Molded articles, automotive components, and methods for manufacturing molded articles

Abstract

A molded body that has a foam section at which a skin layer A, a foam layer that includes cells, and a skin layer B are layered in the thickness direction in the given order. When the foam layer of the foam section is divided into three regions in the direction orthogonal to the thickness direction, the average diameter of the cells in the region a adjacent to skin layer A and the region b adjacent to skin layer B is greater than the average diameter of the cells in the region c that is not adjacent to skin layer A or skin layer B.

Description

Technical Field

[0001] The present disclosure relates to a molded body, an automotive member, and a method for manufacturing a molded body.

Background Art

[0002] In recent years, for the purpose of reducing the weight of automobiles, replacement of metal members with resin members in interior and exterior parts has been progressing. Among them, a molded body containing bubbles (cells) obtained by foaming a resin is lighter than metal, and further improvement in the fuel efficiency of automobiles is expected.

[0003] As a foamed molded body used as an automotive part, for example, one obtained by the method described in Patent Document 1 is known. In this method, molten resin is injected into a cavity formed in a pair of molding dies, and the resin is foamed to produce a molded body.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] In order to further promote the weight reduction of automobiles, further weight reduction of a molded body made of resin is desired. However, there is a risk that sufficient strength cannot be obtained due to the weight reduction of the molded body. In view of the above circumstances, an object of the present disclosure is to provide a molded body suitable as an automotive member, an automotive member including this molded body, and a method for manufacturing a molded body.

Means for Solving the Problems

[0006] Specific means for solving the above problems include the following aspects. <1> A molded body having a foamed region in which a skin layer A, a foamed layer containing cells, and a skin layer B are arranged in this order in the thickness direction, wherein when the foamed layer in the foamed region is divided into three regions perpendicular to the thickness direction, the average diameter of the cells in region a adjacent to skin layer A and region b adjacent to skin layer B is greater than the average diameter of the cells in region c not adjacent to skin layer A and skin layer B. <2> The molded article according to claim 1, wherein the division is performed such that, when the thickness of region c is 1, the thicknesses of region a and region b are in the range of 0.5 to 10, respectively. <3> The average diameter of the cells in region a and region b is at least 1.5 times the average diameter of the cells in region c. <1> or <2> The molded body described above. <4> The thickness of the foam layer is 0.35 mm to 2.50 mm. <1> ~ <3> A molded article as described in any one of the items. <5> The thickness of skin layer A and skin layer B is 0.1 mm to 0.6 mm, respectively. <1> ~ <4> A molded article as described in any one of the items. <6> The thickness of the foamed portion is 1 mm to 6 mm. <1> ~ <5> A molded article as described in any one of the items. <7> Includes thermoplastic resins, <1> ~ <6> A molded article as described in any one of the items. <8> <1> ~ <7> Automotive component comprising a molded body as described in any one of the items. <9> <1> ~ <7> A method for manufacturing a molded article according to any one of the items, A step of supplying a composition containing a resin and a foaming agent into a molding apparatus having a movable part, A method for manufacturing a molded body, comprising the step of moving a part of the molding apparatus to increase the internal volume of the molding apparatus. <10> The process further comprises a step of compressing a portion of the composition present inside the molding apparatus, after a step of moving a part of the molding apparatus to increase the internal volume of the molding apparatus. <9> A method for manufacturing a molded article as described above. [Effects of the Invention]

[0007] This disclosure provides a molded article that can achieve weight reduction and is suitable as an automotive component, an automotive component including this molded article, and a method for manufacturing the same. [Brief explanation of the drawing]

