Palette, box, gear and resin shaped body-manufacturing method

To provide a palette, etc. on which an article is placed, including: a foamed synthetic resin-base material; and a polyurea-resin coating layer covering a front surface of the base material; and manufactured by a method including: injecting a polyurea-resin coating material onto a front surface of a foamed synthetic resin-base material; and drying the coating material after the injecting. The injecting may have injecting the coating material onto all surfaces of the base material. A thickness of the coating material formed on a front surface of the base material in the injecting may be controlled proportionally to an expansion ratio of the foamed synthetic resin. The thickness of the coating material may be controlled by adjusting a speed of conveyance of the base material and/or a distance between an injection port for the coating material and the base material. Heating-pressing the base material may further be included before the injecting.

BACKGROUND

The contents of the following Japanese and PCT patent application(s) are incorporated herein by reference:NO. JP2015-193765 filed on Sep. 30, 2015, andNO. PCT/JP2015/084071 filed on Dec. 3, 2015.

1. Technical Field

The present invention relates to a palette, a box, a gear and a resin shaped body-manufacturing method.

2. Related Art

Palettes for placement and conveyance of articles have been used in physical distribution and the like. Conventionally known palettes include wooden, plastic and metallic palettes (please see Patent Document 1, for example). Related technical documents include the following documents.

Patent Document 1: Japanese Patent Application Publication No. H11-140381

SUMMARY

Palettes and the like preferably are light-weight and have high strength.

A first aspect of the present invention provides a palette on which an article is placed, the palette including: a foamed synthetic resin base material; and a polyurea resin coating layer that covers a front surface of the base material.

A second aspect of the present invention provides a box having an internal space, the box including: a foamed synthetic resin base material to which the internal space is provided; and a polyurea resin coating layer covering a front surface of the base material and an inner wall of the internal space.

A third aspect of the present invention provides a box body having an internal space, the box body including: a foamed synthetic resin base material to which the internal space is provided; a polyurea resin coating layer covering a front surface of the base material at an outer surface of the box body; and a ceramic powder-containing inner wall coating layer covering a front surface of the base material at an inner wall of the internal space.

A fourth aspect of the present invention provides a gear to be attached to a target, the gear including: a foamed synthetic resin base material; and a polyurea resin coating layer covering a front surface of the base material.

In the first to fourth aspects, the coating layer may be formed on all surfaces of the base material.

Assuming that an expansion ratio of the foamed synthetic resin is A, a thickness T1of the coating layer may satisfy:
(A/20)−1≤T1≤(A/20)+1 [mm].

An expansion ratio at a front surface of the base material may be higher than an expansion ratio at a center of the base material.

The base material may have: a plurality of foot portions provided to a surface opposite to a placement surface on which the article is placed; and a positioning portion that is provided to the placement surface and defines positions of the foot portions of another palette if the other palette is placed on the placement surface.

An ID device fixed to the base material may further be included, and the ID device may store identification information identifying the palette.

A fiber sheet provided between the base material and the coating layer may further be included. The polyurea resin may include a polyisocyanate compound and a synthetic resin that are mixed therein.

In the first aspect, the base material may have a plurality of foot portions provided to a surface opposite to a placement surface on which the article is placed, and the fiber sheet may be provided to a region that is on the placement surface and is other than a region facing the foot portions.

A fifth aspect of the present invention provides a manufacturing method of manufacturing a resin shaped body including: injecting a polyurea resin coating material onto a front surface of a foamed synthetic resin base material; and drying the coating material after the injecting.

The injecting may have injecting the coating material onto all surfaces of the base material. A thickness of the coating material formed on a front surface of the base material in the injecting may be controlled in proportion to an expansion ratio of the foamed synthetic resin. The thickness of the coating material may be controlled by adjusting at least one of: a speed of conveyance of the base material; and a distance between an injection portion for the coating material and the base material.

Heating the base material may further be included before the injecting. Pressing the base material may further be included before the injecting.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG. 1is a perspective view showing a palette100according to a first embodiment of the present invention. Articles are placed on the palette100. The palette100is used for example in physical distribution, and is used for storage and conveyance of articles.

The palette100of the present example includes a body portion10and a plurality of foot portions16. The body portion10of the present example has a tabular shape. A surface of the body portion10on which articles are placed is referred to as a placement surface12, and a surface opposite to the placement surface12is referred to as a rear surface14.

