Play equipment, furniture, protective equipment, artwork, monument, toy, and their manufacturing methods

Abstract

To provide a molded article having an excellent cushioning property, smoothness and durability, and a method for manufacturing the molded article.SOLUTION: A molded article 1 includes an elastic resin layer 10, a foamed resin layer 20, and a shaping layer 30 in this order, and an arithmetic mean height (Sa) on a surface of the elastic resin layer 10 opposite to the foamed resin layer 20 is 30 μm or less. A method for manufacturing the molded article 1 includes a mold preparation step, an elastic resin layer formation step, a foamed resin layer formation step, a shaping layer formation step and a mold removal step. In the mold preparation step, a molding die 100 is prepared. In the elastic resin layer formation step, the elastic resin layer 10 is formed on an inner surface of the molding die 100. In the foamed resin layer formation step, the foamed resin layer 20 is formed on a surface of the elastic resin layer 10 opposite to the molding die 100. In the shaping layer formation step, the shaping layer 30 is formed on a surface of the foamed resin layer 20 opposite to the elastic resin layer 10. In the mold removal step, the molded article 1 is removed from the molding die 100.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a molded article and a method for manufacturing a molded article, and more particularly to a molded article having an elastic resin layer and a method for manufacturing the molded article. [Background technology]

[0002] Conventionally, various play equipment have been installed in parks, squares, etc. Such play equipment is required to have excellent cushioning properties in order to prevent players from getting injured when they hit the equipment and to improve safety.

[0003] Patent Document 1 discloses a soft playground equipment containing a soft polymer and fine rock powder in the surface layer. Patent Document 2 discloses a polyurethane foam product in which a coating layer is formed by spraying a paint containing polyurethane with an airbrush onto the surface of a base material cut out from soft polyurethane foam, and Patent Document 3 discloses a polyurethane solution and water are simultaneously sprayed onto a base such as a resin foam to form an air-permeable coating on the surface. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2003-126558 A [Patent Document 2] JP 2011-195703 A [Patent Document 3] JP 2001-246318 A Summary of the Invention [Problem to be solved by the invention]

[0005] In addition to cushioning, playground equipment is required to have a smooth surface so that people can move around easily, and it is also required to be durable.

[0006] A known conventional playground equipment is a molded product in which a polyurethane elastomer is sprayed onto the surface of cut polyurethane foam, as described in Patent Document 2.

[0007] In such molded products, the sprayed polyurethane elastomer leaves fine irregularities on the surface, and the polyurethane elastomer may drip before curing, which may cause the irregularities to become larger, resulting in poor surface smoothness. In order to reduce the irregularities, polishing is required before or after spraying the resin, which not only requires extra labor and time for production, but also leads to increased costs. In addition, the durability of the conventional molded products is insufficient.

[0008] An object of the present invention is to provide a molded article having excellent cushioning properties, smoothness and durability, and a method for producing the molded article. [Means for solving the problem]

[0009] A molded body according to one embodiment of the present invention comprises an elastic resin layer, a foamed resin layer, and a shape-imparting layer, in that order, and the arithmetic mean height (Sa) of the elastic resin layer on the surface opposite to the foamed resin layer is 30 μm or less.

[0010] A method for manufacturing a molded body according to one embodiment of the present invention includes a mold preparation step of preparing a mold, an elastic resin layer formation step of forming an elastic resin layer on the inner surface of the mold, a foamed resin layer formation step of forming a foamed resin layer on the surface of the elastic resin layer opposite the mold, a shape-imparting layer formation step of forming a shape-imparting layer on the surface of the foamed resin layer opposite the elastic resin layer, and a mold removal step of removing a molded body having the elastic resin layer, the foamed resin layer and the shape-imparting layer obtained by the shape-imparting layer formation step from the mold. Effect of the Invention

[0011] According to the present invention, it is possible to provide a molded article having excellent cushioning properties, smoothness and durability, and a method for producing the molded article. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a schematic cross-sectional view showing an example of the molded article of the present invention. [Diagram 2] 2A to 2E are diagrams illustrating the method for producing a molded article of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] 1. Overview The molded body and the manufacturing method of the molded body of the present invention will be described below. Note that the following embodiment is merely one of various embodiments of the present invention. The following embodiment can be modified in various ways depending on the design as long as the object of the present invention can be achieved.