[0008] [Figure 1] This is an X-ray CT scan image of the cross-section of the molded body produced in Example 1. [Figure 2] This is an X-ray CT scan image of the cross-section of the molded body produced in Example 2. [Figure 3] This is an X-ray CT scan image of the cross-section of the molded body produced in Example 3. [Figure 4] This is an X-ray CT scan image of the cross-section of the molded body produced in Example 4. [Figure 5] This is an X-ray CT scan image of the cross-section of the molded body produced in Comparative Example 1. [Figure 6] This is a schematic cross-sectional view of an example of the configuration of a molding apparatus used in the manufacture of molded products. [Figure 7] This is a schematic cross-sectional view of an example of the configuration of an injection molding machine used in the manufacture of molded products. [Modes for carrying out the invention]

[0009] The embodiments for carrying out the present invention will be described in detail below. However, the present invention is not limited to the following embodiments. In the following embodiments, the components (including elemental steps, etc.) are not essential unless otherwise specified. The same applies to numerical values ​​and their ranges, and they do not limit the present invention.

[0010] In this disclosure, the term "process" includes not only processes that are independent of other processes, but also processes that cannot be clearly distinguished from other processes, provided that the purpose of such process is achieved.

[0011] In this disclosure, the numerical range indicated using "~" includes the numbers before and after "~" as the minimum and maximum values, respectively. In the numerical ranges described step by step in the present disclosure, the upper limit value or the lower limit value described in one numerical range may be replaced with the upper limit value or the lower limit value of the numerical range described in other step-by-step descriptions. Further, the upper limit value or the lower limit value of the numerical range described in the present disclosure may be replaced with the value shown in the examples. In the present disclosure, the content rate of each component in the composition means the total content rate of the plurality of substances corresponding to each component in the composition, unless otherwise specified, when there are a plurality of substances corresponding to each component in the composition. In the present disclosure, the term "layer" includes not only the case where it is formed over the entire region where the layer exists but also the case where it is formed only in a part of the region when observing the region where the layer exists. When an embodiment in the present disclosure is described with reference to the drawings, the configuration of the embodiment is not limited to the configuration shown in the drawings. Also, the size of the members in each drawing is conceptual, and the relative relationship of the sizes between the members is not limited thereto.

[0012] <Formed body> The formed body of the present disclosure has a foamed portion in which a skin layer A, a foamed layer containing cells, and a skin layer B are arranged in this order in the thickness direction. When the foamed layer in the foamed portion is divided into three regions in a direction perpendicular to the thickness direction, the average diameter of the cells contained in the region a adjacent to the skin layer A and the region b adjacent to the skin layer B is larger than the average diameter of the cells contained in the region c not adjacent to the skin layer A and the skin layer B.

[0013] In the present disclosure, the "foamed layer" means a portion in a state where cells are contained in the resin, and the "skin layer" means a portion in a state where cells are not contained in the resin. In the present disclosure, the portion where the skin layer A, the foamed layer, and the skin layer B of the formed body are arranged in this order in the thickness direction may be referred to as the "foamed portion", and the skin layer A and the skin layer B may be respectively referred to as the "skin layer".

[0014] The formed body of the present disclosure has a different state of the foamed portion from the foamed formed body conventionally used as an automobile part. In other words, while conventional molded articles have little difference in cell size depending on the location of the foamed area, in the resin molded article of this disclosure, when the foamed layer in the foamed area is divided into three regions perpendicular to the thickness direction, the average diameter of the cells in region a adjacent to skin layer A and region b adjacent to skin layer B is larger than the average diameter of the cells in region c not adjacent to skin layer A or skin layer B. Because the foamed area is in the state described above, it is possible to make, for example, region c, located between region a and region b, relatively dense. As a result, effects such as improved strength of the molded product can be expected.

[0015] Figures 1 to 4 show examples of X-ray CT scan images of the cross-section of the foamed portion of a molded body. The cross-sections shown in Figures 1 to 4 were obtained by cutting the foamed portion of the molded body along the thickness direction. In Figures 1 to 4, the areas shown as relatively low brightness correspond to cells, and the areas shown as relatively high brightness correspond to resin. The areas where cells are present correspond to the foamed layer, and the areas on either side where no cells are observed correspond to the skin layer. As shown in Figures 1 to 4, the foam layer is divided into two regions adjacent to the skin layer, where the cells are relatively large, and a region located between these regions, where the cells are relatively small.

