ACTUATING ELEMENT, IN PARTICULAR A HANDLE ELEMENT, OF AN INNER DOOR HANDLE ARRANGEMENT OF A VEHICLE AND METHOD FOR PRODUCING SUCH AN ACTUATING ELEMENT

Abstract

An actuating member (14), in particular a handle element, an interior door handle arrangement of a vehicle, wherein the actuating member (14) includes a carrier substrate (20) preferably made of plastic and a decorative layer (21) covering the surface of the carrier substrate (20). The decorative layer (21) includes a visible area (22) that in particular in the intended installed state, and in particular in the non-actuated state of the actuating member (14) forms a visible side of the actuating member (14), at least one gate region (2) in particular formed in a gate lip or gate tab (4), and at least one edge region or arcuate region (25, 26) by which the gate region (2) is preferably continuously connected to the visible area (22) of the decorative layer (21).

Claims

1. Actuating member (14), wherein the actuating member (14) comprises a carrier substrate (20) made of plastic and a decorative layer (21) at least regionally covering the surface of the carrier substrate (20), wherein the decorative layer (21) comprises: a visible area (22) which, in the intended installed state of the actuating member (14) and further in the non-actuated state of the actuating member (14), forms a visible side of the actuating member (14); at least one gate region (2) formed in a gate lip or gate tab (4); and at least one edge region or arcuate region (25, 26) by which the gate region (2) is continuously connected to the visible area (22) of the decorative layer (21).

2. The actuating member (14) according to claim 1, wherein the gate lip or gate tab (4), in which the at least one gate region (2) is formed, as seen in a top view, has an at least substantially U-shaped, V-shaped or wedge-shaped design, and wherein the gate lip or gate tab (4) tapers from the at least one edge region or arcuate region (25, 26) towards the at least one gate region (2); and/or wherein the gate lip or gate tab (4), in which the at least one gate region (2) is formed, is formed in an end region of the actuating member (14), and in a converging region of the actuating member (14).

3. The actuating member (14) according to claim 1, wherein, as seen in a top view onto the gate lip or gate tab (4), the gate lip or gate tab (4) has two boundary lines (5) diverging in relation to each other towards the at least one edge region or arcuate region (25, 26) and adjacent to the carrier substrate (20) that converge in the area of the at least one gate region (2), in a continuous manner and over at least two curved regions with constant curvature.

4. The actuating member (14) according to claim 3, wherein an angle is α spanned between the diverging boundary lines (5) in the direction of the at least one edge region or arcuate region (25, 26), wherein 90°>α>10° applies; and/or wherein each of the diverging boundary lines (5) comprises a curved region with a constant curvature into the at least one edge region or arcuate region (25, 26), wherein the curvature of the curved region, by the diverging boundary lines (5) each transition into the at least one edge region or arcuate region (25, 26), corresponds to the curvature of the at least one arcuate region by which the boundary lines (5) adjacent to the carrier substrate (20) converge.

5. The actuating member (14) according to claim 1, wherein the at least one edge region or arcuate region (25, 26) is selected between the at least one gate region (2) and the visible area (22) of the decorative layer (21) such that the decorative layer (21) is continuously redirected from the at least one gate region (2) to the visible area (22) by an angle β of at least 35° and more continuously redirected by an angle β of at least 45°; and/or wherein the at least one edge region or arcuate region (25, 26) is selected between the at least one gate region (2) and the visible area (22) of the decorative layer (21) such that the decorative layer (21) is continuously redirected from the gate region (2) to the visible area (22) by an angle β not to exceed 155° and more continuously redirected by an angle β not to exceed 145°.

6. The actuating member (14) according to claim 1, wherein the gate lip or gate tab (4) is formed in an area of the decorative layer (21) that is continuously connected to the visible area (22) of the decorative layer (21) by a single edge region or arcuate region (25), wherein the decorative layer (21) is redirected from the gate region (2) to the visible area (22) by the only edge region or arcuate region (25) by an angle β of at least 35° and preferably not to exceed 155°, and wherein the gate region (2) is formed by a straight-line tunnel gate (3).