[0014] After extensive research, the inventors discovered that the above-mentioned problems could be solved by adopting a specific multi-layered structure and giving the upper surface a specific structure, and thus completed the present invention.

[0015] The molded article 1 of the present invention comprises, in this order, an elastic resin layer 10, a foamed resin layer 20, and a shape-imparting layer 30. The arithmetic mean height (Sa) of the elastic resin layer 10 on the surface opposite to the foamed resin layer 20 is 30 μm or less.

[0016] The molded article 1 of the present invention is excellent in cushioning, smoothness, and durability. The molded article 1 has a structure in which an elastic resin layer 10, a foamed resin layer 20, and a molded layer 30 are laminated in this order, and therefore it is possible to improve both cushioning and durability. In addition, by laminating the elastic resin layer 10 on the foamed resin layer 20 having a large amount of surface irregularities, and setting the arithmetic mean height (Sa) of the surface of the elastic resin layer 10 to the specific value or less, it is possible to provide excellent smoothness.

[0017] The method for producing the molded body 1 of the present invention includes a mold preparation step, an elastic resin layer formation step, a foamed resin layer formation step, a shape-imparting layer formation step, and a mold removal step. In the mold preparation step, a mold 100 is prepared. In the elastic resin layer formation step, an elastic resin layer 10 is formed on the inner surface of the mold 100. In the foamed resin layer formation step, a foamed resin layer 20 is formed on the surface of the elastic resin layer 10 opposite the mold 100. In the shape-imparting layer formation step, a shape-imparting layer 30 is formed on the surface of the foamed resin layer 20 opposite the elastic resin layer 10. In the mold removal step, the molded body 1 having the elastic resin layer 10, the foamed resin layer 20, and the shape-imparting layer 30 obtained in the shape-imparting layer formation step is removed from the mold 100.

[0018] According to the method for producing the molded article 1 of the present invention, a molded article having excellent cushioning properties, smoothness and durability can be produced easily without requiring extra time or effort, and at reduced cost.

[0019] In the manufacturing method of the molded body 1 of the present invention, a mold preparation step is first performed, and an elastic resin layer 10 is formed on the inner surface of the mold, so that the smoothness of the surface of the elastic resin layer 10 can be further improved. Subsequently, a foamed resin layer formation step and a shape-imparting layer formation step are performed, so that a molded body 1 having cushioning properties, smoothness and durability can be easily manufactured.

[0020] 2.Details <Molded body> FIG. 1 is a cross-sectional view showing an example of a molded body 1 of the present invention.

[0021] The molded body 1 includes an elastic resin layer 10, a foamed resin layer 20, and a shape-imparting layer 30 in this order. The elastic resin layer 10, the foamed resin layer 20, and the shape-imparting layer 30 are different layers from each other. The molded body 1 preferably further includes an adhesive layer 50 between the foamed resin layer 20 and the shape-imparting layer 30. Each layer of the molded body 1 will now be described.

[0022] [Elastic resin layer] The elastic resin layer 10 refers to a layer containing an elastic resin as a main component. The "main component" refers to the component with the largest content ratio, and means that the content ratio is usually 50 mass% or more, preferably 70 mass% or more, more preferably 90 mass% or more, and even more preferably 100 mass%. The elastic resin layer 10 usually does not contain air bubbles inside. In other words, the elastic resin layer 10 is formed of an elastic resin that is not a foamed resin.

[0023] "Elastic resin" refers to a resin that exhibits rubber-like elasticity, and when it is stretched to 1.5 times its original length by applying an external force, it immediately returns to 1.25 times its original length when the external force is removed. Elastic resins include synthetic resins, natural resins, and rubbers such as natural rubber, synthetic rubber, and silicone rubber. Elastic resins are usually non-foamed resins.

[0024] Examples of the elastic resin include thermoplastic elastomers such as thermoplastic polyurethane elastomers, polyolefin elastomers, polystyrene elastomers, polyester elastomers, and polyamide elastomers; thermosetting elastomers such as thermosetting polyurethane elastomers, epoxy elastomers, and silicone elastomers; and rubbers such as natural rubber, isoprene rubber, butadiene rubber, styrene-butadiene rubber, and silicone rubber. Among these, at least one of the thermoplastic polyurethane elastomers and the thermosetting polyurethane elastomers is preferred.

