from the first resin part 11 to the second resin part 12 is increased, and the second resin part In step 12, foaming of the foaming agent contained in the molten resin can be promoted.

The air conditioning case 1 of the fourth embodiment described above has a simple configuration in which the radius of curvature R1 of the first curved surface portion 15 is made smaller than the radius of curvature R2 of the second curved surface portion 16, so that the intended location ( That is, the second resin part 12) can be made highly foamable.

(Fifth embodiment)
A fifth embodiment will be described. The fifth embodiment is also different from the first embodiment, etc. because a part of the configuration of the air conditioning case 1 is changed from the first embodiment etc., and the other aspects are the same as the first embodiment etc. Only parts will be explained.

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

Furthermore, in the fifth embodiment, the second resin part 12 has a shape in which the plate thickness gradually decreases as the distance from the first resin part 11 increases. Specifically, the thickness of the root portion 12a of the second resin portion 12 that is closer to the first resin portion 11 is T2. The thickness of the tip portion 12b of the second resin portion 12 that is far from the first resin portion 11 is T5. At this time, in the fifth embodiment, the relationship is T2>T5. In the fifth embodiment, the relationship T2>T5 means that the difference between the plate thickness T2 of the root portion 12a and the plate thickness T5 of the tip portion 12b is larger than the manufacturing tolerance. Furthermore, in the fifth embodiment, the shape in which the plate thickness gradually decreases refers to a change in plate thickness that is steeper than the minimum draft angle of the mold. Therefore, the root portion 12a of the second resin portion 12 is more foamed than the tip portion 12b of the second resin portion 12. In other words, the total volume occupied by air bubbles per unit volume in the root portion 12a of the second resin portion 12 is larger than the total volume occupied by air bubbles per unit volume in the tip portion 12b of the second resin portion 12. This prevents the second resin portion 12 from warping, and allows the tip portion 12b to have physical properties similar to those of a solid resin.

By the way, in general, in a resin molded product including the first resin part 11 and the second resin part 12, warping of the second resin part 12 tends to occur at the root part 12a of the second resin part 12. On the other hand, in the fifth embodiment, during foam molding, the root part 12a of the second resin part 12 generates a sudden reduction in pressure in the molten resin by rapidly expanding the space in the mold, and the root part 12a is highly foamed. It is possible to prevent the resin portion 12 from warping. On the other hand, the tip end 12b of the second resin part 12 can achieve low foaming by gradually increasing the pressure of the molten resin during foam molding by gradually reducing the space within the mold.

The air conditioning case 1 of the fifth embodiment described above has a simple configuration in which the plate thickness T2 of the second resin part 12 is made smaller as the distance from the first resin part 11 increases, so that the root part 12a of the second resin part 12 is raised. The foaming prevents the second resin portion 12 from warping, and the tip portion 12b can have physical properties similar to those of a solid resin.

(Third comparative example)
In the first to fifth embodiments described above, the second resin part 12 provided in the air conditioning case 1 mainly corresponds to the ribs 7, 8, and 9 provided in the ventilation path of the air conditioning case 1, and the ribs 7, 8 , 9 was explained as preventing shrinkage and warping. On the other hand, in the third comparative example and the sixth embodiment described below, the second resin part 12 included in the air conditioning case 1 is mainly located at the bottom of the air conditioning case 1 (i.e., the lower part in the direction of gravity). This will be explained as corresponding to an outer rib provided on an outer wall.

Before describing the sixth embodiment, a third comparative example will first be described with reference to FIGS. 14 and 15. The air conditioning case 103 of the third comparative example is a conventional and common case, and is not formed by foam molding, but is made of a resin (that is, solid) that does not contain bubbles.

As shown in FIG. 14, a plurality of outer ribs 30 are provided at the bottom of the air conditioning case 103 of the third comparative example. The plurality of outer ribs 30 are mainly provided at a lower position in the direction of gravity with respect to the air cooling heat exchanger provided in the ventilation path of the air conditioning case 1. The plurality of outer ribs 30 have the function of increasing the heat insulation of the air conditioning case 103 and preventing the formation of dew condensation against temperature changes caused by the operation of the air cooling heat exchanger.

FIG. 15 is a sectional view schematically showing the bottom of the air conditioning case 103 shown in FIG. 14. The air conditioning case 103 of the third comparative example also includes a first resin part 11 and a second resin part 12. Although not shown, the gate part 10 that supplies molten resin to the first resin part 11 and the second resin part 12 during injection molding is arranged on the left side of the paper in FIG.

