Manufacturing method for board members with a surface coating.

Abstract

The present invention provides a method for manufacturing a surfaced board member that allows for the beautiful and stable application of a surface coating to corners, even when the base material has corners at its ends. [Solution] A method for manufacturing a board member 10 in which the first surface 11A of a base material 11 is covered with a surface skin 20 comprising a first portion 22 extending from a first edge 12, a second portion 23 extending from a second edge 13, and a third portion 24 located between the first portion 22 and the second portion 23, comprising an overlapping step of overlapping the surface skin 20 onto the first surface 11A, a first folding step of folding the first portion 22 back along the first edge 12, and overlapping The following steps are performed in order: a pin insertion step in which positioning pins 30 are inserted all at once into the third portion 24 which is in a fixed state; a clamping step in which the superimposed third portion 24 is clamped all at once; a retraction step in which the positioning pins 30 are retracted; a second folding step in which the second portion 23 is folded back along the second edge 13 while moving the chuck 31 so that the superimposed portion 24L overlaps the second surface 11B; and a welding step in which the superimposed surface 20 is welded together.

Description

Technical Field

[0001] The technology disclosed in this specification relates to a method for manufacturing a board member with a skin.

Background Art

[0002] Conventionally, a board member with a skin in which one side of a plate-shaped base material is covered with a skin is known. In Patent Document 1, an example of a method for covering the surface of a base material having an undercut portion with a skin material is disclosed. Specifically, Patent Document 1 discloses a method in which the base material is placed on the mold surface of the lower mold of a vacuum forming mold, the end of the skin material is clamped by a chuck device, the skin material is placed over the surface of the base material, and then the upper mold supporting the slide member is lowered. At this time, when the upper mold has descended to a predetermined height, the skin material is released, and after the upper mold is completely closed, the slide mold is moved, so that the end of the skin material is sandwiched between a fixed plate provided at the lower end of the slide member and a wrinkle suppressing surface of the lower mold, and the skin material can be shaped following the base material while being stretched without generating wrinkles.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, for example, at the end of an interior material for a vehicle, a process is performed to wind the skin protruding from the outer periphery of the base material to the back side of the base material. Even during such a process, a device that clamps the end of the skin with a chuck device and winds it by pulling it to the back side of the base material is used. However, when the base material has a corner at the end, it is difficult to properly wind the skin at the corner.

[0005] Specifically, the process involves gripping the outer layer of the base material at the corner and pulling it inward towards the corner to wrap it up. However, the outer layer may protrude from the corner or lift away from the surface of the base material around the corner, resulting in a reduced appearance. Furthermore, if the outer layer protrudes from the base material, a gap may form between it and adjacent components during assembly. In addition, when chucking a soft and unstable outer layer, the chuck's position may be unstable due to the bending of the outer layer, resulting in variations in the quality of the resulting interior materials for vehicles. Ultimately, this makes automation difficult.

[0006] The technology disclosed herein was developed based on the circumstances described above, and aims to provide a method for manufacturing a surfaced board member that can beautifully and stably coat the corners of the substrate even when the substrate has corners at its ends. [Means for solving the problem]

[0007] A technology disclosed herein, completed to solve the above problems, is a method for manufacturing a skinned board member in which the first surface of a plate-shaped substrate having a first side and a second side adjacent to the first side is covered with a skin comprising: a first portion extending outward from the first side of the substrate; a second portion extending outward from the second side of the substrate; and a third portion located between the first portion and the second portion outside the corner between the first and second sides, comprising: an overlapping step of overlapping the skin onto the first surface of the substrate; a first folding step of folding the first portion of the skin back along the first side toward the second surface opposite to the first surface; and the surface The process involves sequentially performing the following steps: a pin insertion step in which positioning pins are inserted all at once into the third portion of the leather that has been placed in an overlapping state by the first folding step; a clamping step in which the overlapping third portion is clamped all at once by a chuck at a position in the overlapping third portion that is more adjacent to the base material than the positioning pins; a retraction step in which the positioning pins are retracted from the third portion; a second folding step in which the second portion is folded back towards the second surface along the second edge while the chuck is moved so that the overlapping third portion overlaps the second surface; and a welding step in which the first portion, third portion, and second portion that have been placed in an overlapping state by the second folding step are welded together.