[0025] The type C durometer hardness of the surface of the elastic resin layer 10, i.e., the surface of the elastic resin layer 10 opposite to the foamed resin layer 20, is preferably 30 to 90, more preferably 33 to 87, and particularly preferably 35 to 85. The type C durometer hardness of the surface of the elastic resin layer 10 is an index indicating the cushioning properties of the molded body 1. By setting the type C durometer hardness of the surface of the elastic resin layer 10 within the above range, the cushioning properties of the molded body 1 can be further improved. In other words, the cushioning properties of the molded body 1 can be made more appropriate. The type C durometer hardness is a value measured at 23°C using a durometer hardness tester (type C) in accordance with JIS-K7312.

[0026] The density of the elastic resin layer 10 is, for example, 1000 kg / m 3 More than 1300kg / m 3 Less than 1100kg / m 3 More than 1250kg / m 3 It is preferable that:

[0027] The thickness of the elastic resin layer 10 is preferably 0.01 cm to 10 cm, more preferably 0.05 cm to 2 cm, and even more preferably 0.1 cm to 0.7 cm. The thickness of the elastic resin layer 10 may be uniform or may vary depending on the location.

[0028] The elastic resin layer 10 can be formed, for example, by spraying an elastic resin.

[0029] It is important that the arithmetic mean height (Sa) of the surface of the elastic resin layer 10, i.e., the surface opposite to the foamed resin layer 20, is 30 μm or less. This makes the molded body 1 excellent in smoothness. If the arithmetic mean height (Sa) exceeds the above value, the smoothness of the surface of the molded body 1 deteriorates, which may cause inconveniences such as making it difficult for a person playing on the surface to move. The arithmetic mean height (Sa) can be measured, for example, using a curved surface micro-shape measuring system in accordance with ISO25178. The arithmetic mean height (Sa) is preferably 20 μm or less, more preferably 12 μm or less, and even more preferably 8 μm or less. The lower limit of the arithmetic mean height (Sa) is not particularly limited, and is, for example, 0.1 μm or more, and preferably 1 μm or more.

[0030] The maximum height (Sz) of the surface of the elastic resin layer 10 is, for example, 400 μm or less, preferably 300 μm or less, more preferably 200 μm or less, and even more preferably 150 μm or less. In this case, the smoothness of the molded body 1 can be further improved. The maximum height (Sz) can be measured by the same method as the arithmetic mean height (Sa). The lower limit of the maximum height (Sz) is not particularly limited, and is, for example, 1 μm or more, preferably 10 μm or more.

[0031] The elastic resin layer 10 having a surface with such an arithmetic mean height (Sa) and maximum height (Sz) can be formed, for example, by adhering an elastic resin, for example, by spraying it onto a molding die having a surface with small surface roughness such as the arithmetic mean height (Sa), maximum height (Sz), etc. Such a molding die can be produced, for example, by using metal, fiber reinforced plastic (FRP), etc. as the material.

[0032] [Foamed resin layer] The foamed resin layer 20 refers to a layer containing foamed resin as a main component. The term "foamed resin" refers to a resin containing air bubbles inside, and refers to a resin formed into a foamed shape by dispersing gas in a synthetic resin. In this way, the foamed resin layer 20 is made of a different material from the elastic resin layer 10.

[0033] Examples of resins constituting the foamed resin include polyurethane resin, polystyrene resin, polyolefin resin, phenol resin, polyvinyl chloride resin, urea resin, silicone resin, polyimide resin, melamine resin, etc. Among these, polyurethane resin is preferred, and soft polyurethane resin is more preferred.

[0034] The foamed resin layer 20 contains bubbles. The bubbles may be closed bubbles, open bubbles, or both. The foamed resin constituting the foamed resin layer 20 may be, for example, one that is expanded 4 times or more and 10 times or less, and preferably about 6 times.

[0035] The thickness of the foamed resin layer 20 is, for example, 0.2 cm to 20 cm, preferably 0.3 cm to 10 cm, and more preferably 0.5 cm to 5 cm. The thickness of the foamed resin layer 20 may be uniform or may vary depending on the location.

[0036] The foamed resin layer 20 can be formed by, for example, spraying a foamed resin onto the surface of the elastic resin layer 10 to adhere it thereto.

[0037] [Adhesive layer] The adhesive layer 50 refers to a layer formed from an adhesive. The adhesive layer 50 refers to a region where a cured product of the adhesive exists, and may overlap with the foamed resin layer 20 and the molding layer 30. By providing the adhesive layer 50, the molded body 1 can further improve the adhesion between the foamed resin layer 20 and the molding layer 30 and further suppress peeling, thereby further improving the durability of the molded body 1.