The first resin part 11 is a part that mainly constitutes the outer shell of the air conditioning case 103, and is also called a general part. The plurality of second resin parts 12 are connected to the first resin part 11 and extend in a direction (substantially perpendicular to the direction in this embodiment) that intersects with the direction in which the first resin part 11 extends. The plurality of second resin parts 12 correspond to the outer ribs 30, and are provided in large numbers at the bottom of the air conditioning case 1 in order to improve the heat insulation of the air conditioning case 103 and prevent dew condensation.

(Sixth embodiment)
Next, a sixth embodiment will be described with reference to FIG. 16. The air conditioning case 1 of the sixth embodiment is formed by foam molding.

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

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

(Modified example of the sixth embodiment)
A modification of the sixth embodiment will be described. As shown in FIG. 17, an air conditioning case 1 according to a modification of the sixth embodiment includes a first resin part 11 and a plurality of second resin parts 12. Also in this modification, the thickness T1 of the first resin portion 11 and the thickness T2 of the plurality of second resin portions 12 have a relationship of T1<T2. Therefore, also in the modification of the sixth embodiment, the second resin part 12 can be highly foamed at low cost with a simple configuration.

In the modified example of the sixth embodiment, the plate thickness T2 of the second resin part 12 is larger than the plate thickness T2 of the second resin part 12 explained in the third comparative example. Therefore, in the modified example of the sixth embodiment, the number of second resin parts 12 can be smaller than in the third comparative example. In this way, also in the modification of the sixth embodiment, by making the second resin part 12 (namely, the outer rib 30) highly foamed, it is possible to improve the heat insulation and reduce the weight.

(Seventh embodiment)
A seventh embodiment will be described. In the seventh embodiment, a part of the configuration of the second resin part 12 included in the air conditioning case 1 is changed, and other parts are the same as in the first embodiment, so there are differences from the first embodiment, etc. I will only explain about.

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

Here, the distance between the upstream second resin section 121 and the downstream second resin section 122 is defined as D1. At this time, in the seventh embodiment, there is a relationship of T1<D1. That is, the interval D1 between the plurality of second resin parts 12 adjacent to each other in the direction in which the molten resin flows through the first resin part 11 is larger than the plate thickness T1 of the first resin part 11. In the seventh embodiment, the relationship T1<D1 means that the difference between the interval D1 between the plurality of second resin parts 12 and the plate thickness T1 of the first resin part 11 is larger than the manufacturing tolerance.

The reason why the interval D1 between the plurality of second resin parts 12 is made larger than the plate thickness T1 of the first resin part 11 is as follows. That is, if the flow direction is changed when the molten resin flows from the first resin section 11 to the upstream second resin section 121 during foam molding, the resin flows in the upstream region near the entrance of the upstream second resin section 121. Separation E occurs and sudden pressure reduction occurs. This promotes foaming of the foaming agent contained in the molten resin in the upstream second resin section 121. In the seventh embodiment, by making the interval D1 between the plurality of second resin parts 12 larger than the plate thickness T1 of the first resin part 11, the first resin part connecting the plurality of second resin parts 12 can be used. The distance between portions 11 (ie, D1) is longer. Therefore, as shown by the arrow F, the inertia of the molten resin that has changed its flow direction from the first resin section 11 to the upstream second resin section 121 causes the gap between the plurality of second resin sections 12 in the first resin section 11 to It is reduced while the molten resin is flowing through D1. As a result, even when the molten resin flows from the first resin section 11 to the downstream second resin section 122, the direction of the molten resin changes, and the resin near the inlet of the downstream second resin section 122 Separation G occurs in the region on the upstream side of the flow, resulting in sudden pressure reduction. Therefore, foaming of the foaming agent contained in the molten resin is also promoted in the downstream second resin section 122.

Here, in order to compare with the seventh embodiment described above, an air conditioning case 104 as a fourth comparative example will be described.