[0008] According to the above manufacturing method, the outer layer that is wrapped around the second surface of the base material at the corners of the base material can be folded back to the second surface by the second folding step in a state where the overlapping third portion, which was created by the first folding step, does not shift. This prevents the wrapped outer layer from protruding outside the base material from around the corners, and prevents the outer layer from lifting away from the surface of the base material around the corners. In other words, the outer layer can be wrapped around the corners of the base material beautifully.

[0009] Furthermore, during the second folding process, a positioning pin is inserted through the overlapping third portion, and then it is clamped by a chuck. This allows the surface to be stably clamped in the predetermined position without causing the overlapping third portion to shift position. Consequently, the quality of the resulting surface-covered board member is stabilized, and the winding process can be automated.

[0010] In the third portion, two insertion holes may be formed in advance at the position through which the positioning pin is inserted. In the first folding step, the first portion may be folded so that the two insertion holes coincide, and in the pin insertion step, the positioning pin may be inserted into both insertion holes at once. With such a manufacturing method, the position through which the positioning pin is inserted can be set more accurately.

[0011] Vertical walls are formed on the first and second sides of the base material, rising toward the second surface side, and a notch is provided in the second vertical wall rising from the second side, with the third portion being housed in the notch during the second folding process.

[0012] According to the above manufacturing method, even when the base material has vertical walls, the corners can be beautifully finished by housing the skin (third portion) that is wrapped around the corners of the base material within the notches. Furthermore, when the base material is viewed from the side (vertical wall side), the skin that is wrapped around the second surface side is hidden inside the vertical wall, thus improving the appearance. [Effects of the Invention]

[0013] According to the technology disclosed herein, it is possible to provide a method for manufacturing a surfaced board member that can beautifully and stably coat the corners of a substrate even when the substrate has corners at its ends. [Brief explanation of the drawing]

[0014] [Figure 1]Perspective view of the base material of the trim board member of Embodiment 1 viewed from the second surface side [Figure 2] Figure showing the state where the skin is overlapped on the first surface of the base material (overlaying step) [Figure 3] Figure showing the state where the first part of the skin is folded back to the second surface side along the first side (first folding-back step) [Figure 4] Figure showing the state where the positioning pin is inserted through the pin insertion hole (pin insertion step) [Figure 5] Figure showing the state where the overlapping part of the third part of the skin is clamped by a chuck (clamping step) [Figure 6] Figure showing the state where the positioning pin is retracted (retraction step) [Figure 7] Figure showing the state where the second part of the skin is folded back to the second surface side along the second side and the overlapping part of the third part is folded back so as to overlap the second surface and welded (second folding-back step and welding step) [Figure 8] Figure showing the state where the positioning pin of Embodiment 2 is retracted (retraction step) [Figure 9] Figure showing the state where the overlapping part of the third part of the skin is folded back so as to overlap the second surface (second folding-back step) [Figure 10] Figure showing the state where the second part of the skin is folded back to the second surface side along the second side and welded (second folding-back step and welding step) [Figure 11] Perspective view of the base material of the trim board member of Embodiment 3 viewed from the second surface side [Figure 12] Figure showing the state where the first part of the skin is folded back to the second surface side along the first side and the positioning pin is inserted through the pin insertion hole (first folding-back step and pin insertion step) [Figure 13] Figure showing the state where the overlapping part of the third part of the skin is clamped (clamping step) [Figure 14] Figure showing the state where the overlapping part of the third part of the skin is folded back so as to overlap the second surface and the second part is folded back along the second side and welded (second folding-back step and welding step)

Mode for Carrying Out the Invention

[0015] <Embodiment 1> Embodiment 1 will be described with reference to FIGS. 1 to 8. In this embodiment, as a board member with skin, a trim board member 10 that constitutes a door trim for a vehicle such as an automobile and a manufacturing method thereof will be exemplified.