[0038] As the adhesive, for example, polyurethane resin paint, acrylic resin paint, aminoalkyd resin paint, vinyl resin paint, epoxy resin paint, etc. can be used.

[0039] Commercially available adhesives can also be used, such as urethane resins, such as one-liquid wet-dry polyurethane resin paints Ultrac 895 and NTX Ultrac 898 (both manufactured by Osaka Paint Industries Co., Ltd.).

[0040] The thickness of the adhesive layer 50 is not particularly limited, but is, for example, 0.1 μm or less, and preferably 0.05 μm or less. The thickness of the adhesive layer 50 may be uniform or may vary depending on the location.

[0041] The adhesive layer 50 can be formed, for example, by applying an adhesive to the surface of the foamed resin layer 20 and then curing the adhesive.

[0042] [Shaping layer] The shape-imparting layer 30 is a layer that determines the shape of the molded body 1. In other words, the shape of the molded body 1 is similar to the shape of the shape-imparting layer 30. A material having high rigidity is usually used as a material constituting the shape-imparting layer 30. Thus, the material constituting the shape-imparting layer 30 is different from the materials constituting the elastic resin layer 10 and the foamed resin layer 20.

[0043] Examples of materials constituting the shape-imparting layer 30 include resin, concrete, metal, etc. Examples of resins constituting the shape-imparting layer 30 include fiber-reinforced plastic (FRP), polyolefin resin, polystyrene resin, etc. From the viewpoint of ease of formation, the shape-imparting layer 30 is preferably made of resin, and from the viewpoint of improving durability, it is more preferably made of fiber-reinforced plastic.

[0044] The thickness of the shape-imparting layer 30 is, for example, 0.01 cm to 10 cm, preferably 0.05 cm to 5 cm, more preferably 0.1 cm to 2 cm, and even more preferably 0.2 cm to 1 cm. The thickness of the shape-imparting layer 30 may be uniform or may vary depending on the location.

[0045] The shape-imparting layer 30 can be formed, for example, by disposing the material of the shape-imparting layer 30 on the surface of the foamed resin layer 20 or the adhesive layer 50 .

[0046] The mold-imparting layer 30 is preferably provided with through holes for allowing the gas generated in the foamed resin layer 20 to escape to the outside of the molded body 1. This makes it possible to suppress peeling between the foamed resin layer 20 and other layers caused by the generated gas, and further improves the durability of the molded body 1.

[0047] The thickness ratio of the elastic resin layer 10, the foamed resin layer 20, and the shape-imparting layer 30, that is, elastic resin layer:foamed resin layer:shape-imparting layer, is, for example, 1:5-30:1-5, and preferably 1:10-20:2-3.

[0048] The molded body 1 may have other parts in addition to the elastic resin layer 10, the foamed resin layer 20, and the molding layer 30. Each of the elastic resin layer 10, the foamed resin layer 20, and the molding layer 30 may have a heavy part such as metal or concrete or a hollow part in order to adjust the weight of the molded body 1 or improve the stability.

[0049] <Method of manufacturing molded body> The method for producing a molded article of the present invention includes a mold preparation step, an elastic resin layer formation step, a foamed resin layer formation step, a shape-imparting layer formation step, and a mold removal step. It is preferable that the method for producing a molded body further includes an adhesive layer forming step, after the foamed resin layer forming step and before the shape-imparting layer forming step, of forming an adhesive layer on the surface of the foamed resin layer opposite the elastic resin layer. Each step will be described below with reference to FIGS. 2A to 2E.

[0050] [Mold preparation process] In this step, a molding die 100 is prepared as shown in FIG. 2A.

[0051] The shape of the inner surface of the molding die 100 is usually the same as the shape of the upper surface of the desired molded body 1. In addition, the arithmetic mean height (Sa) of the inner surface of the molding die 100 is preferably equal to or less than the arithmetic mean height (Sa) of the surface of the elastic resin layer 10 of the desired molded body 1. Therefore, a master mold having the same shape as the desired molded body 1 may be produced, and the molding die 100 may be produced using this master mold.

[0052] From the viewpoint of making it easier to remove molded body 1 in the mold removal step and easier to manufacture molded body 1, molding die 100 is preferably composed of a plurality of separable members.