The rear surface14is provided with the plurality of foot portions16. The plurality of foot portions16may be formed integral with the body portion10, or may be bonded to the body portion10. The respective foot portions16are arranged at predetermined intervals. The foot portions16are preferably arrayed in a lattice-like form so that carriers such as fork lifts can pass through between the respective foot portions16.

FIG. 2is a figure showing a partial cross-section of the palette100.FIG. 2shows a cross-section at part of the body portion10. The palette100has a base material20and coating layers22. The base material20is formed of a foamed synthetic resin.

As one example, the synthetic resin forming the base material20is a highly polymerized compound. As a more specific example, the synthetic resin forming the base material20is formed of one or more materials selected from polystyrene, polyethylene, polypropylene and polyurethane. Foamed synthetic resins refer to ones containing micro bubbles dispersed in these synthetic resins. In one example, the base material20is formed of a styrene foam (foamed polystyrene).

The coating layers22are formed covering the front surfaces of the base material20. The coating layers22are formed of a polyurea resin. Polyurea resins are resins having urea bonds formed by chemical reactions between isocyanate and amino groups, for example. As one example, a polyurea resin is formed by causing a reaction between polyisocyanate and polyamine. A polyurea resin may be formed using a mixed solvent prepared by mixing a polyisocyanate compound with specific gravity of 1.09 to 1.12 and a synthetic resin as a hardener with specific gravity of 1.13 to 1.02, approximately at a volume ratio of 1:1 or a weight ratio of 109:100.

The coating layers22are preferably formed over all the surfaces of the base material20. That is, the coating layers22cover all among the placement surface12, rear surface14and side surfaces of the body portion10. The side surfaces refer to surfaces between the placement surface12and the rear surface14. In addition, the coating layers22cover all the front surfaces of the foot portion16. A coating layer22may be or may not be formed on a surface that is among the front surfaces of a foot portion16and at which the foot portion16is connected with the body portion10.

A thickness T1of a coating layer22is smaller than a thickness T2of the base material20. As one example, the thickness of the base material20is equal to or larger than 3 cm, and the thickness T1of a coating layer22is equal to or smaller than 5 mm.

The base material20is very light-weight because it is formed of a foamed synthetic resin. In addition, the coating layers22have high strength, excel in water resistance and excel in impact resistance because they are formed of a polyurea resin. Because of this, by coating the front surfaces of the base material20with the coating layers22, a palette100that is ultra-light-weight and excels in strength, water resistance and impact resistance can be provided.

Because the palette100of the present example is very light-weight, it can facilitate carriage, storage and the like to reduce the cost such as energy cost necessary for conveyance of articles or the like. Because of this, it can contribute to environmental measures.

In addition, it excels in workability as compared with wooden, metallic and other palettes, and in addition, can be manufactured at low cost. Furthermore, because it excels in corrosiveness as compared with wooden palettes or the like, running cost can be reduced.

FIG. 3is a figure showing the relationship between the expansion ratio of a foamed synthetic resin forming the base material20and the thickness T1of a coating layer22. In the present example, the thickness T1of a coating layer22is determined according to the expansion ratio of the base material20. Expansion ratios indicate percentages of expansion (volume ratios) that is observed if synthetic resin grains (raw material beads) are heated by steam or the like to be expanded, for example. More specifically, in a foamed body with an expansion ratio of 50 times, air occupies 98% of the entire product (volume) and the synthetic resin occupies 2% of it. Generally, the expansion ratio and the strength of the foamed synthetic resin are inversely proportional to each other. For example, if the expansion ratio of a foamed synthetic resin is 30 times, its strength is twice the strength of a foamed synthetic resin with expansion ratio of 60 times, but its volume is approximately half of the volume of the latter foamed synthetic resin.

The expansion ratio is selected according to uses of the base material20. According to uses, the thickness and strength that the base material20should have are determined. The expansion ratio is determined according to the strength of the base material20.

The thickness T1of a coating layer22is set to be generally proportional to the expansion ratio. Normally, the thickness T1of a coating layer22is approximately A/20 [mm], assuming that the expansion ratio is A. For example, in normal palette uses, if the expansion ratio is 40 times, the thickness T1of a coating layer22is preferably 2 mm approximately. In addition, if the expansion ratio is 60 times, the thickness T1of a coating layer22is preferably 3 mm approximately. By making the thickness T1of a coating layer22proportional to the expansion ratio A, the thickness T1of the coating layer22is increased as the strength of the base material20decreases so that the strength of the entire palette100can be maintained.