[0016] The door trim includes a plurality of trim board members (an example of a board member with skin) 10 assembled to each other. The trim board member 10 includes a plate-like base material 11 formed of a synthetic resin material such as polypropylene or ABS, and a skin 20 that covers a surface (hereinafter referred to as the first surface 11A) of the base material 11 disposed on the vehicle interior side. Note that the base material 11 is not limited to a synthetic resin material, and may be, for example, a mixture of a wood-based material (such as bast plant fibers such as kenaf) and a synthetic resin.

[0017] FIG. 1 is a perspective view of the base material 11 viewed from the side of the surface (hereinafter referred to as the second surface 11B) disposed on the vehicle exterior side. As shown in this figure, the base material 11 has a substantially flat plate shape that is slightly long and substantially triangular. Specifically, the substantially triangular base material 11 has a first side 12 that constitutes one side thereof, and a second side 13 that is disposed adjacent to the first side 12 and extends in a direction different from the first side 12. The corner 14 between the first side 12 and the second side 13 is an acute angle.

[0018] The skin 20 covers the first surface 11A of the base material 11 and constitutes the design surface of the trim board member 10. The skin 20 is formed of a sheet-like member having flexibility and stretchability, such as fabric, synthetic leather, or a synthetic resin sheet. The skin 20 may have a configuration in which the back surface of these sheet-like members is lined with various functional layers such as a cushion layer or a non-breathable layer. The skin 20 is attached to the base material 11 via an adhesive. The skin 20 is in a state of being wound around the second surface 11B side of the base material 11 by folding back a portion extending from the edge of the base material 11 (see FIG. 8).

[0019] Figure 2 shows the unfolded state of the skin 20 before it is wrapped around the second surface 11B of the base material 11. In the unfolded state, the skin 20 has a main surface covering portion 21 that covers the first surface 11A of the base material 11, a first portion 22 that extends outward from the first side 12 of the base material 11, a second portion 23 that extends outward from the second side 13 of the base material 11, and a third portion 24 that is located between the first portion 22 and the second portion 23 and extends outward from the corner 14 of the base material 11 to connect them. The extension dimension of the third portion 24 from the corner 14 is set to be longer than the extension dimension of the first portion 22 from the first side 12 and the extension dimension of the second portion 23 from the second side 13. Thus, the skin 20 is slightly larger than the base material 11.

[0020] Next, a method for covering the base material 11 with the above-described surface layer 20 (a method for manufacturing the trim board member 10) will be explained.

[0021] <Overlay process> First, a plate-shaped substrate 11 molded into a predetermined shape is prepared, and an adhesive layer (not shown) is formed on the first surface 11A side of this substrate 11. The adhesive layer may be formed by applying or spraying a liquid adhesive, or by attaching a solid adhesive such as a film or tape.

[0022] Next, the surface layer 20 is bonded to the base material 11 via the adhesive layer. Specifically, for example, the base material 11, with the adhesive layer facing upwards, and the sheet-like surface layer 20 cut to a predetermined shape are set between a pair of molds (not shown) of a predetermined shape so that the surface layer 20 faces the top of the base material 11, and the upper and lower molds are closed. If the surface of the base material 11 has irregularities, the surface layer 20 may be shaped to conform to the surface of the base material 11 using a vacuum suction device provided on the upper mold before closing the mold.

[0023] Figure 2 shows the state in which the base material 11 and the skin 20 are superimposed by the superimposing process, viewed from the second surface 11B side of the base material 11. As described above, the skin 20 is made to be slightly larger in dimensions than the base material 11. Also, as shown in the figure, the portion of the third part 24 of the skin 20 that extends from the first part 22 along the first side 12 is tapered to be narrower than the first part 22. In addition, the portion of the third part 24 of the skin 20 that extends from the second part 23 along the second side 13 is wider than the second part 23.

[0024] The second portion 23 of the epidermis 20 has a wedge-shaped notch 26 cut out from the edge of the epidermis 20, adjacent to the wider portion of the third portion 24. The third portion 24 of the epidermis 20 also has two pin insertion holes 25 side-by-side. These notches 26 and pin insertion holes 25 will be described in detail later.