[0016] There are no particular limitations on the method for bringing the foamed layer into a state that satisfies the conditions of regions a, b, and c, but it can be carried out, for example, by the following method. In a molding apparatus comprising a movable mold and a fixed mold, molten resin is supplied to the cavity between the two molds. When the movable mold is moved to increase the distance between the molds, the resin in the cavity foams, forming a foamed layer. After moving the movable mold to a predetermined distance, the movable mold is stopped. Then, the stopped movable mold is moved in a direction that reduces the distance between the molds. This compresses the region near the center of the foamed layer, where the temperature is relatively high, and the cells formed by foaming shrink. As a result, it is presumed that a foamed layer is formed that satisfies the conditions of regions a, b, and c.

[0017] If, depending on the location of the molded body, the foam layer satisfies the above-mentioned conditions in some areas and not in others, the molded body shall be considered to be a molded body of the present disclosure if the conditions are met at the location where the thickness of the foam layer is maximum.

[0018] The average diameter of cells in regions a and b may be 1.5 times or more, 2 times or more, or 3 times or more, the average diameter of cells in region c. The average diameter of the cells in regions a and b may be 10 times or less, 7 times or less, or 5 times or less than the average diameter of the cells in region c.

[0019] The average diameter of the cells in regions a and b is preferably 100 μm or more, more preferably 110 μm or more, and even more preferably 115 μm or more. When the average diameter of the cells in regions a and b is 100 μm or more, sufficient weight reduction of the molded article tends to be achieved. The average diameter of the cells in regions a and b is preferably 250 μm or less, more preferably 220 μm or less, and even more preferably 190 μm or less. When the average diameter of the cells in regions a and b is 250 μm or less, variations in strength between different parts of the molded body tend to be suppressed.

[0020] The maximum diameter of cells in regions a and b is preferably 300 μm or less, more preferably 280 μm or less, and even more preferably 260 μm or less. When the maximum diameter of cells in regions a and b is 300 μm or less, variations in strength between different parts of the molded body tend to be suppressed.

[0021] The average diameter of the cells in region c is preferably 150 μm or less, more preferably 130 μm or less, and even more preferably 110 μm or less. The average diameter of the cells included in region c is preferably 1 μm or more, and more preferably 3 μm or more.

[0022] The maximum diameter of the cells included in region c is preferably 300 μm or less, more preferably 280 μm or less, and even more preferably 250 μm or less.

[0023] In this disclosure, the average and maximum diameters of the cells are measured by observing cross-sectional images of the foamed portion of the molded body. The type of cross-sectional image is not particularly limited, and X-ray CT scan images, electron microscope images, etc., can be used. The observation area is at least 100 mm. 2 Configure it so that it is secured. Specifically, the transverse and longitudinal diameters of the cells observed in the cross-section of the foamed portion of the molded body are measured. In this disclosure, the transverse diameter of the cell refers to the maximum width of the cell in the direction perpendicular to the thickness direction of the foamed portion, and the longitudinal diameter of the cell refers to the maximum width of the cell in the thickness direction of the foamed portion. Furthermore, the "average cell diameter" is defined as the sum of the arithmetic mean of the horizontal diameter and the arithmetic mean of the vertical diameter of all observed cells (excluding cells where at least one of the horizontal or vertical diameters is less than 1 μm) divided by 2. The "maximum cell diameter" is defined as the maximum value among the horizontal and vertical diameters of all cells.

[0024] The proportion of each region when dividing the cross-sectional image of the foamed portion of the molded body into regions a to c is not particularly limited. For example, if the thickness of region c is 1, the regions a and b may be divided so that their thicknesses are in the range of 0.5 to 10, 1 to 8, or 2 to 5, respectively.