As shown in FIG. 19, in the air conditioning case 104 of the fourth comparative example, the interval D2 between the plurality of second resin parts 12 adjacent to each other in the direction in which the molten resin flows through the first resin part 11 is is smaller than the plate thickness T1. That is, there is a relationship of T1>D2. Also in the fourth comparative example, when molten resin flows from the first resin part 11 to the upstream second resin part 121 during foam molding, peeling H occurs in the region upstream of the resin flow near the entrance of the upstream second resin part 121. occurs, causing a sudden decompression. This promotes foaming of the foaming agent contained in the molten resin in the upstream second resin section 121. However, in the fourth comparative example, since the interval D2 between the plurality of second resin parts 12 is smaller than the plate thickness T1 of the first resin part 11, the first resin part connecting the plurality of second resin parts 12 is The distance between portions 11 (ie, D2) is short. Therefore, as shown by arrow I, the flow direction of the molten resin is changed from the first resin part 11 to the upstream second resin part 121 under the influence of inertia, and from the first resin part 11 to the downstream second resin part 121 Molten resin flows into the resin section 122. Therefore, when the molten resin flows from the first resin section 11 to the downstream second resin section 122, the molten resin hardly changes the flow direction, so that peeling occurs near the inlet of the downstream second resin section 122. No decompression occurs. As a result, in the fourth comparative example, foaming of the foaming agent contained in the molten resin in the downstream second resin section 122 is suppressed.

Compared to the fourth comparative example described above, the air conditioning case 1 of the seventh embodiment has the following effects.
The air conditioning case 1 of the seventh embodiment has a configuration in which the interval D1 between the upstream second resin section 121 and the downstream second resin section 122 is larger than the plate thickness T1 of the first resin section 11. That is, the air conditioning case 1 of the seventh embodiment has a simple configuration in which the interval between the plurality of second resin parts 12 adjacent to each other in the flow direction of the molten resin is made larger than the plate thickness of the first resin part 11, thereby achieving low cost. Both of the plurality of second resin parts 12 (that is, the upstream second resin part 121 and the downstream second resin part 122) can be made highly foamable at a low cost.

(Modification of seventh embodiment)
A modification of the seventh embodiment will be described. As shown in FIG. 20, also in the modification of the seventh embodiment, the air conditioning case 1 includes a first resin part 11 and a plurality of second resin parts 12. The plurality of second resin parts 12 include one that extends to one side of the first resin part 11 in the thickness direction, and one that extends to the other side of the first resin part 11 in the thickness direction. In the first resin part 11 extending to the other side in the thickness direction, the distance D1 between the plurality of second resin parts 12 arranged in the direction in which the molten resin flows through the first resin part 11 is It is larger than the plate thickness T1. Therefore, in this modification as well, during foam molding, peeling J, K, and L occur near the entrances of the plurality of second resin parts 12, causing sudden pressure reduction. Thereby, all of the plurality of second resin parts 12 can be highly foamed.

(Eighth embodiment)
An eighth embodiment will be described. In the eighth embodiment, the configuration of the gate section 10 included in the air conditioning case 1 is changed, and other aspects are the same as in the first embodiment, so only the parts that are different from the first embodiment will be described.

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

As shown by the arrow D in FIG. 21, the molten resin injected from the gate part 10 into the first resin part 11 in the mold during foam molding flows into the first resin part 11 from the gate part 10. The sudden expansion of the space within the mold causes a sudden pressure reduction, which promotes foaming of the foaming agent contained in the molten resin in the first resin section 11 . As described above, the air conditioning case 1 of the eighth embodiment has a simple configuration in which the thickness T1 of the first resin part 11 is larger than the thickness Tg of the gate part 10, and thus the first resin part 11 can be manufactured at low cost. can be highly foamed.

Note that the eighth embodiment and each of the above-described embodiments and modifications are combined (that is, by making the plate thickness T2 of the second resin part 12 larger than the plate thickness T1 of the first resin part 11, etc.) In addition to making the first resin part 11 highly foamable, the second resin part 12 can also be made highly foamable.

(Other embodiments)
(1) In the first embodiment and the like, it has been explained that the thickness T1 of the first resin part 11 and the thickness T2 of the second resin part 12 have a relationship of T1<T2, but the relationship is, for example, It is also possible that T1×1.1<T2.

(2) In the first embodiment etc., it has been explained that the plate thickness Tg of the gate part 10 and the plate thickness T1 of the first resin part 11 have Tg>T1, but the relationship is, for example, Tg>T1×1 It may be set to .1.

(3) In the second embodiment, the plate thickness T1 of the portion of the first resin portion 11 closer to the gate portion 10 than the adjacent recess 13 and the plate thickness of the portion of the first resin portion 11 where the adjacent recess 13 is provided. Although it has been explained that the thickness T3 has a relationship of T1>T3, the relationship may be, for example, T1>T3×1.1.