[0025] <First folding process> As described above, once the skin 20 is overlapped and bonded to the first surface 11A of the base material 11, the first portion 22 of the skin 20 is then folded back along the first edge 12 of the base material 11 toward the second surface 11B side (exterior side of the vehicle interior) (see Figure 3). At this time, the third portion 24, which is connected to the first portion 22, is folded back continuously to its end (end of the skin 20). As a result, almost the entire first portion 22 is overlapped with the second surface 11B of the base material 11, and a portion of the third portion 24 of the skin 20 is folded in half and superimposed.

[0026] Hereinafter, the portion of the third part 24 that is in this superimposed state will be referred to as the superimposed portion 24L. The two pin insertion holes 25 described above are pre-formed in this superimposed portion 24L at positions that overlap in the thickness direction of the base material 11. In other words, the two pin insertion holes 25 are formed at positions that are symmetrical with respect to the extension line of the first side 12 of the base material 11 when the surface layer 20 is unfolded (the state in Figure 2).

[0027] <Pin insertion process> Next, the positioning pins 30 are inserted all at once into the pin insertion holes 25 (two pin insertion holes 25 that overlap in the thickness direction of the base material 11) as described above (see Figure 4). This ensures that the overlapping portion 24L (overlapping portion) of the third portion 24 is aligned by the positioning pins 30 so that it does not shift in the planar direction.

[0028] <Holding process> Next, the overlapping portion 24L is clamped collectively by the chuck 31 at a position within the overlapping portion 24L that is adjacent to the base material 11 (main surface covering portion 21) more than the positioning pin 30 (pin insertion hole 25) (see Figure 5). At this time, since the overlapping portion 24L is positioned in the surface direction by the positioning pin 30, displacement of the overlapping state is suppressed when the overlapping portion 24L is clamped.

[0029] <Evacuation process> Next, the positioning pin 30 is retracted from the pin insertion hole 25 (see Figure 6). At this time, since the superimposed portion 24L is held by the chuck 31, even if the positioning pin 30 is retracted, the superimposed state of the third portion 24 is prevented from shifting.

[0030] <Second Folding Process> Next, the chuck 31 is moved so that the overlapping third portion 24 (overlapping portion 24L) folds back the second portion 23 and third portion 24 of the skin 20 along the second side 13 of the base material 11 toward the second surface 11B side (exterior side of the vehicle interior) (see Figure 7). Specifically, the chuck 31 is moved so that the end portion 24E of the third portion 24 (the end portion of the extension of the first side 12) of the folded portion folded back in the first folding step aligns with the first side 12. At this time, by strongly pulling the chuck 31 in the direction along the first side 12 (lower right of Figure 7), the folded portion of the third portion 24 is stretched so that it fits snugly along the second side 13, and the inner edges of the wedge-shaped notches 26 abut against each other, resulting in a closed state.

[0031] As a result, the area around the corners 14 of the base material 11 is beautifully covered by the stretched surface 20 without any bulging. Furthermore, during this second folding process, the overlapping portion 24L is held in place by the chuck 31, so that the overlapping state does not shift in the planar direction and is superimposed on the second surface 11B via the first portion 22.

[0032] As described above, the notch 26 is pre-set to a position, shape, and dimensions such that the inner edges abut against each other during this second folding process.

[0033] <Welding process> Finally, the overlapping first part 22, third part 24, and second part 23 are fixed to each other or to the base material 11 by ultrasonic welding, and then the chuck 31 is released.

[0034] In this way, the skin 20 is folded back while maintaining the overlapping state of the overlapping portion 24L of the third portion 24, so that the finished trim board member 10 does not have the skin 20 protruding outside the end of the base material 11.