7. The actuating member (14) according to claim 6, wherein the area of the decorative layer (21), in which the gate lip or gate tab (4) is formed, at least at the edge region or arcuate region (25) has a first average layer thickness B, and wherein the area of the decorative layer (21), in which the visible area (22) is formed, at least at the edge region or arcuate region (25) has a second average layer thickness A, wherein the first average layer thickness B is less than the second average layer thickness A, wherein the second average layer thickness A is 0.5 mm to 3.5 mm, and/or wherein the first average layer thickness B is 0.4 mm to 3.3 mm.

8. The actuating member (14) according to claim 6, wherein the gate region (2) is at least substantially round or oval and has an average diameter C, wherein the average diameter C of the gate region (2) is less than the average layer thickness B of the area of the decorative layer (21) in which the gate lip or gate tab (4) is formed, wherein the average diameter C of the gate region (2) is 0.3 mm to 3.1 mm, and/or wherein the average layer thickness B of the area of the decorative layer (21) in which the gate lip or gate tab (4) is formed is 0.4 mm to 3.3 mm.

9. The actuating member (14) of claim 6, wherein the gate lip or gate tab (4) transitions over an intermediate area (27) into the visible area (22) of the decorative layer (21), wherein the only edge region or arcuate region (25) is arranged between the intermediate area (27) and the visible area (22), wherein the decorative layer (21) has an average layer thickness B in the area of the gate lip or gate tab (4) and in the intermediate area (27), wherein the average layer thickness B is 0.4 to 3.3 mm.

10. The actuating member (14) according to claim 9, wherein the intermediate area (27) has an average length D that is greater than the average layer thickness A of the decorative layer (21) in the visible area (22), wherein the decorative layer (21) has an average layer thickness in the visible area (22) of 0.5 mm to 3.5 mm.

11. The actuating member (14) according to claim 1, wherein the gate lip or gate tab (4) is formed in an area of the decorative layer (21) that is connected by a first edge region or arcuate region (26) to an intermediate area (27) of the decorative layer (21), wherein the intermediate area (27) of the decorative layer (21) is continuously connected to the visible area (22) of the decorative layer (21) by a second edge region or arcuate region (25), wherein in the first edge region or arcuate region (26), the decorative layer (21) is redirected by an angle γ of at least 45°, and wherein in the second edge region or arcuate region (25) of the decorative layer (21), the decorative layer (21) is redirected by an angle β of at least 35° and not to exceed 155°.

12. The actuating member (14) according to claim 11, wherein the intermediate area (27) of the decorative layer (21) has an average layer thickness B, and wherein the visible area (22) of the decorative layer (21) at least at the edge region or arcuate region (25) has an average layer thickness A, wherein the average layer thickness B of the intermediate area (27) of the decorative layer (21) is less than the average layer thickness A of the visible area of the decorative layer (21), wherein the average layer thickness B of the intermediate area (27) of the decorative layer (21) at least in the edge region or the arcuate region (25) is in a range between 0.3 mm to 3.5 mm, and wherein the average layer thickness A of the visible area of the decorative layer (21) at least in the edge region or the arcuate region (25) is in a range between 0.4 mm to 3.7 mm.

13. The actuating member (14) according to claim 12, wherein the gate region (2) is formed at least substantially round or oval and has an average diameter C, wherein the average diameter C of the gate region (2) is less than the average layer thickness B of the intermediate area (27) of the decorative layer (21), wherein the average diameter C of the gate region (2) is in a range between 0.2 mm to 3.4 mm.

14. The actuating member (14) according to claim 1, wherein the decorative layer (21) is formed from a plastic material having pigments embedded therein.

15. Method for manufacturing an actuation member (14) according to claim 1, with a multi-component injection molding process, wherein the method comprises the following method steps: A) Manufacture a carrier substrate (20) from a first plastic in a first injection molding shot using a first mold half and a second mold half defining a first cavity, resulting in a first molded part; and B) Manufacture a decorative layer (21) in a second injection molding shot onto the first molded part onto an outer surface of the first molded part after a change of the second mold half to define a second cavity, resulting in a second molded part while the first molded part remains in the first mold half until the second molded part has been shot onto the first molded part, or wherein the method comprises the following method steps: A) Manufacture a decorative layer (21) from a first plastic in a first injection molding shot using a first mold half and a second mold half defining a first cavity, resulting in a first molded part; and B) Manufacture a carrier substrate (20) in a second injection molding shot onto the first molded part onto an outer surface of the first molded part after a change of the second mold half to define a second cavity, resulting in a second molded part while the first molded part remains in the first mold half until the second molded part has been shot onto the first molded part, wherein in the second injection molding shot, the heated injection molding compound of the second plastic is initially injected into a homogenization region in the mold cavity defined by the first molded part and the second mold half, wherein said homogenization region is selected such that a homogenization of the melt occurs and the volumetric flow of the melt is smoothed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0121] Exemplary embodiments of the invention are described in more detail below with reference to the accompanying drawings.