[0053] The material of the molding die 100 is not particularly limited, but examples include metal, coated wood, and resin such as fiber reinforced plastic (FRP).

[0054] It is preferable to apply wax to the inner surface of the mold 100. After applying the wax, it is preferable to apply a lubricant such as talc using a brush or the like. After applying the lubricant, it is preferable to apply a liquid mold release agent using a brush or the like. This makes it easier to remove the molded body 1 in the mold removal step.

[0055] [Elastic resin layer formation process] In this step, as shown in FIG. 2B, an elastic resin layer 10 is formed on the inner surface of the molding die 100 prepared in the molding die preparation step.

[0056] In this step, for example, the elastic resin layer 10 is formed by spraying the elastic resin onto the inner surface of the molding die 100 using a dedicated gun.

[0057] [Foamed resin layer formation process] In this step, as shown in FIG. 2C, a foamed resin layer 20 is formed on the surface of the elastic resin layer 10 formed in the elastic resin layer forming step, opposite to the molding die 100.

[0058] In this step, for example, a foamed resin layer 20 is formed by spraying a foamed resin onto the surface of the elastic resin layer 10 using a dedicated gun.

[0059] [Adhesive layer formation process] In this step, as shown in FIG. 2D, an adhesive layer 50 is formed on the surface of the foamed resin layer 20 formed in the foamed resin layer forming step, opposite to the elastic resin layer 10.

[0060] In this step, for example, an adhesive is applied to the surface of the foamed resin layer 20 using an applicator such as a brush, thereby forming the adhesive layer 50.

[0061] [Shaping layer formation process] In this process, a shape-imparting layer 30 is formed on the side of the foamed resin layer 20 formed in the foamed resin layer forming process opposite the elastic resin layer 10, or on the side of the adhesive layer 50 formed in the adhesive layer forming process opposite the foamed resin layer 20.

[0062] In this step, for example, the material of the shape-imparting layer 30 is placed on the surface of the foamed resin layer 20 or the adhesive layer 50, thereby forming the shape-imparting layer 30.

[0063] When the molding layer 30 is made of fiber-reinforced plastic, in this process, first, a gel coat made of a mixture of unsaturated polyester resin, talc and a hardener to form the resin portion of the fiber-reinforced plastic is applied using an applicator such as a brush, and then a fiber mat that constitutes the fiber portion of the fiber-reinforced plastic is attached so that it is impregnated with the applied gel coat, and then the gel coat is hardened to form the molding layer 30 made of fiber-reinforced plastic.

[0064] [Mold removal process] In this step, the formed molded body 1 is removed from the molding die 100. In this way, the molded body 1 (see FIG. 2E) can be obtained.

[0065] When the molding die 100 is composed of a plurality of parts that can be separated from one another, removal of the molding die 100 can be made easier by separating the molding die 100 from one another.

[0066] In the obtained molded body 1, it is preferable to adjust the shape of the mold-imparting layer 30. In addition, in the obtained molded body 1, it is preferable to remove the liquid mold release agent applied to the mold 100 by washing with water or the like. Furthermore, if the molded body 1 has burrs or unevenness, these may be scraped off using an air sander or the like, or if the molded body 1 has a mating surface such as a parting surface and there is a gap therebetween, a filler or the like may be inserted to adjust the shape of the molded body 1.

[0067] The surface of the obtained molded body 1 is painted or coated with a surfacer, thereby completing the molded body 1.

[0068] The molded body 1 of the present invention can be suitably used as a playground equipment. Examples of playground equipment include slides, spring playground equipment, and mountain-like shaped objects. In addition to playground equipment, the molded body 1 of the present invention can be suitably used as furniture, protective equipment, art works, monuments, toys, and the like. Examples of furniture include chairs such as stools and ottomans, sofas, tables, and children's furniture. Examples of protective equipment include safety blocks, enclosures, walls, and various protective pads that are installed around sandboxes and on stairs. Examples of art works include various art works, such as objets d'art. Examples of monuments include monuments such as memorials and memorial statues, and character shaped objects in general. Examples of toys include educational toys such as puzzles and building blocks. EXAMPLES

[0069] The present invention will be described in more detail below with reference to examples, but the present invention is not limited to only these examples.

[0070] <Production of Molded Product> [Example] The molded bodies of the examples were produced according to the following procedure.