[0025] In the foamed layer, the boundaries between regions with different average cell diameters may or may not be clearly observed. If the boundaries between regions with different average cell diameters are clearly observed, it is preferable to divide the foamed layer into regions a to c near the boundaries and measure the average cell diameter in each region.

[0026] The thickness of the foam layer in the foamed area is not particularly limited. For example, the thickness of the foam layer may be 0.35 mm to 2.50 mm, 0.55 mm to 2.00 mm, or 0.80 mm to 1.50 mm. When the thickness of the foam layer is within the above range, weight reduction tends to be achieved while ensuring sufficient strength when a general foam molding method is implemented. If the thickness of the foam layer is not uniform, the thickness measured at the location where the foam layer is thickest shall be defined as the "thickness of the foam layer."

[0027] The thickness of the skin layer in the foamed area is not particularly limited. For example, the thickness of the skin layer may be 0.1 mm to 0.6 mm, 0.2 mm to 0.5 mm, or 0.3 mm to 0.4 mm. When the thickness of the skin layer is within the above range, weight reduction tends to be achieved while ensuring sufficient strength when a general foam molding method is used. The thickness of the skin layer mentioned above is the thickness of each (one layer) of skin layer A and skin layer B, which are located on both sides of the foam layer. If the skin layer thickness is not constant, the thickness measured at the location where the foamed area is thickest shall be defined as the "skin layer thickness."

[0028] In this disclosure, the thickness of the skin layer and the foam layer is measured by observing the cross-section of the foamed portion of the molded article. More specifically, in a cross-sectional image of the foamed portion of the molded article obtained in the same manner as the measurement of the average and maximum diameters of cells, the thickness of the region where no cells are observed is measured as the thickness of the skin layer, and the thickness of the region where cells are observed is measured as the thickness of the foam layer. In the above measurement, the boundary between the skin layer and the foam layer is determined as follows: In the cross-sectional image of the foamed area, a straight line perpendicular to the thickness direction of the foamed area is drawn and moved from the outermost surface of the foamed area toward the center. The movement of this line stops at the point where it first comes into contact with a cell whose horizontal and vertical diameters are 10 μm or larger, and this point marks the boundary between the skin layer and the foamed layer.

[0029] The thickness of the foamed portion of the molded body (i.e., the total thickness of the foamed layer and the skin layers on both sides thereof) is not particularly limited and can be set according to the intended use of the molded body. From the viewpoint of balancing rigidity and weight reduction, the thickness of the foamed portion of the molded body is preferably 6 mm or less, more preferably 5 mm or less, and even more preferably 4 mm or less. From the viewpoint of flow resistance when filling the mold with molten resin, the thickness of the foamed portion of the molded body is preferably 1 mm or more, more preferably 1.5 mm or more, and even more preferably 2 mm or more.

[0030] When a molded body has both foamed areas and areas that are not foamed (for example, the bent parts of the molded body), the proportion of the foamed areas to the entire molded body is not particularly limited and can be set according to the intended use of the molded body. For example, the proportion of the foamed areas to the entire molded body may be 50% to 100%, 70% to 100%, or 80% to 100% based on area when the molded body is viewed in plan.

[0031] The type of resin included in the molded article is not particularly limited. From the viewpoint of ease of molding and balance between toughness and strength, it is preferable that the resin included in the molded article be a thermoplastic resin. The molded article may contain only one type of resin or two or more types.

[0032] Specifically, the resins include at least one selected from the group consisting of polyethylene resins, polypropylene resins, composite polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, ionomer resins, polyamide resins, acrylonitrile-butadiene-styrene copolymer resins (ABS), and polycarbonate resins. Among these, at least one selected from the group consisting of polypropylene resins, composite polypropylene resins, and acrylonitrile-butadiene-styrene copolymer resins (ABS) is preferred.

[0033] The molded article may contain components other than resin as needed. Examples of components other than resin include inorganic fillers, rubber, additives such as carbon black, and components derived from foaming agents, which will be described later. If the molded article contains components other than resin, the total amount is preferably 15% by mass or less of the total amount of the molded article, more preferably 10% by mass or less, and even more preferably 5% by mass or less.