[0122] The drawing show in:

[0123] FIG. 1 a schematic illustration and an isometric view of an exemplary embodiment of the interior door handle arrangement according to the present invention;

[0124] FIG. 2 a schematic illustration and an isometric view, respectively of the actuating member or handle element of the interior door handle arrangement according to FIG. 1, in an enlarged view;

[0125] FIG. 3 a schematic illustration and a top view of the A-side of an exemplary embodiment of the actuating member according to the invention;

[0126] FIG. 4 a schematic illustration and a cross-sectional view of the exemplary embodiment of the actuating member according to the invention according to FIG. 3;

[0127] FIG. 5A a schematic illustration and a detail view of a region of the actuating member according to FIG. 4, to explain an exemplary embodiment of the gate region;

[0128] FIG. 5B a schematic illustration and a top view of the gate region in the exemplary embodiment according to FIG. 5A;

[0129] FIG. 6A a schematic illustration and a cross-sectional view of the gate region of an actuating member according to a further embodiment of the invention; and

[0130] FIG. 6B a schematic illustration and a top view of the gate region according to FIG. 6A.

DETAILED DESCRIPTION

[0131] Unless otherwise indicated, the same reference symbols in the figures refer to the same objects.

[0132] The interior door handle arrangement shown in FIG. 1 comprises a housing 10 that allows it to be mounted to a door of a vehicle, such as a passenger car or commercial truck.

[0133] The housing 10 comprises a handle recess 12 in which an actuating member 14, in the present example a handle element 14, is received in the resting position shown in FIG. 1. From this resting position, the handle element 14 can be pivoted with its right free end in FIG. 1 out of the handle recess 12 about a pivot axis, for example a vertical pivot axis. By means of a corresponding connection, the vehicle door is unlocked by pivoting out the handle element 14 so that the vehicle door can subsequently be opened by a vehicle occupant. As the handle element 14 is pivoted out, the vehicle occupant reaches into the handle recess 12 and grasps behind the handle element 14. In the example shown, the handle element 14 forms a handle lever. A speaker 16 that is surrounded by a bezel 18 is also integrated in the housing 10.

[0134] In the enlarged illustration of FIG. 2, it can be seen that the handle element 14 comprises a carrier substrate 20 facing away from the vehicle interior in the resting position and a decorative layer facing the vehicle interior, preferably a visible area 22.

[0135] The carrier substrate 20 forms the rear face of the handle element 14 to be grasped behind by a vehicle occupant, and the visible area 22 of the decorative layer forms the front face of the handle element 14 that is directly visible from the vehicle interior. On its left end in FIG. 2, the carrier comprises bearing devices 24, with which the handle element 14 can be pivoted on the housing 10.

[0136] The visible area 22 of the decorative layer is connected to the carrier substrate 20 with a substance-to-substance bond. In the example shown, the visible area 22 of the decorative layer has been injected onto the carrier substrate with a two-component injection molding method.

[0137] The carrier substrate 20 is made of a plastic, for example a reinforced plastic, such as a fiberglass-reinforced plastic. The plastic can comprise an embedded mineral filler or embedded metal particles, for example ferromagnetic metal particles, such that a vehicle occupant perceives a cool surface upon grasping behind the carrier substrate 20 to pivot the handle element 14 out of the handle recess 12 of the housing 10 and thus perceiving the impression of a metal.

[0138] Accordingly, the visible area 22 of the decorative layer can consist of a plastic (mold-in-metal color—MIMC) with metallic visual appearance.

[0139] However, the visible area 22 of the decorative layer could also consist of other plastics, for example, differently colored plastics or the like. The visible area 22 of the decorative layer could also have been bonded to the carrier substrate 20 in a substance-to-substance bond with an in-mold painting method.