[0071] (Creating a mold) A mold made of fiber-reinforced plastic (FRP) was prepared, with the same shape on the inner surface as the top surface of the target molded body. Specifically, multiple FRP molds were prepared by dividing the shape of the target mold, and wax was applied to the inner surface of each FRP mold, after which excess wax was wiped off with a cloth, and then talc (hydrated magnesium silicate) powder was applied to the inner surface of each FRP mold with a brush, after which excess talc powder was removed with an air gun, and then liquid mold release agent (water-based vinyl-based) (DIC Materials' FRP mold release agent "RR-301" (blue)) was applied to the inner surface of each FRP mold with a brush, and then these FRP molds were joined together and fixed with bolts to prepare the mold.

[0072] (Formation of elastic resin layer) A polyurethane elastomer ("GS-80" manufactured by Urethane Giken Kogyo Co., Ltd.) was sprayed onto the inner surface of the mold using a special gun to form an elastic resin layer.

[0073] (Formation of foamed resin layer) A polyurethane foam (Kiguratan 515 manufactured by Kigura Corporation) was sprayed onto the inner surface of the elastic resin layer formed above using a dedicated gun to form a foamed resin layer.

[0074] (Formation of adhesive layer) An adhesive (Ultrac 898, manufactured by Osaka Paint Industries Co., Ltd.) was applied to the inner surface of the foamed resin layer formed above with a brush to form an adhesive layer.

[0075] (Formation of the molding layer) The shape-imparting layer was formed as follows. Unsaturated polyester resin (4072PT manufactured by Nippon U-Pica Co., Ltd.) and talc (Dantalc SW manufactured by Nippon Talc Co., Ltd.) were kneaded together to prepare a gel coat (hard knead). A hardener (Permec NRK-04 manufactured by Nippon Tokushu Toryo Co., Ltd.) was then mixed into this and the resulting mixture was applied to the inner surface of the adhesive layer formed above using a brush. Next, a fiber mat of fiber reinforced plastic (chopped strand mat "MC600AS (soft type)" manufactured by Nitto Boseki Co., Ltd.) was attached so as to be impregnated with the applied gel coat, and then dried to form a molded body.

[0076] (Removal of mold) The molded body thus formed was removed from the mold. Excess fiber-reinforced plastic was removed from the molded body, the liquid release agent remaining on the surface was washed off with tap water, burrs and irregularities were removed with an air sander, and a surfacer was applied and painting was performed to complete the molded body.

[0077] [Comparative Example] The same polyurethane elastomer used in the examples ("GS-80" manufactured by Urethane Giken Kogyo Co., Ltd.) was sprayed onto the surface of a polyurethane foam cut to the shape of the target molded body using a special gun to form an elastic resin layer, thereby producing a molded body for the comparative example.

[0078] <Evaluation> (smoothness) For the molded bodies of the examples and comparative examples produced, the surface roughness of the arithmetic mean height (Sa) and maximum height (Sz) on the surface of the elastic resin layer was measured in accordance with ISO25178 using a curved surface microshape measurement system (Keyence Corporation's "VR-3200") under measurement conditions of 12 times, using analysis software TalyMap Gold 7.1.7106.

[0079] (Cushioning) For the molded articles of the examples and comparative examples produced, the type C durometer hardness at 23°C was measured on the surface of the elastic resin layer opposite the foamed resin layer using a durometer hardness tester (type C) conforming to JIS-K7312.

[0080] The measurement results of the arithmetic mean height (Sa), maximum height (Sz) and type C durometer hardness are shown in Table 1 below.

[0081] [Table 1]

[0082] As can be seen from the results in Table 1, the molded products of the Examples have excellent surface smoothness and cushioning properties, whereas the molded products of the Comparative Examples only have low surface smoothness.

[0083] (summary) As is apparent from the above-described embodiments, the present invention includes the following aspects.

[0084] The molded article (1) according to the first aspect of the present invention comprises, in this order, an elastic resin layer (10), a foamed resin layer (20), and a shape-imparting layer (30). The arithmetic mean height (Sa) of the elastic resin layer (10) on the surface opposite to the foamed resin layer (20) is 30 μm or less.

[0085] According to the first aspect, a molded article having excellent cushioning properties, smoothness and durability can be obtained.

[0086] The molded article (1) according to the second embodiment is the same as that of the first embodiment, and further comprises an adhesive layer (50) between the foamed resin layer (20) and the shape-imparting layer (30).