[0034] If the molded article contains components other than resin, the total amount of resin is preferably 85% by mass or more of the total amount of the molded article, more preferably 90% by mass or more, and even more preferably 95% by mass or more.

[0035] The applications of the molded articles of this disclosure are not particularly limited. Because the molded articles of this disclosure are lightweight and have excellent strength, they are suitable for use in applications where both weight reduction and strength are important, such as interior and exterior components of automobiles. Specific examples of interior and exterior components of automobiles include sacco moldings, arch moldings, side moldings, rocker moldings, bumpers, and back door trims.

[0036] <Automotive components> The automotive components of this disclosure include the molded articles described above. There are no particular restrictions on the types of automotive components; you can choose from automotive interior and exterior components such as side garnishes, sacco moldings, arch moldings, side moldings, rocker moldings, bumpers, side door trims, and back door trims.

[0037] <Method for manufacturing molded articles> The method for manufacturing a molded article described herein is the method for manufacturing a molded article described above, A step of supplying a composition containing a resin and a foaming agent into a molding apparatus having a movable part, A method for manufacturing a molded body, comprising the step of moving a part of the molding apparatus to increase the internal volume of the molding apparatus.

[0038] In the above method, the movable part of the molding apparatus to which the composition is supplied is moved to increase the volume inside the molding apparatus. At that time, cells are generated by the action of the foaming agent contained in the composition. As a result, a molded article having a foamed layer containing cells and skin layers arranged on both sides thereof can be manufactured.

[0039] In the above method, there are no particular limitations on the method for controlling the state of the molded article produced. For example, this could involve adjusting the type and amount of resin and foaming agent contained in the composition, the molding conditions (temperature of the composition and molding apparatus, molding time, etc.), etc.

[0040] In particular, it is preferable to control the molding conditions such that, after increasing the internal volume of the molding apparatus, the movement of the movable part of the molding apparatus is stopped, and the area near the center of the foamed composition becomes easily compressed. That is, the above method may include a step of compressing a portion of the composition present inside the molding apparatus after the step of increasing the internal volume by moving a part of the molding apparatus. For example, it may include a step of moving a movable part of the molding apparatus so that a portion of the composition is compressed. One method for controlling molding conditions so that the center of the foamed composition is easily compressible is injection compression molding.

[0041] The type of resin included in the composition is not particularly limited and may be selected from the resins that may be included in the molded articles described above.

[0042] The type of blowing agent included in the composition is not particularly limited; both organic and inorganic blowing agents can be used. Examples of organic blowing agents include azodicarbonamide (ADCA), N,N-dinitrosopentamethylenetetramine (DPT), 4,4-oxybisbenzenesulfonyl hydrazide (OBSH), and hydrazodicarbonamide (HDCA). Examples of inorganic blowing agents include sodium bicarbonate.

[0043] Among organic blowing agents, azodicarbonamide (ADCA) is preferred when the molded body is an exterior component. The use of azodicarbonamide (ADCA) improves resistance to hot water and tends to suppress the occurrence of blisters in hot water tests. Blisters refer to a condition in which gas generated by the reaction of unreacted foaming agent remaining in the skin layer with water pushes up the skin layer.

[0044] The decomposition temperature of the foaming agent is preferably 50°C to 200°C, and more preferably 80°C to 200°C. The decomposition temperature of the foaming agent may also be 130°C to 200°C.

[0045] The content of the blowing agent in the composition is preferably set appropriately depending on the type of blowing agent, etc. For example, when an organic blowing agent (preferably azodicarbonamide) is used as the blowing agent, from the viewpoint of foaming properties, the content of the organic blowing agent in the composition is preferably in the range of 0.05% to 1.0% by mass, and more preferably in the range of 0.1% to 0.5% by mass. The above-mentioned foaming agent content is the content in the composition before it is supplied to the molding apparatus.