[0140] In the example shown, the bezel 18 of the speaker 16 has also been injected into the housing 10 with a two-component injection molding method. For example, the bezel 18 can be comprised of the material used for the visible area 22 of the decorative layer.

[0141] The decorative layer, and in particular the visible area 22 of the decorative layer, is intended to be visible at least partially directly from the vehicle interior and faces the vehicle interior, wherein the handle element 14 has a front face facing the vehicle interior and a rear face facing away from the vehicle interior.

[0142] Referring now to the illustrations in FIG. 3 through FIG. 5B, an exemplary embodiment of the actuating member or handle element 14 is described in detail.

[0143] In detail, FIG. 3 shows a schematic illustration and a top view of the A-side of the exemplary embodiment of the actuating member or handle element 14, while FIG. 4 shows a schematic longitudinal cross-sectional view of the actuating member or handle element 14 according to FIG. 3.

[0144] As shown, the actuation member or handle element 14 according to the invention comprises a carrier substrate 20 made of a first plastic material and a decorative layer 21 covering the surface of the carrier substrate 20 at least regionally. It is in this case in particular provided that the decorative layer 21 not only comprises the visible area 22 (seen in FIG. 3), but also an edge region 23 of the actuating member or handle element 14.

[0145] Specifically, the edge region 23 is connected by an edge region or arcuate region 25 to the visible area 22 of the decorative layer 21, as can be seen from the cross-sectional view in FIG. 4.

[0146] The actuating member or handle element 14 according to this exemplary embodiment is preferably manufactured with a two-component injection molding method. It is in this case in particular provided that the plastic material of the decorative layer 21 is at least partially applied to the surface of the carrier substrate 20 and is bonded to the carrier substrate 20 in substance-to-substance bond.

[0147] In order to manufacture the actuation member or handle element 14, and in particular to form the decorative layer 21 on the regions of the surface of the carrier substrate 20, it is in particular provided that the plastic material of the decorative layer 21 is injected through gate channels as a heated injection molding compound into a corresponding mold cavity, wherein this mold cavity is regionally constrained by the carrier substrate 20 and at least one tool plate (not shown in the drawings).

[0148] To this end, an injection molding tool is used, which comprises at least one distributor channel, which leads to a gate region 2. The solution according to the invention in particular provides at least one point gate in order to form the decorative layer 21 at least regionally on the carrier substrate 20.

[0149] As will be described in more detail below, the solution according to the invention in particular provides an underfloor gate system, such as the so-called banana gate, to form the decorative layer 21 onto the carrier substrate 20, wherein the decorative layer 21 is injected such that the heated injection molding compound of the plastic material of the decorative layer 21 is homogenized and smoothed as a volumetric flow in the mold cavity corresponding to the decorative layer 21 before the heated injection molding compound reaches the area of the mold cavity that corresponds to the visible area 22 of the completed actuating member or handle element 14.

[0150] An exemplary embodiment for a possible injection is illustrated below with reference to the schematic drawings in FIG. 5A, and in FIG. 5B.

[0151] Specifically, FIG. 5A schematically shows the edge region or arcuate region 25 shown in FIG. 4 in an enlarged illustration, namely together with a gate channel 3 of the injection molding tool. The gate channel 3 in this case terminates in a region of the mold cavity that does not belong to the A-side of the actuating member or handle element 14 of the completed actuating member or handle element 14. The gate channel 3 instead terminates in a side region or edge region 23 that is connected to the visible area 22 of the actuation member or handle element 14 by the edge region or arcuate region 25.

[0152] As shown in the schematic cross-sectional view in FIG. 5A, the gate channel 3 can preferably comprise a cross-sectional shape converging in the direction of the gate region 2, such that the heated injection melt of the plastic material for the decorative layer 21 can be appropriately injected into the side region or edge region 23 of the mold cavity.

[0153] FIG. 5B shows a schematic top view of the gate region 2 of the gate channel 3 according to FIG. 5A.

[0154] Briefly summarized, it can be seen that the gate region 2 is formed in a gate lip or gate tab 4, wherein the gate region 2 is continuously connected to the visible area 22 of the decorative layer 21 by the edge region or arcuate region 25.