[0087] According to the second aspect, the adhesion between the foamed resin layer (20) and the shape-imparting layer (30) in the molded body (1) can be further improved, thereby making it possible to further improve the durability of the molded body (1).

[0088] The molded article (1) according to the third embodiment is the first or second embodiment, in which the elastic resin layer (10) has a type C durometer hardness of 30 or more and 90 or less on the surface opposite to the foamed resin layer (20).

[0089] According to the third aspect, the cushioning properties of the molded body (1) can be further improved.

[0090] The manufacturing method of the molded body (1) according to the fourth aspect of the present invention includes a mold preparation step, an elastic resin layer forming step, a foamed resin layer forming step, a shape-imparting layer forming step, and a mold removal step. In the mold preparation step, a mold (100) is prepared. In the elastic resin layer forming step, an elastic resin layer (10) is formed on the inner surface of the mold (100). In the foamed resin layer forming step, a foamed resin layer (20) is formed on the surface of the elastic resin layer (10) opposite the mold (100). In the shape-imparting layer forming step, a shape-imparting layer (30) is formed on the surface of the foamed resin layer (20) opposite the elastic resin layer (10). In the mold removal step, the molded body (1) having the elastic resin layer (10), the foamed resin layer (20), and the shape-imparting layer (30) obtained in the shape-imparting layer forming step is removed from the mold (100).

[0091] According to the fourth aspect, a molded article having excellent cushioning properties, smoothness and durability can be easily produced.

[0092] The manufacturing method of the molded body (1) according to the fifth aspect is the fourth aspect, which further includes an adhesive layer forming step after the foamed resin layer forming step and before the shape-imparting layer forming step. In the adhesive layer forming step, an adhesive layer (50) is formed on the surface of the foamed resin layer (20) opposite to the elastic resin layer (10). In the shape-imparting layer forming step, a shape-imparting layer (30) is formed on the surface of the adhesive layer (50) opposite to the foamed resin layer (20).

[0093] According to the fifth aspect, it is possible to produce a molded body (1) having improved durability.

[0094] In the method for producing the molded body (1) according to the sixth aspect, in the fourth or fifth aspect, the shape-imparting layer (30) is made of fiber-reinforced plastic.

[0095] According to the sixth aspect, the molded body (1) can be produced more easily, and the durability of the molded body (1) can be further improved. [Industrial Applicability]

[0096] The molded article of the present invention has excellent cushioning properties, smoothness, and durability. Therefore, the molded article of the present invention can be suitably used for products that require cushioning properties, smoothness, and durability, such as play equipment, furniture, protective equipment, art works, monuments, toys, etc. [Explanation of symbols]

[0097] 1 Molded body 10 Elastic resin layer 20 Foamed resin layer 30 Molding layer 50 adhesive layer 100 molds

Claims

1. The elastic resin layer, the foamed resin layer, and the shape-imparting layer are provided in this order, A molded article, wherein the elastic resin layer has an arithmetic mean height (Sa) of 30 μm or less on the surface opposite to the foamed resin layer.

2. An adhesive layer is further provided between the foamed resin layer and the shape-imparting layer. The molded article according to claim 1.

3. The elastic resin layer has a type C durometer hardness of 30 or more and 90 or less on the surface opposite to the foamed resin layer. The molded article according to claim 1 or 2.

4. a mold preparation step of preparing a mold; an elastic resin layer forming step of forming an elastic resin layer on an inner surface of the molding die; a foamed resin layer forming step of forming a foamed resin layer on a surface of the elastic resin layer opposite to the molding die; A shape-imparting layer forming step of forming a shape-imparting layer on a surface of the foamed resin layer opposite to the elastic resin layer; a mold removal step of removing a molded body having the elastic resin layer, the foamed resin layer and the mold layer obtained by the shape-imparting layer forming step from the mold; A method for producing a molded body comprising the steps of:

5. After the foamed resin layer forming step and before the shape-imparting layer forming step, An adhesive layer forming step of forming an adhesive layer on the surface of the foamed resin layer opposite to the elastic resin layer. Further equipped with In the shape-imparting layer forming step, the shape-imparting layer is formed on the surface of the adhesive layer opposite to the foamed resin layer. A method for producing the molded article according to claim 4.

6. The shape-imparting layer is made of fiber-reinforced plastic. A method for producing the molded article according to claim 4 or 5.

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