[0035] Next, the effects will be described. This embodiment is a method for manufacturing a trim board member 10 in which the first surface 11A of a plate-shaped base material 11 having a first side 12 and a second side 13 adjacent to the first side 12 is covered with a skin 20 comprising a first portion 22 extending outward from the first side 12 to the outside of the base material 11, a second portion 23 extending outward from the second side 13 to the outside of the base material 11, and a third portion 24 located between the first portion 22 and the second portion 23 on the outside of the corner 14 between the first side 12 and the second side 13, comprising an overlapping step of overlapping the skin 20 onto the first surface 11A of the base material 11, a first folding step of folding the first portion 22 of the skin 20 back along the first side 12 to the second surface 11B on the opposite side of the first surface 11A, and the skin 20 The process involves, in order, inserting positioning pins 30 all at once into the third portion 24 (overlapping portion 24L) which has been placed in an overlapping state by the first folding process; clamping the overlapping portion 24L of the overlapping third portion 24 at a position adjacent to the base material 11 than the positioning pins 30 using a chuck 31; retracting the positioning pins 30 from the third portion 24; moving the chuck 31 so that the overlapping portion 24L overlaps the second surface 11B, while folding the second portion 23 back along the second edge 13 towards the second surface 11B; and welding the first portion 22, third portion 24, and second portion 23 which have been placed in an overlapping state by the second folding process.

[0036] According to the above manufacturing method, the skin 20 that is wrapped around the corner 14 of the base material 11 to the second surface 11B side of the base material 11 can be folded back to the second surface 11B side by the second folding step in a state where the third portion 24 (overlapping portion 24L), which is in an overlapping state by the first folding step, does not shift. Therefore, it is suppressed that the wrapped skin 20 protrudes outside the base material 11 from around the corner 14, or that the skin 20 lifts up from the surface (first surface 11A) of the base material 11 around the corner 14. In other words, the skin 20 can be beautifully wrapped around the corner 14 of the base material 11.

[0037] Furthermore, during the second folding process, the positioning pin 30 is inserted through the superimposed third portion 24 (superimposed portion 24L) and then clamped by the chuck 31. This allows the surface 20 to be stably clamped in a predetermined position without causing the superimposed third portion 24 to shift position in the planar direction. Consequently, the quality of the resulting trim board member 10 is stabilized, and the winding process can be automated.

[0038] Furthermore, two pin insertion holes 25 are pre-formed in the third portion 24 at the positions through which the positioning pins 30 are inserted. In the first folding step, the first portion 22 is folded so that the two pin insertion holes 25 coincide, and in the pin insertion step, the positioning pins 30 are inserted into both pin insertion holes 25 simultaneously. This manufacturing method allows for more precise setting of the position through which the positioning pins 30 are inserted.

[0039] <Embodiment 2> Next, Embodiment 2 will be described with reference to Figures 8 to 10. In the following, only configurations that differ from Embodiment 1 will be described, and the same reference numerals will be used for components similar to those in Embodiment 1, and redundant explanations will be omitted.

[0040] In the above embodiment 1, a notch 26 is provided in the outer layer 20, but if a notch is not provided in the outer layer 120, the trim board member 110 can be manufactured as follows.

[0041] This embodiment is the same as Embodiment 1 up to the retraction step, but the folding method in the second folding step following the retraction step differs from that of the above embodiment. Specifically, in this embodiment, as shown in Figure 8, first, the third portion 24 is folded back at a position that passes through the corner 14 of the base material 11 (position of the two dashed line in Figure 8), and the chuck 31 is moved so that the end 24E of the folded portion of the third portion 24 (the end of the extension of the first side 12) overlaps with the first side 12 (see Figure 9). At this time, since the overlapping portion 24L that is folded back is held in an overlapping state by the chuck 31, the overlapping state does not shift in the planar direction and is superimposed on the second surface 11B via the first portion 22.

[0042] Next, the second portion 23 of the skin 120 is folded back along the second edge 13 of the base material 11 toward the second surface 11B side (exterior side of the vehicle interior) (see Figure 10). As a result, the first portion 22 of the skin 20, the third portion 24 which is folded into three, and the second portion 23 are superimposed in order at a position adjacent to the corner 14 of the second surface 11B of the base material 11.

[0043] Furthermore, the external shape of the third part 24 in its unfolded state before being folded in this manner is set so that when the third part 24 is finally folded in this manner, it does not protrude from the base material 11.