Note that the thickness T1of a coating layer22may be increased or decreased relative to a normal thickness. As one example, if it is desired to provide a higher strength, the thickness T1of a coating layer22is increased, and if it is desired to lower the cost, the thickness T1of the coating layer22is made smaller. As one example, the thickness T1of a coating layer22may be in the range shown below, which corresponds to the range indicated with dotted lines inFIG. 3.
(A/20)−1≤T1≤(A/20)+1 [mm]

The expansion ratio of a foamed synthetic resin can be estimated from the material type of the synthetic resin and the weight per unit volume of the foamed synthetic resin. That is, the volume of a foamed synthetic resin before foaming is estimated from the weight per unit volume of the synthetic resin and the material of the synthetic resin. Then, the expansion ratio is calculated from the estimated volume of the synthetic resin before foaming and the unit volume of the foamed synthetic resin.

FIG. 4is a flowchart showing one example of a process of manufacturing a resin shaped body. First, at a use selection step S201, the use of a resin shaped body is selected. Other than the palette100, examples of uses of resin shaped bodies may include protectors and box bodies mentioned below, but these are not the sole examples. In the present example, the use of a resin shaped body is the palette100.

Next, at an expansion ratio selection step S202, the expansion ratio of a foamed synthetic resin used for a resin shaped body is selected. The expansion ratio may be determined according to the use selected at S201. As one example, the thickness of a resin shaped body in a case that a protector is to be manufactured is smaller than the thickness of a resin shaped body in a case that the palette100is to be manufactured, in some cases. For example, the thickness of the protector is assumed to be approximately ⅓ of the thickness of the palette100. In this case, the expansion ratio in a case that the protector is to be manufactured may be set to approximately ⅓ of the expansion ratio in a case that the palette100is to be manufactured.

Next, at a base material shaping step S203, a foamed synthetic resin base material is shaped into a predetermined shape. For example, the foamed synthetic resin base material20is shaped into the shape of the palette100. At S203, the base material20shaped into a rectangular parallelepiped may be cut into a predetermined shape. In addition, at S203, a plurality of parts may be shaped. For example, the body portion10and the foot portions16of the palette100may be shaped separately.

In addition, at a heating-pressing step S205, the base material20is heated and pressed. By heating the base material20, moisture content contained in the base material20is removed. Thereby, unevenness of the coating layers22to be formed on the front surfaces of the base material20can be reduced. If a lot of moisture content is contained in the base material20, the body portion10of the palette100warps, forming an upward protrusion, for example. In addition, by pressing the base material20, bubbles at the front surfaces of the base material20are crushed, and the resin density at the front surfaces of the base material20becomes higher than the resin density at the center of the base material20. Thereby, it is possible to prevent the coating material from being diffused into the base material20when the coating material is injected onto the front surfaces of the base material20. Whichever one of S204and S205may be performed first or they may be performed simultaneously.

Next, at an injection step S206, the coating material is injected onto the base material. At S206, the coating material is preferably injected onto all the surfaces of each base material.

Next, at a drying step S207, the coating material is dried. Thereby, the coating layers22are formed on the front surfaces of the base material.

In addition, at a device attachment step S208, an ID device may be attached to the resin shaped body. The ID device stores identification information identifying resin shaped bodies, and the ID device transmits the identification information to the outside or the identification information is read out from the outside. The ID device may have a circuit that operates through magnetic-flux coupling with an external reading apparatus, a circuit that converts radio waves from the outside into operating power, or the like.

FIG. 5Ais a figure for explaining one example of the heating-pressing step S205. In the present example, a plurality of rollers306to revolve are used to convey the base material20. During the conveyance, the base material20is heated and pressed by a heating-pressing portion305. The heating-pressing portion305is provided revolvably at a position to face any of the rollers306. In addition, the heating-pressing portion305has a built-in heating means such as heater.

The distance between the roller306and the heating-pressing portion305is smaller than the thickness of the base material20before being heated and pressed. By the base material20passing through between the roller306and the heating-pressing portion305, the base material20is pressed.

FIG. 5Bis a figure showing the base material20having front surfaces on which the coating layers22are formed. The expansion ratio of the base material20at regions21on front surface sides is lower than the expansion ratio of the base material20at a central region23. The center of the base material20refers to the center of the base material20in the thickness direction.

That is, the resin density in the regions21is higher than the resin density in the region23. For example, respective regions obtained by dividing the base material20into three equally in the thickness direction are treated as a region21, a region23and a region21. At this time, the average mass per unit volume of the regions21is greater than the average mass per unit volume of the region23.

With such a structure, diffusion of the coating material into the base material20can be suppressed at the injection step S206. Accordingly, the thickness of the coating layers22can be controlled accurately. Because of this, the strength of the entire base material20and coating layers22can be controlled accurately.