[0155] In particular, it is advantageous in this case that the gate lip or gate tab 4, in which the gate region 2 is formed, has an at least substantially U-shaped, V-shaped or wedge-shaped design as shown in a top view (see FIG. 5B). The gate lip or gate tab 4 in this case tapers from the edge region or arcuate region 25 towards the gate region 2.

[0156] In other words, in the top view shown in FIG. 5B onto the gate lip or gate tab 4, the gate lip or gate tab 4 comprises two boundary lines 5 diverging towards one another in the direction of the edge region or arcuate region 25 and adjacent to the carrier substrate 20, wherein the two boundary lines 5 converge in particular in a continuous manner in the area of the gate region 2.

[0157] This embodiment of the gate region 2 effectively forms a corresponding homogenization region in the mold cavity corresponding to the decorative layer 21. It is in this case advantageously provided that an angle a is spanned between the boundary lines 5 diverging in the direction of the edge region or arcuate region 25, wherein this angle is between 10° and 90°.

[0158] Of course, other angular ranges are also conceivable in this case.

[0159] The edge region or arcuate region 25 between the gate region 2 and the visible area 22 of the decorative layer 21 is selected such that the decorative layer 21 is preferably continuously redirected from the gate region 2 to the visible area 22 by an angle β of at least 35° and preferably by at least 45°.

[0160] In the embodiment illustrated in FIGS. 5A and 5B, the gate lip or the gate tab 4 is formed in an area of the decorative layer 21 that is continuously connected to the visible area 22 of the decorative layer 21 by a single edge region or arcuate region 25, wherein the decorative layer 21 is redirected by the edge region or arcuate region 25 from the gate region 2 to the visible area 22 by an angle of β of at least 35°. In this case, the gate region 2 is formed by a preferably straight-line tunnel gate (gate channel 3).

[0161] In order to form a corresponding homogenization region in the mold cavity that comprises the decorative layer 21 of the actuation member or handle element 14, it is preferably provided that the area of the decorative layer 21, in which the gate lip or gate tab 4 is formed, has a first layer thickness B at least at the edge region or arcuate region 25, wherein the area of the decorative layer 21 in which the visible area 22 is formed has at least an average second layer thickness A at the edge region or arcuate region 25.

[0162] In particular, it is provided that at least at the edge region or arcuate region 25, the first layer thickness B is less than the second layer thickness A. According to preferred embodiments, at least at the edge region or arcuate region 25, the second layer thickness A is preferably 0.5 mm to 3.5 mm, while the first layer thickness B is preferably 0.4 mm to 3.3 mm.

[0163] Furthermore, with regard to the most efficient homogenization of the melt of the second plastic material when it is introduced into the mold cavity, it is advantageous that the gate region 2 is preferably formed at least substantially round or oval (see the top view in FIG. 5B) and has an average diameter C, as illustrated in FIG. 5A.

[0164] The average diameter C of the gate region 2 should be less than the layer thickness B of the area of the decorative layer 21, in which the gate lip or gate tab 4 is formed.

[0165] According to conceivable realizations of the actuation member or handle element 14 according to the invention, the average diameter C of the gate region 2 is preferably 0.3 mm to 3.1 mm, while the layer thickness B of the area of the decorative layer 21 in which the gate lip or gate tab 4 is formed is preferably 0.4 mm to 3.3 mm. However, other dimensions for the respective diameters and layer thicknesses are of course also conceivable.

[0166] FIG. 6A and FIG. 6B show an alternative embodiment of the actuation member or handle element 14.

[0167] As also shown in the embodiments described with reference to the illustrations in FIG. 3 to FIG. 5B, the embodiment illustrated in FIG. 6 provides the gate region 2 for the decorative layer 21 in a region of the corresponding mold cavity that is different from the visible area 22 of the decorative layer 21.

[0168] In particular, the embodiment illustrated in FIG. 6A provides that the second plastic material of the decorative layer 21 is injected into the corresponding mold cavity through a banana gate 6.

[0169] The embodiment illustrated in FIG. 6A in particular differs from the embodiment shown in FIG. 5A in that the gate region 2 is formed in a gate lip or a gate tab 4 that is formed in an area of the decorative layer 21 connected by a first edge region or arcuate region 26 to an intermediate area 27 of the decorative layer 21, wherein the intermediate area 27 of the decorative layer 21 is preferably continuously connected to the visible area 22 of the decorative layer 21 by a second edge region or arcuate region 25. By providing such an intermediate area 27, a particularly efficient homogenization of the plastic melt can be effected when it is introduced into the mold cavity.