[0044] Furthermore, in this embodiment, in the second folding step, as shown in Figure 9, the third portion 24 is first folded so that it overlaps the second surface 11B of the base material 11 via the first portion 22, and then the second portion 23 is folded as shown in Figure 10. However, the second portion 23 may be folded first, and then the third portion 24 may be folded so that it overlaps the second surface 11B. In this case, the first portion 22 of the surface 20, the second portion 23, and the third portion 24, which is folded into four, are superimposed at a position adjacent to the corner 14 of the second surface 11B of the base material 11.

[0045] According to this manufacturing method of the embodiment, even if the epidermis 20 is not elastic, the epidermis 20 can beautifully and stably cover the corner portion 14.

[0046] <Embodiment 3> Next, Embodiment 3 will be described with reference to Figures 11 to 14. In the following, only configurations that differ from Embodiment 1 will be described, and configurations similar to Embodiment 1 will be denoted by the same reference numerals as in Embodiment 1 plus 30, and redundant explanations will be omitted.

[0047] The trim board member 40 of this embodiment differs from Embodiment 1 in that vertical walls 45 and 46 are provided on the first side 42 and second side 43 of the base material 41, rising toward the second surface 41B. Hereinafter, the vertical wall rising from the first side 42 will be referred to as the first vertical wall 45, and the vertical wall rising from the second side will be referred to as the second vertical wall 46 (see Figure 11).

[0048] Figure 12 is a perspective view showing the intermediate process of the skin 50 of this embodiment being wrapped around the second surface 41B side of the base material 41. Specifically, it is a perspective view showing the state after the pin insertion process in Embodiment 1. As shown in the figure, the skin 50 has a main surface covering portion 51 that covers the first surface 41A (interior surface) of the base material 41, a first portion 52 that extends outward from the first side 42 of the base material 41 and is folded back in a U-shape to wrap around the first vertical wall 45 from the outside, a second portion 53 that extends outward from the second side 43 of the base material 41 and is folded back in a U-shape to wrap around the second vertical wall 46 from the outside, and a third portion 54 that is located between the first portion 52 and the second portion 53 and extends outward from the corner portion 44 of the base material 41 to connect the two.

[0049] In Figure 12, pin insertion holes 55 are pre-formed in the overlapping portions (opposing portions) of the third portion 54, and positioning pins 60 are inserted through these pin insertion holes 55. As a result, the overlapping portions 54L of the third portion 54 (opposing portions that overlap in the thickness direction) are aligned by the positioning pins 60 so as not to shift in the plane direction.

[0050] Once the first portion 52 and third portion 54 of the skin 50 are folded back to the end so as to wrap around the first vertical wall 45 from the outside, and the positioning pin 60 is inserted through the pin insertion hole 55, as shown in Figure 12, the overlapping portion 54L is then clamped together by a chuck at a position within the overlapping portion 54L that is more adjacent to the base material 11 (main surface covering portion 51) than the positioning pin 60 (pin insertion hole 55) (clamping step). Figure 13 shows the state of the skin 50 when the overlapping portion 54L is clamped by the chuck, and the chuck is omitted in this figure for convenience. Even when clamping the third portion 54 (overlapping portion 54L) which is separated and facing each other as shown in Figure 12, the overlapping portion 54L is positioned in the planar direction by the positioning pin 60, so that the overlapping state does not shift.

[0051] Subsequently, the positioning pin 60 is retracted from the pin insertion hole 55 (retraction step), and the chuck is moved so that the superimposed third portion 54 (superimposed portion 54L) overlaps the second surface 41B, while the second portion 53 of the skin 50 is folded back towards the second surface 41B side (exterior side of the vehicle interior) along the second edge 43 of the base material 41, wrapping around the second vertical wall 46 from the outside (second folding step).

[0052] In this embodiment, a notch 47 is provided in the second vertical wall 46 at a position including the corner 44 formed between the second vertical wall 46 and the first vertical wall 45, and is cut out in a concave shape from the tip side in the rising direction of the second vertical wall 46. Therefore, the chuck is moved so that the folded second portion 53 and the third portion 54 connected thereto are pulled from the notch 47 towards the second surface 41B side of the base material 41 (see Figure 14). In this case as well, since the overlapping portion 54L is held in an overlapping state by the chuck, it remains in a state where it is superimposed on the second surface 41B of the base material 41 without shifting in the planar direction.