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

(5) In the fourth embodiment, it has been explained that the radius of curvature R1 of the first curved surface portion 15 and the radius of curvature R2 of the second curved surface portion 16 have a relationship of R1<R2, but the relationship is, for example, , R1×1.1<R2.

(6) In the fifth embodiment, it has been explained that in the second resin part 12, the plate thickness T2 of the root part 12a and the plate thickness T5 of the tip part 12b have a relationship of T2>T5. , for example, T2>T5×1.1.

(7) In the seventh embodiment, the interval D1 between the plurality of second resin parts 12 adjacent to each other in the direction in which the molten resin flows through the first resin part 11 and the plate thickness T1 of the first resin part 11 are T1< Although it has been described that the relationship is D1, the relationship may be, for example, T1×1.1<D1.

(8) In the eighth embodiment, it has been explained that the thickness Tg of the gate portion 10 and the thickness T1 of the first resin portion 11 have a relationship of Tg<T1, but the relationship is, for example, Tg×1 .1<T1.

(9) In the first embodiment, the first resin part 11 has been described as a part that constitutes the outer shell of the air conditioning case 1. However, the first resin part 11 is not limited to this, and the first resin part 11 is made of a resin that is close to solid in the air conditioning case 1. It can be applied to any part that requires physical properties. Alternatively, as described in the eighth embodiment, the first resin part 11 can also be applied to each part of the air conditioning case 1 where heat insulation by foam molding is required or where dimensional accuracy is required.

(10) In the first embodiment and the like, the second resin part 12 includes the ribs 7, 8, and 9 provided in the ventilation path of the air conditioning case 1, and furthermore, this may lead to abnormal noise or poor assembly of the air conditioning case. The description has been made assuming that the present invention is applied to all ribs, and in the sixth embodiment and the like, the present invention has been described as being applied to the outer rib 30 provided on the outer wall of the bottom of the air conditioning case 1, but the present invention is not limited thereto. The second resin part can be applied to each part of the air conditioning case 1 that requires insulation through foam molding or each part that requires dimensional accuracy.

The present invention is not limited to the embodiments described above, and can be modified as appropriate within the scope of the claims. Furthermore, the embodiments described above are not unrelated to each other, and can be combined as appropriate, except in cases where combination is clearly impossible. Furthermore, in each of the above embodiments, it goes without saying that the elements constituting the embodiments are not necessarily essential, except in cases where it is specifically stated that they are essential or where they are clearly considered essential in principle. stomach. In addition, in each of the above embodiments, when numerical values such as the number, numerical value, amount, range, etc. of the constituent elements of the embodiment are mentioned, when it is clearly stated that it is essential, or when it is clearly limited to a specific number in principle. It is not limited to that specific number, except in cases where In addition, in each of the above embodiments, when referring to the shape, positional relationship, etc. of constituent elements, etc., the shape, It is not limited to positional relationships, etc.

(Features of the present invention)
The features of the present invention are shown below.
[Claim 1]
In vehicle air conditioner cases formed by foam molding,
a gate part (10) as a part into which molten resin containing a foaming agent is injected during foam molding;
a first resin part (11) in which a portion connected to the gate part extends in a direction intersecting a direction in which molten resin is injected into the gate part;
a second resin part (12), the part connected to the first resin part extending in a direction crossing the direction in which the first resin part extends;
The plate thickness (T2) of the second resin part is formed to be larger than the plate thickness (T1) of the first resin part, and the second resin part is larger than the total volume occupied by bubbles per unit volume in the first resin part. A vehicle air conditioner case in which the total volume occupied by air bubbles per unit volume is large.
[Claim 2]
The vehicle air conditioner case according to claim 1, wherein a thickness of the first resin portion is smaller than a thickness (Tg) of the gate portion.
[Claim 3]
The vehicle air conditioner case according to claim 1, wherein the first resin portion has a thickness greater than that of the gate portion.
[Claim 4]
an adjacent recess (13) provided in a portion of the first resin portion adjacent to the second resin portion on a side closer to the gate portion;
A thickness (T3) of a portion of the first resin portion where the adjacent recess is provided is smaller than a thickness (T1) of a portion of the first resin portion closer to the gate portion than the adjacent recess; The vehicle air conditioner case according to any one of claims 1 to 3.
[Claim 5]
Provided on a surface (11e) of the first resin part opposite to the surface (11d) on which the second resin part is provided at the connection point between the first resin part and the second resin part. a concave portion (14) on the opposite side;
1 . The distance (T4) between the surface of the first resin portion on which the second resin portion is provided and the surface of the opposite recess is smaller than the thickness of the first resin portion. 4. The vehicle air conditioner case according to any one of items 4 to 4.
[Claim 6]
A first curved surface portion (15) provided on a side closer to the gate portion of a corner portion where the first resin portion and the second resin portion connect; further comprising a second curved surface portion (16) provided on a side far from the gate portion of the connecting corner portion,
The vehicle air conditioner case according to any one of claims 1 to 5, wherein a radius of curvature (R1) of the first curved surface portion is smaller than a radius of curvature (R2) of the second curved surface portion.
[Claim 7]
The second resin part has a shape in which the plate thickness gradually decreases as it moves away from the first resin part,
The total volume occupied by air bubbles per unit volume in the root portion (12a) of the second resin portion that is close to the first resin portion is the same as the total volume occupied by bubbles per unit volume of the root portion (12b) of the second resin portion that is far from the first resin portion. The vehicle air conditioner case according to any one of claims 1 to 6, wherein the air conditioner case is larger than the total volume occupied by air bubbles per unit volume.
[Claim 8]
comprising a plurality of the second resin parts (121, 122) arranged in the direction in which molten resin flows from the gate part to the first resin part during foam molding,
Any one of claims 1 to 7, wherein an interval (D1) between the plurality of second resin parts adjacent to each other in the direction in which the molten resin flows through the first resin part is larger than the plate thickness of the first resin part. The vehicle air conditioner case described in item 1.