FIG. 6is a perspective view for explaining one example of a manufacturing apparatus300used for the injection step S206. In the manufacturing apparatus300also, the plurality of rollers306to revolve are used to convey the base material20. The apparatuses used for S205and S206may be provided integral with each other. That is, the resin shaped body having passed through the apparatus used for S205is automatically conveyed to the manufacturing apparatus300used for S206. InFIG. 6, the palette100is shown as one example of resin shaped bodies. If the palette100is to be manufactured, an apparatus to bond the plurality of foot portions16to the body portion10may be provided to be used after the heating-pressing step S205.

The manufacturing apparatus300includes a frame body302, a support portion304, the plurality of rollers306, a control apparatus308, side surface-injection apparatuses310, a lower surface-injection apparatus312and a top surface-injection apparatus314. The frame body302of the present example has two rails arranged in parallel. The plurality of rollers306are arrayed between the two rails and along a predetermined direction of conveyance. The frame body302has a rotating mechanism to rotate the plurality of rollers306. The support portion304supports the frame body302at a predetermined height. In the present example, the base material20is conveyed by the respective rollers306rotating while being in contact with a surface of the base material20.

The side surface-injection apparatuses310are provided on both sides of the frame body302. Surfaces of the side surface-injection apparatuses310at which they face the frame body302are provided with one or more injection ports311. In the present example, a plurality of the injection ports311are arrayed in the height direction. At least one injection port311is arranged at a position higher than the conveyance surface on which the base material20is conveyed. In addition, at least one injection port311may be arranged at a position lower than the conveyance surface. The coating material is injected from the respective injection ports311. The coating material is a liquid polyurea resin. InFIG. 6, the coating material being injected is schematically shown with broken lines.

The lower surface-injection apparatus312has one or more injection ports311that face, at a position lower than the conveyance surface for the base material20, the conveyance surface for the base material20. In the present example, a plurality of the injection ports311are arrayed in a direction orthogonal to the direction of conveyance of the base material20.

The top surface-injection apparatus314has one or more injection ports311that face, at a position higher than the conveyance surface for the base material20, the conveyance surface of the base material20. In the present example, a plurality of the injection ports311are arrayed in a direction orthogonal to the direction of conveyance of the base material20. The control apparatus308causes the respective injection apparatuses to inject the coating material when the base material20passes before the respective injection apparatuses.

With such a structure, the coating material can be injected onto the respective surfaces of the resin shaped body. In order for the side surface-injection apparatuses310to be able to inject the coating material onto all the side surfaces of the resin shaped body, a mechanism to convey the resin shaped body while rotating it in the conveyance surface may be provided to at least some of the rollers306.

In addition, a plurality of the side surface-injection apparatuses310, a plurality of the lower surface-injection apparatuses312and/or a plurality of the top surface-injection apparatuses314may be provided. In addition, the order of the side surface-injection apparatuses310, lower surface-injection apparatus312and top surface-injection apparatus314is not limited to that shown in the example ofFIG. 6.

FIG. 7Ais a figure for explaining a height H1of an injection surface of the lower surface-injection apparatus312. The injection surface refers to a surface on which injection ports311are provided. By adjusting the height H1of the injection surface, the distance between the injection ports311and the resin shaped body can be adjusted. The shorter the distance between the injection ports311and the resin shaped body is, the larger the amount of the coating material injected from the injection ports311to adhere the base material20per unit area is. That is, by adjusting the height H1of the injection surface, the thickness of a coating layers22to be formed on the lower surface of the base material20(in the example ofFIG. 6, the surface corresponding to the placement surface12of the palette100) can be controlled.

FIG. 7Bis a figure for explaining a distance D between an injection surface of a side surface-injection apparatus310and the frame body302. By adjusting the distance D, the distance between injection ports311and the resin shaped body can be adjusted. That is, by adjusting the distance D, the thickness of a coating layer22to be formed on a side surface of the base material20can be controlled.

FIG. 7Cis a figure for explaining a height H2of an injection surface of the top surface-injection apparatus314. By adjusting the height H2of the injection surface, the distance between injection ports311and the resin shaped body can be adjusted. That is, by adjusting the height H2, the thickness of the coating layers22to be formed on the top surface of the base material20(in the example ofFIG. 6, the surface corresponding to the rear surface14of the palette100) can be controlled.