[0046] In the above method, the temperature of the composition when supplied to the molding apparatus is not particularly limited. If the composition contains a thermoplastic resin, it is preferable that the temperature is above its softening point.

[0047] The molding apparatus used in the method of this disclosure is not particularly limited as long as at least a part of it is movable. From the viewpoint of workability, it is preferable to use a pair of molds in which at least one of them is movable.

[0048] Figure 6 shows an example of a molding apparatus. The molding apparatus shown in Figure 6 comprises a movable mold 1, a fixed mold 2, a cavity 6 which is the gap between the movable mold 1 and the fixed mold 2, and a gate 4 which penetrates the fixed mold 2 from the outside of the mold to the cavity 6. Hereafter, the movable mold 1 and the fixed mold 2 may be collectively referred to as "mold".

[0049] First, as shown in Figure 6(A), composition 3, which includes resin and foaming agent, is supplied into the cavity 6 from an injection device (not shown) through a gate 4. If composition 3 contains a thermoplastic resin, composition 3 is supplied into the cavity 6 in a state in which the thermoplastic resin is melted or softened and has fluidity.

[0050] The mold is typically at a lower temperature than the supplied composition 3. Therefore, as shown in Figure 6(B), when composition 3 is filled into the cavity 6, solidification of composition 3 begins from the part that touches the mold.

[0051] Then, as shown in Figure 6(C), the movable mold 1 is moved to increase the distance between the molds (core back), causing the unsolidified portion of composition 3 to foam and form a foamed layer 5. Between the foamed layer 5 and the mold, a skin layer 7 is formed by the solidified composition 3.

[0052] The material of the molding apparatus is not particularly limited, and common materials can be used. Examples include stainless steel, pre-hardened steel, alloy tool steel, high-speed tool steel, and cemented carbide tool steel.

[0053] The method of supplying the composition to the molding apparatus shown in Figure 6 is not particularly limited. For example, it may be done using an injection apparatus that continuously prepares the composition and supplies it to the molding apparatus, as shown in Figure 7.

[0054] The injection device 10 shown in Figure 7 comprises a cylinder 11 and a hopper 12 for introducing the raw materials of the composition into the cylinder 11. The outlet of the cylinder 11 is connected to the mold 13 of the molding device.

[0055] The cylinder 11 includes a screw 11A that stirs the raw material to prepare a composition and moves the composition toward the mold 13 of the molding apparatus, a motor 11B that drives the screw 11A, and a heater (not shown) that heats the inside of the cylinder 11. The raw material supplied into the inside of the cylinder 11 becomes molten as it moves toward the mold 13. [Examples]

[0056] The present disclosure will be described in detail below with reference to examples, but the present disclosure is not limited to these examples.

[0057] <Manufacturing of molded products> Resin (100 parts by mass), foaming agent (0.3 parts by mass), and additive (2 parts by mass) were placed in the hopper of an injection molding apparatus configured as shown in Figure 7. The resin was melted and mixed in the cylinder to prepare the composition. This composition was supplied to the cavities of a pair of molds, one of which was movable. After supplying the composition to the cavities, the movable mold was moved (core back) to foam the composition. The movable mold was stopped when it reached a predetermined movement distance. Next, the movable mold was moved in a direction that reduced the distance between the molds. After that, it was cooled to produce a molded body.

[0058] Details of the materials used in preparing the composition are as follows. Details of the molding conditions are shown in Table 1 below. Resin: Polypropylene Foaming agent: Azodicarbonamide (ADCA)-containing masterbatch Additives: Black pigment masterbatch

[0059] [Table 1]

[0060] The "CB start delay time" shown in Table 1 refers to the time from the completion of the supply of the composition to the cavity to the start of movement of the movable mold.