[0170] The first edge region or arcuate region 26 is preferably formed such that in the first edge region or arcuate region 26, the decorative layer 21 is redirected by an angle y of at least 45° and preferably by an angle γ of about 90°, wherein in the second edge region and arcuate region 25 of the decorative layer 21, the decorative layer 21 is redirected by an angle β of 35° and by an β angle not to exceed 155°.

[0171] FIG. 6B shows a top view of the gate lip or gate tab 4 of the gate region 2 of the exemplary embodiment according to FIG. 6A.

[0172] As with the gate lip or gate tab 4 schematically shown in FIG. 5B, the embodiment according to FIG. 6B provides that the gate lip or gate tab 4 in which the gate region 2 is formed as seen in a top view, has a design that is at least substantially U-shaped, V-shaped, or wedge-shaped, wherein the gate lip or gate tab 4 extends from the first edge region or arcuate region 26 towards the gate region 2.

[0173] In detail, as seen in a top view onto the gate lip or gate tab 4 (see FIG. 6B), the gate lip or gate tab 4 has two boundary lines 5 diverging in relation to each other in the direction of the first edge region or arcuate region 26 and adjacent to the carrier substrate 20, and which continuously converge in the area of the gate region 2.

[0174] In this embodiment, it is also preferred that an angle a is formed between the two boundary lines 5 diverging in the direction of the first edge region or arcuate region 26, wherein said angle is between preferably 10° and 90°.

[0175] The actuation member or handle element 14 is preferably manufactured with a multi-component injection molding method using the following steps:

[0176] A) Manufacture the carrier substrate 20 of the first plastic in a first injection molding shot using a first mold half and a second mold half that define a first cavity, resulting in a first molded part;

[0177] B) Manufacture the decorative layer 21 in a second injection molding shot onto the first molded part onto an outer surface of the first molded part after a change of the second mold half to define a second cavity, resulting in a second molded part while the first molded part remains in the first mold half until the second molded part has been shot onto the first molded part. The first molded part is in this case preferably held in the corresponding cavity by a slider that for example covers the holes for a pivot axis of the handle element.

[0178] In the second injection molding shot, the heated injection molding compound of the second plastic is initially injected into a homogenization region in the mold cavity defined by the first molded part and the second mold half, wherein said homogenization region is selected such that a homogenization of the melt occurs and the volumetric flow of the melt is smoothed.

[0179] The plastic melt then flows over the at least one edge region or arcuate region 25 towards the visible side of the actuating member, thereby forming the plastic melt of the visible area 22.

[0180] The invention in particular introduces an interior door handle/method for manufacturing such a door handle (actuating member). The latter comprises at least two plastic layers, namely a first plastic layer formed by the carrier substrate 20 and a second plastic layer formed by the decorative layer 21, wherein both plastic layers are bonded by injection molding. The first layer forms a rear face and the second layer forms a visible front face of the actuation member or handle element 14.

[0181] It is preferable that the first layer be formed by a first tool cavity, wherein the second layer is formed onto the first layer using a modified tool cavity, while the first layer remains in a region of the first cavity.

[0182] By injecting the second layer into the tool cavity such that homogenization of the plastic melt occurs first before it flows to the visible area of the actuating member/handle element, a surface structure of the visible area of particular quality can be achieved.

[0183] The invention is not limited to the embodiments shown in the drawings, but results when all of the features disclosed herein are considered together.

LIST OF REFERENCE SYMBOLS

[0184] 2 Gate region

[0185] 3 Gate channel

[0186] 4 Gate lip/Gate tab

[0187] 5 Boundary line

[0188] 6 Banana gate

[0189] 10 Housing

[0190] 12 Handle recess

[0191] 14 Actuating member/Handle element

[0192] 16 Speaker

[0193] 18 Bezel

[0194] 20 Carrier substrate

[0195] 21 Decorative layer

[0196] 22 Visible area of decorative layer

[0197] 23 Edge region of decorative layer

[0198] 24 Bearing device

[0199] 25 Edge region/Arcuate region

[0200] 26 Edge region/Arcuate region

[0201] 27 Intermediate area of the decorative layer