The control apparatus308shown inFIG. 6controls these height H1, distance D and height H2. Thereby, the thicknesses of the coating layers22formed on the respective surfaces of the resin shaped body can be controlled independently. The thicknesses of the coating layers22formed on the respective surfaces of the resin shaped body may be uniform or may be different from each other. For example, the coating layer22formed on the placement surface12of the palette100may be thicker than a coating layer22formed on a side surface of the palette100. Thereby, the strength of the coating layer22to contact an article can be increased.

In the present example, the thickness of the coating material formed on the front surfaces of the base material20at the injection step S206is made proportional to the expansion ratio of the foamed synthetic resin forming the base material20. The control apparatus308controls the thickness of the coating material by adjusting at least one of the speed of conveyance of the base material20and the distance between the injection ports of each injection apparatus and the base material20. For example, if it is desired to increase the thickness of the coating material, the control apparatus308lowers the speed of conveyance of the base material20or make the distance between the injection ports of each injection apparatus and the base material20smaller. The distance can be adjusted based on the above-mentioned height H1, distance D and height H2.

Assuming that the speed of conveyance of the base material20by the rollers306is V, and the distance between the base material20and the injection ports of each injection apparatus is L, the film thickness T1of a coating layer22is inversely proportional to V and inversely proportional to L2. That is, T1is inversely proportional to V×L2. The control apparatus308may set the speed of conveyance V and distance L based on this relationship. For example, if the thickness of the coating layer22is to be doubled, the speed of conveyance V may be set to a half speed, and the distance L may be set to 0.51/2-fold.

In addition, the control apparatus308may adjust the distance between the injection ports of each injection apparatus and the base material20according to the width, length and height of the resin shaped body. For example, the larger the resin shaped body is, the longer the distance is made, to inject the coating material over a wide range uniformly.

If the palette100for physical distribution is to be manufactured, the length and width of the palette100is stipulated as 1100 mm by JIS, for example. The height H1, distance D and height H2of each injection apparatus are preferably able to be changed in a range that allows manufacturing of resin shaped bodies with the size.

FIG. 8is a side view of the manufacturing apparatus300. The manufacturing apparatus300has a coating preparation region, a coating region and a drying region. A heated and pressed base material20is conveyed to the coating preparation region. The base material20passes the coating region in which the side surface-injection apparatuses310, the lower surface-injection apparatus312and the top surface-injection apparatus314are arranged. Thereby, the coating material is stacked on all the surfaces of the base material20.

The coating region may be provided with a cover to prevent the coating material from scattering about. The cover preferably surrounds a region in which at least the side surface-injection apparatuses310, the lower surface-injection apparatus312and the top surface-injection apparatus314are provided.

The base material20having passed the coating region is conveyed to the drying region. One or more drying portions318are arranged in the drying region. The drying portions318are fans, for example. The drying portions318feed air to the coating material formed on the front surfaces of the base material20. The manufacturing apparatus300of the present example has auxiliary members316for the respective rollers306in the coating region.

FIG. 9is a side view showing one example of the auxiliary members316. On the side opposite to the conveyance surface for the base material20, the auxiliary members316are arranged to face the respective rollers306. In the present example, a first auxiliary member316-1and a second auxiliary member316-2are provided to each roller306.

The first auxiliary member316-1is arranged upstream of the second auxiliary member316-2in the direction of rotation of the rollers306. The first auxiliary member316-1causes the coating material adhered onto the front surface of the roller306to be detached from the roller306. The first auxiliary member316-1may have a detaching portion that contacts the front surface of the roller306to scrape off the coating material corresponding to rotation of the roller306. The detached coating material is discharged from an outlet320.

The second auxiliary member316-2applies a detaching material, which facilitates detachment of the coating material, onto the front surface of the roller306. The detaching material is oil, for example. The second auxiliary member316-2may have an applying portion that contacts the front surface of the roller306to apply a detaching material corresponding to rotation of the roller306.

If the apparatus shown inFIG. 5AtoFIG. 8is used, a polyurea resin is injected from injection apparatuses that are installed at an upper portion, a lower portion and side portions of a roller conveyer, while the base materials20having a standardized structure and size are moved on the roller conveyer. Thereafter, the polyurea resin is dried to form the polyurea resin coating layers22on the front surfaces of the base materials20. Such a method allows mass production of resin shaped bodies with uniform quality in a short time.

FIG. 10Ais a perspective view showing another structural example of the palette100. The palette100of the present example has positioning portions17in addition to the structure of the palette100shown inFIG. 1. The positioning portions17are provided to the placement surface12. The positioning portions17define positions of the foot portions16of another palette100if the other palette100is placed on the placement surface12. The positioning portions17are also formed of the base material20and the coating layers22, similar to other members of the palette100. The positioning portions17may be formed integral with the body portion10or may be bonded to the body portion10.