[0061] Figure 1 shows an X-ray CT scan image of a cross-section obtained by cutting the molded body produced in Example 1 along the thickness direction. As shown in Figure 1, it was observed that the foam layer was divided into three regions with different cell sizes. Table 2 shows the average cell diameter in each region, the thickness of each region, the thickness of the skin layer, and the overall thickness of the foamed area when the foam layer was divided at the boundaries of the three regions.

[0062] Figure 2 shows an X-ray CT scan image of a cross-section obtained by cutting the molded body produced in Example 2 along the thickness direction. As shown in Figure 2, it was observed that the foam layer was divided into three regions with different cell sizes. Table 2 shows the average cell diameter in each region, the thickness of each region, the thickness of the skin layer, and the overall thickness of the foamed area when the foam layer was divided at the boundaries of the three regions.

[0063] Figure 3 shows an X-ray CT scan image of a cross-section obtained by cutting the molded body produced in Example 3 along the thickness direction. As shown in Figure 3, it was observed that the foam layer was divided into three regions with different cell sizes. Table 2 shows the average cell diameter in each region, the thickness of each region, the thickness of the skin layer, and the overall thickness of the foamed area when the foam layer was divided at the boundaries of the three regions.

[0064] Figure 4 shows an X-ray CT scan image of a cross-section obtained by cutting the molded body produced in Example 4 along the thickness direction. As shown in Figure 4, it was observed that the foam layer was divided into three regions with different cell sizes. Table 2 shows the average cell diameter in each region, the thickness of each region, the thickness of the skin layer, and the overall thickness of the foamed area when the foam layer was divided at the boundaries of the three regions.

[0065] Figure 5 shows an X-ray CT scan image of a cross-section obtained by cutting the molded body produced in Comparative Example 1 along the thickness direction. Since there was no difference in cell size in the thickness direction of the foam layer of the molded body produced in Comparative Example 1, the average diameter of cells in each region and the thickness of each region were not measured when the foam layer was divided.

[0066] [Table 2]

[0067] The disclosure of Japanese Patent Application No. 2021-001024 is incorporated herein by reference in its entirety. All documents, patent applications, and technical standards described herein are incorporated by reference to the same extent as if each individual document, patent application, and technical standard were specifically and individually noted as being incorporated by reference.

Claims

1. A molded body having a foamed region in which a skin layer A, a foamed layer containing cells, and a skin layer B are arranged in this order in the thickness direction, wherein when the foamed layer in the foamed region is divided into three regions perpendicular to the thickness direction, the average diameter of the cells in region a adjacent to skin layer A and region b adjacent to skin layer B is 1.7 times or more the average diameter of the cells in region c not adjacent to skin layer A and skin layer B.

2. The molded article according to claim 1, wherein the division is performed such that, when the thickness of region c is 1, the thicknesses of region a and region b are each in the range of 0.5 to 10.

3. The molded article according to claim 1 or claim 2, wherein the average diameter of the cells in region a and the cells in region b is 5 times or less the average diameter of the cells in region c.

4. The molded article according to any one of claims 1 to 3, wherein the thickness of the foam layer is 0.35 mm to 2.50 mm.

5. The molded article according to any one of claims 1 to 4, wherein the thickness of skin layer A and skin layer B is 0.1 mm to 0.6 mm, respectively.

6. The molded article according to any one of claims 1 to 5, wherein the thickness of the foamed portion is 1 mm to 6 mm.

7. A molded article according to any one of claims 1 to 6, comprising a thermoplastic resin.

8. An automotive component comprising a molded body according to any one of claims 1 to 7.

9. A method for manufacturing a molded article according to any one of claims 1 to 7, A step of supplying a composition containing a resin and a foaming agent into a molding apparatus having a movable part, A method for manufacturing a molded body, comprising the step of moving a part of the molding apparatus to increase the internal volume of the molding apparatus.

10. A method for manufacturing a molded article according to claim 9, further comprising the step of moving a part of the molding apparatus to increase the internal volume of the molding apparatus, followed by the step of compressing a part of the composition present inside the molding apparatus.

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