[0053] Finally, the overlapping first part 52, third part 54, and second part 53 are welded together and fixed in place by ultrasonic welding, and then the chuck is released.

[0054] Thus, in this embodiment as well, the surface layer 50 is folded back with the superimposed third portion 54 positioned in the planar direction, so that the finished board member does not have the surface layer 50 protruding outside the end of the base material 41. Furthermore, even when the base material 41 has vertical walls 45 and 46, the surface layer 50 (third portion 54) that is wrapped around the corner 44 of the base material 41 is housed in the notch 47, allowing the corner to be finished beautifully. In addition, when the base material 41 is viewed from the side (vertical wall 45 and 46 side), the surface layer 50 that is wrapped around the second surface 41B side is hidden inside the vertical walls 45 and 46, thus improving the appearance.

[0055] <Other Embodiments> The technologies disclosed herein are not limited to the embodiments described above in the description and drawings, but also include, for example, the following embodiments.

[0056] (1) In the above embodiment, a form was shown in which the surface layer 20, 50, 120 was applied to the base material 11, 41 having acute corners 14, 44, but the corners are not limited to acute angles, and may be right angles or obtuse angles.

[0057] (2) In the above embodiment, a configuration in which pin insertion holes 25, 55 are formed in the third portion in advance is shown, but the pin insertion holes may be drilled when inserting the pin through the superimposed third portion.

[0058] (3) In the above embodiment, trim board members 10, 40, and 110 that constitute a door trim for a vehicle were given as examples of surface-covered board members. However, the technology disclosed herein is not limited to trim board members for door trims, but can be applied in various ways to interior materials for vehicles such as pillar garnishes, ceiling materials, console boxes, dashboards, various instrument panels, and deck trims, as well as interior materials for vehicles such as railways, airplanes, and ships, and for applications other than interior materials for vehicles. [Explanation of Symbols]

[0059] 10,40,110: Trim board member (board member with surface) 11,41: Base material 11A,41A: First surface 11B,41B: Second surface 12,42: First edge 13,43: Second edge 14,44: Corner 20,50,120: Surface 21,51: Main surface covering 22,52: First part 23,53: Second part 24,54: Third part 24E: End 24L,54L: Overlapping part 25,55: Pin insertion hole 30,60: Positioning pin 31: Chuck 45: First vertical wall 46: Second vertical wall 47: Notch

Claims

1. A method for manufacturing a surfaced board member, wherein the first surface of a plate-shaped base material having a first side and a second side adjacent to the first side comprises a first portion extending outward from the first side of the base material, a second portion extending outward from the second side of the base material, and a third portion located between the first portion and the second portion on the outside of the corner between the first and second sides, the surface of which is covered with a surface, A superimposing step of superimposing the surface layer onto the first surface of the substrate, A first folding step in which the first portion of the surface is folded back along the first edge towards the second surface on the opposite side of the first surface, A pin insertion step involves inserting positioning pins collectively through the third portion of the skin that has been made into an overlapping state by the first folding step, A clamping step in which the superimposed third portion is clamped collectively by a chuck at a position adjacent to the base material than the positioning pin among the superimposed third portion, A retraction step of retracting the positioning pin from the third portion, A second folding step involves moving the chuck so that the superimposed third portion overlaps the second surface, while folding the second portion back along the second edge toward the second surface, A method for manufacturing a surfaced board member, comprising: a welding step of welding the first part, third part, and second part, which are in a state of being overlapped by the second folding step, in order.

2. Of the third portion, two insertion holes are pre-formed at the position through which the positioning pin is inserted. In the first folding step, the first portion is folded back so that the two insertion holes coincide, The method for manufacturing a surfaced board member according to claim 1, wherein in the pin insertion step, the positioning pins are inserted simultaneously into the two insertion holes.

3. Vertical walls are formed on the first and second sides of the substrate, rising toward the second surface, and a notch is provided in the second vertical wall that rises from the second side, cut out from the tip of the second vertical wall. A method for manufacturing a surfaced board member according to claim 1 or claim 2, wherein in the second folding step, the third portion is housed in the notch.

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