The positioning portions17of the present example are provided at the respective corners of the placement surface12. The positioning portions17are each formed over a predetermined length along two sides that are orthogonal to each other at a corner of the placement surface12. The length of a positioning portion17at each side of the placement surface12may be the same as the length of the foot portions16. The foot portions16of the present example have a length11, a width w1and a height h1. The length and width of the positioning portions17may be the same as those of the foot portions16. The height of the positioning portions17is smaller than the height h1of the foot portions16. For example, the height of the positioning portions17is equal to or smaller than half of the height of the foot portions16.

In the present example, the length l and width w of the body portion10are equal to each other. In one example, the length l and width w of the body portion10is 1100 mm. In addition, the height h2of the body portion10is 30 mm. In addition, the length11, width w1and height h1of the foot portions16are 100 mm. In addition, an interval p between the respective foot portions16is 400 mm.

FIG. 10Bis a perspective view showing two stacked palettes100. The positions of the foot portions16of an upper palette100-2are defined by the positioning portions17of a lower palette100-1.

FIG. 11is a perspective view showing another structural example of the palette100. The palette100of the present example has positioning portions18in addition to the structure of the palette100shown inFIG. 1. The positioning portions18are provided to the placement surface12. The positioning portions18are provided at positions to face the respective foot portions16.

The positioning portions18are hollows provided to the placement surface12. The depth of the positioning portions18is smaller than the thickness of the body portion10. That is, the positioning portions18do not penetrate the body portion10. The depth of the positioning portions18is equal to or smaller than half of the thickness of the body portion10, for example. In addition, a length12and width w2of the positioning portions18are equal to or slightly larger than the length11and width w1of the foot portions16. Such a structure also can facilitate stacking of a plurality of the palettes100.

FIG. 12is a perspective view showing another structural example of the palette100. An ID device19is fixed to the palette100of the of the present example. The ID device19stores information identifying the palette100, and transmits the identification information to the outside. For example, by bringing a reading apparatus close to the ID device19, it reads out the identification information of the palette100.

In the palette100, a plurality of the ID devices19may be provided symmetrically about the middle of the body portion10. For example, the ID devices19may each be provided to the middle of each side of the body portion10. Thereby, identification information can be read out from the ID devices19, without having to take the orientation of the palette100into consideration. The ID devices19may be embedded in the foot portions16. The ID devices19of the present example can be applied to any of the examples shown inFIG. 1,FIG. 10AandFIG. 11.

In addition, in the palette100shown inFIG. 1,FIG. 10AandFIG. 11, the respective foot portions16may have cavities. Thereby, the palette100can further be made light-weight. In addition, the ID devices19may be housed in the cavities. In addition, the ID devices19may be pasted onto the rear surface of the body portion10.

In addition, the ID devices19may store information indicting the condition of the palette100such as positional information. The information may be written by an external writing apparatus. The ID devices19may send the information at a predetermined cycle using Bluetooth® Low Energy (BLE), for example. A built-in receiver in a mobile terminal or the like may receive the information. The mobile terminal may transmit the received information to a cloud server or the like. By accessing the cloud server with the mobile terminal or the like, the conditions of the respective palettes100can be grasped.

FIG. 13is a perspective view showing an array example of the foot portions16on the rear surface14of the body portion10. The present example corresponds to the palette100shown inFIG. 1. Among the plurality of foot portions16, foot portions16that are provided along the circumference of the body portion10are arranged to be flush with the side surface of the body portion10. In addition, a foot portion16is arranged on the inner side of the body portion10, at the same interval from the circumference of the body portion10.

FIG. 14is a perspective view showing another array example of the foot portions16. The present example corresponds to the palette100shown inFIG. 10AandFIG. 11. Among the plurality of foot portions16, foot portions16that are provided along the circumference of the body portion10are arranged on the inner side relative to the side surfaces of the body portion10. Thereby, if the palettes100are stacked, the foot portions16of an upper palette100are positioned by the positioning portions of a lower palette100. A foot portion16is arranged on the inner side of the body portion10, at the same interval from the circumference of the body portion10.

FIG. 15Ais a figure showing one example of a surface condition of the palette100.FIG. 15Bis a figure showing another example of a surface condition of the palette100. The front surface of the palette100shown inFIG. 15A(that is, a front surface of a coating layer22) is less uneven than a front surface of the palette100shown inFIG. 15B.