10 Gate part 11 First resin part 12 Second resin part T1 Plate thickness of first resin part T2 Plate thickness of second resin part

Claims (8)

In vehicle air conditioner cases formed by foam molding,
a gate part (10) as a part into which molten resin containing a foaming agent is injected during foam molding;
a first resin part (11) in which a portion connected to the gate part extends in a direction intersecting a direction in which molten resin is injected into the gate part;
a second resin part (12), the part connected to the first resin part extending in a direction crossing the direction in which the first resin part extends;
The plate thickness (T2) of the second resin part is formed to be larger than the plate thickness (T1) of the first resin part, and the second resin part is larger than the total volume occupied by bubbles per unit volume in the first resin part. A vehicle air conditioner case in which the total volume occupied by air bubbles per unit volume is large. The vehicle air conditioner case according to claim 1, wherein a thickness of the first resin portion is smaller than a thickness (Tg) of the gate portion. The vehicle air conditioner case according to claim 1, wherein the first resin portion has a thickness greater than that of the gate portion. an adjacent recess (13) provided in a portion of the first resin portion adjacent to the second resin portion on a side closer to the gate portion;
A thickness (T3) of a portion of the first resin portion where the adjacent recess is provided is smaller than a thickness (T1) of a portion of the first resin portion closer to the gate portion than the adjacent recess; The vehicle air conditioner case according to claim 1 or 2. Provided on a surface (11e) of the first resin part opposite to the surface (11d) on which the second resin part is provided at the connection point between the first resin part and the second resin part. a concave portion (14) on the opposite side;
1 . The distance (T4) between the surface of the first resin portion on which the second resin portion is provided and the surface of the opposite recess is smaller than the thickness of the first resin portion. Or the vehicle air conditioner case described in 2. A first curved surface portion (15) provided on a side closer to the gate portion of a corner portion where the first resin portion and the second resin portion connect; further comprising a second curved surface portion (16) provided on a side far from the gate portion of the connecting corner portion,
The vehicle air conditioner case according to claim 1 or 2, wherein a radius of curvature (R1) of the first curved surface portion is smaller than a radius of curvature (R2) of the second curved surface portion. The second resin part has a shape in which the plate thickness gradually decreases as it moves away from the first resin part,
The total volume occupied by bubbles per unit volume in the root portion (12a) of the second resin portion that is close to the first resin portion is the same as the total volume occupied by bubbles per unit volume of the root portion (12b) of the second resin portion that is far from the first resin portion. The vehicle air conditioner case according to claim 1 or 2, wherein the air conditioner case is larger than the total volume occupied by air bubbles per unit volume. a plurality of the second resin parts (121, 122) arranged in a direction in which molten resin flows from the gate part to the first resin part during foam molding;
The distance (D1) between the plurality of second resin parts adjacent to each other in the direction in which the molten resin flows through the first resin part is larger than the plate thickness of the first resin part, according to claim 1 or 2. Vehicle air conditioner case.

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