The condition shown inFIG. 15Bcan be realized by injecting the coating material multiple times with different injection amounts. Specifically, first, the coating material is injected onto all the surfaces of the base material20at a predetermined injection amount. Thereby, the front surface of the palette100attains a less uneven condition shown inFIG. 15A.

Next, the coating material is injected onto the base material20with an injection amount of the coating material reduced from the first coating. At this time, the injection amount of the coating material is reduced, to the extent that the coating material adheres sparsely onto the front surfaces of the base material20. Thereby, the front surface of the palette100attains the condition shown inFIG. 15B.

The control apparatus308shown inFIG. 6may control the unevenness condition of the front surfaces of resin shaped bodies according to uses of the resin shaped bodies. For example, if it is desired to increase a coefficient of friction of a surface, a more uneven coating layer22is formed on the surface. In addition, if it is not necessary to increase a coefficient of friction of a surface, a less uneven coating layer22is formed on the surface. A less uneven coating layer22can attain a condition which resembles a mirror surface, and can realize an antibacterial action. For example, relatively more uneven coating layers22are formed on the placement surface12and rear surface14of the palette100, and relatively less uneven coating layers22are formed on side surfaces.

FIG. 16is a perspective view showing one example of a box400according to a second embodiment of the present invention. The box400has an internal space406. The box400of the present example has a housing portion404and a lid portion402. A hollow as the internal space406is formed in the housing portion404. The lid portion402is placed at an upper portion of the housing portion404to close up the internal space406tightly. The lid portion402may be fixed to the housing portion404by part of the lid portion402being inserted into the internal space406. The box400is used as a cooler box to house perishable foodstuff or the like, for example, but this is not the sole use of the box400.

FIG. 17is a figure showing partial cross-sections of a lid portion402and a housing portion404. The lid portion402and the housing portion404have the base materials20and coating layers22, similar to the palette100shown inFIG. 2. The base materials20have shapes that are similar to those of the lid portion402and housing portion404shown inFIG. 16.

The coating layers22cover the front surfaces of the base materials20. The coating layers22of the present example cover all the surfaces of the base materials20corresponding to the lid portion402and the housing portion404. For example, the coating layers22are formed on the entire outer surface of the box400and are formed on the entire inner wall of the internal space406.

In addition, a coating layer22is formed also on a surface that is part of the lid portion402and faces the housing portion404as shown inFIG. 17. In addition, a coating layer22is formed also on the surface that is part of the housing portion404and faces the lid portion402.

The coating layers22at the outer surfaces of the box400may be more uneven than the coating layers22at the inner walls of the internal space406. Thereby, the coefficient of friction of the outer surfaces of the box400is increased to facilitate carriage or the like, and an antibacterial condition of the inner walls of the internal space406can be attained. Such a structure makes it possible to provide a light-weight and high strength box400.

FIG. 18is a plan view showing one example of a gear500according to a third embodiment of the present invention. The gear500is attached to a target such as a living body. The gear500shown inFIG. 18is a protector to cover at least part of the chest and abdomen of a human body.

The gear500of the present example has a body502, shock absorbing portions504and fixing portions506. The body502may be formed of a material softer than the shock absorbing portions504. The fixing portions506fix the body502to the target. The fixing portions506are belts or the like.

The shock absorbing portions504are provided to a partial region of the body502. The shock absorbing portions504may be fit into a region formed by hollowing out part of the body502or may be pasted onto the front surface of the body502. The gear500may not have the body502, but be entirely the shock absorbing portions504.

FIG. 19is a figure showing a partial cross-section of a shock absorbing portion504. The shock absorbing portion504has the base material20and coating layers22, similar to the palette100shown inFIG. 2. The base material20has a shape similar to that of the shock absorbing portions504shown inFIG. 18.

The coating layers22cover the front surfaces of the base material20. The coating layers22of the present example cover all the surfaces of the base material20. Such a structure makes it possible to provide a light-weight and high strength gear500.

FIG. 20is a figure showing another example of a partial cross-section of the palette100shown inFIG. 1. Similar toFIG. 2,FIG. 20shows a cross-section at part of the body portion10. The palette100of the present example further includes a fiber sheet30, in addition to the base material20and coating layers22shown inFIG. 2.

The fiber sheet30is provided between the base material20and a coating layer22. The fiber sheet30may have a higher cutting strength than that of the coating layers22. In addition, the fiber sheet30may be more fire-resistant than the coating layers22are. The fiber sheet30may be a sheet containing carbon fibers formed by carbonizing fibers formed of a predetermined material. In addition, the fiber sheet30may be a basalt fiber sheet. The basalt fiber sheet is a sheet containing fibers formed by melting basalt.

While containing silicon dioxide (SiO2) as its main component, the basalt fiber sheet contains aluminum oxide (Al2O3), calcium oxide (CaO), magnesium oxide (MgO), sodium oxide (Na2O), potassium oxide (K2O), titanium oxide (TiO2), ferric oxide Fe2O3+FeO) or the like. The content percentages by weight ratio of the respective components are as follows: SiO2: approximately 51 to 60%; Al2O3: approximately 14 to 19%; CaO: approximately 5 to 10%; MgO: approximately 3 to 6%; Na2O+K2O: approximately 3 to 6%; TiO2: approximately 0 to 3%; and Fe2O3+FeO: approximately 9 to 14%. The basalt fiber sheet may further contain other components.

The fiber sheet30is provided at least in a partial region of the placement surface12of the palette100. The fiber sheet30may be provided also on the rear surface14of the palette100or may be provided on side surfaces.

The fiber sheet30may be thinner than the coating layers22. The thickness of the fiber sheet30may be equal to or smaller than 1 mm, or may be equal to or smaller than 0.6 mm. By using such a fiber sheet30, the strength of the palette100can be enhanced without having to increase its thickness much.

In addition, the volume of space included in a unit volume of the fiber sheet30may be smaller than the volume of bubbles contained in a unit volume of the base material20. That is, it may be more difficult for a material for forming a coating layer22to be soaked into the fiber sheet30than into the base material20. Thereby, while enhancing the strength of the palette100, the amount of the coating material required to form the coating layers22with a predetermined thickness can be reduced.

FIG. 21is a figure showing an example of a range in the palette100over which the fiber sheet30is provided. InFIG. 21, a range over which the fiber sheet30is provided is hatched. In the palette100of the present example, the fiber sheet30is provided to the entire placement surface12of the palette100. In addition, the fiber sheet30is not provided to surfaces other than the placement surface12. Thereby, the strength of the surface on which articles are placed can be enhanced.

FIG. 22is a figure showing another example of the range in the palette100over which the fiber sheet30is provided. In the palette100of the present example, the fiber sheet30is provided in regions of the placement surface12that are other than regions to face the foot portions16. In addition, the rear surface and side surfaces of the palette100are not provided with the fiber sheet30. Thereby, portions with relatively low strengths against a load from above can be reinforced. In addition, by forming a coating layer22with a uniform thickness on the fiber sheet30in a pattern shown inFIG. 22, hollows can be formed in regions where the fiber sheet30is not arranged. The hollows can also be used as the positioning portions18shown inFIG. 11.

FIG. 23is a figure showing another example of a range in the palette100over which the fiber sheet30is provided. In the palette100of the present example, the fiber sheet30is provided at edge portions of the placement surface12. In addition, the fiber sheet30is not provided to portions other than the edge portions of the placement surface12. Thereby, portions with relatively insufficient strengths can be reinforced, and the amount of the fiber sheet30to be used can be reduced.

FIG. 24is a figure showing another example of a partial cross-section of the box400shown inFIG. 16. In the box400of the present example, a front surface of the base material20on an outer surface408side of the box400is covered with a coating layer22. In addition, a front surface of the base material20on the inner wall410in the internal space is covered with an inner wall coating layer40.

As mentioned above, the coating layers22are a polyurea resin. In addition, the inner wall coating layer40is a layer of a paint containing ceramic powders, or the like. Ceramic powders are powders that exhibit an antibacterial action. Ceramic powders may be powders formed by coating a carbide such as charcoal or bamboo charcoal with a ceramic, may be powders formed by coating another material that exhibits an antibacterial action with a ceramic, or may be powders formed by causing ceramic particles to support a material that exhibits an antibacterial action such as silver ions.

Such a structure can enhance an antibacterial action of the internal space to house articles. On the outer surface408side, the fiber sheet30may be provided between a coating layer22and the base material20. The fiber sheets30can be provided as appropriate between the coating layers22and the base material20in the respective embodiments explained with reference toFIG. 1andFIG. 24.

In addition, on the inner wall410side of the box400, between the inner wall coating layer40and the base material20, a coating layer22may be provided, and a coating layer22and a fiber sheet30may be provided. Thereby, the strength of the base material20on the inner wall410side can also be enhanced.

EXPLANATION OF REFERENCE SYMBOLS