Plectrum gear shift lever with anti-warping function

Abstract

The invention relates to a plectrum shift lever (1) for a steering handle. A paddle shift lever (1) includes a base member (2) having an operating portion (3a) and a connecting portion (3b). The base part (2) further comprises an insertion part (4) and a housing part (5). The insert part (4) comprises a connecting element (4a) in the region of the connecting portion (3b) and a protruding element (4b) in the region of the operating portion (3a). The housing part (5) covers the insertion part (4) at least in the region of the operating portion (3a), thereby forming a housing for the insertion part (4). Preferably, the insert part (4) and the housing part (5) are assembled or manufactured from a plastic material using overmolding. In order to prevent warpage, the plug-in part (4) and the housing part (5) are connected in the region of the operating section by means of an interlocking structure (10, 10 ').

Description

Technical Field

[0001] The present disclosure relates to a paddle shifter for a steering handle (e.g., a vehicle's steering wheel). Furthermore, the present disclosure relates to a steering handle for a vehicle, comprising a corresponding paddle shifter. Furthermore, the present disclosure relates to a method for manufacturing the corresponding paddle shifter. Background Art

[0002] Paddle shifters or rocker switches are control elements used to operate a sequential or automatic transmission or gearbox in a vehicle. Paddle shifters are typically mounted on the vehicle's steering wheel. Operating the paddle shifters allows the driver to select gears without removing their hands from the steering wheel. For example, a paddle shifter can be mounted on both the left and right sides of the steering wheel. Operating one of the paddle shifters (for example, the left one) downshifts, while operating the other (for example, the right one) upshifts.

[0003] To operate the lever, the driver pulls it toward them or toward the steering wheel, which triggers a gear change. To do this, the driver grasps the side of the lever facing away from them, pulling from behind while keeping their hands on the steering handle. However, other operating techniques are also possible, such as pushing or rotating or pivoting in the opposite direction, for example, parallel to the steering handle.

[0004] To enable operation, the paddle shift lever includes a protrusion or overhang feature relative to the mounting base on the steering handle. This means that the lever can protrude beyond the edge of the steering handle in the installed position. The resulting protrusion can be referred to as the operating portion or operating side of the lever. The mounting base can be referred to as the connecting portion or connecting side of the lever. In other words, the lever can include an operating portion for operating the lever that extends beyond or protrudes from the connecting portion used to connect or secure the lever to the steering handle.

[0005] Such levers are generally known. For example, WO 2019 223 911 A1 discloses a rocker switch having a base body and an insert element in the operating section of the base body. To ensure stability, the insert element is back-injected through the base body material and connected to the base body via a material bond formed from a long-fiber-reinforced plastic material.

[0006] Back injection is a manufacturing method that can be performed through injection molding. Injection molding is a common, popular manufacturing process for producing workpieces by injecting molten material (such as thermoplastic) into a mold. The molding tool then uses a semi-liquid or viscous material to fill voids and cavities within the mold, resulting in the desired shape of the designed tool or workpiece. After cooling, the workpiece or component can be ejected from the corresponding injection mold.

[0007] When molding plastic materials, an undesirable effect is warping. Warping occurs when the intended shape of a molded part distorts during the cooling process. For example, mold warping can cause the part to fold, bend, twist, or bow. Warping in paddle shifters, as described previously, can lead to reduced operability, undesirable optical properties, or instability in overhanging features, resulting in a shortened lifespan or susceptibility to defects. Summary of the Invention

[0008] The object of the present disclosure is to provide a warping prevention possibility for manufacturing a paddle shifter.

[0009] This object is achieved by the subject matter of the independent claims. Advantageous developments with convenient and non-trivial further embodiments of the disclosure are specified in the dependent claims, the following description and the drawings.

[0010] The present disclosure is based on the recognition that mechanical interlocks or interlocking features can be used in the assembly of a paddle shifter to achieve better buckling results. According to one aspect, the present disclosure provides a paddle shifter for a steering handle of a vehicle (e.g., a motor vehicle). The paddle shifter (hereinafter referred to as the lever) includes a base member or body having an operating portion or side for operating the lever, as previously described. The base member includes a connecting portion for connecting or securing the lever to the steering handle.

[0011] The insert or inlay component and the housing component form a base component. The insert includes a connecting element in the region of the connecting portion. The connecting element provides a physical connection to the steering handle, in particular a corresponding connecting element of the steering handle. Furthermore, the insert includes a protruding element that forms a protrusion or overhang relative to the connecting element in the region of the operating portion. As a result, the operating portion of the paddle shifter protrudes beyond the connecting portion.

[0012] The housing component covers the insert component at least in the area of ​​the operating section. This means that the housing component can at least partially serve as a housing, envelope, or cover for the insert component. Preferably, the housing component can cover the insert component in the area of ​​the operating section and the connecting section. In this case, the housing component can include an opening for the connecting element in the area of ​​the connecting section. Thus, the connecting element can be guided out of the housing provided by the housing component through the opening.

[0013] The insert and housing components are connected by means of or via an interlocking structure in the area of ​​the operating section. In other words, the housing and insert components are connected by interlocking, for example, using one or more corresponding interlocking elements. Thus, the insert and housing components can be dovetailed or intermeshed via the interlocking structure. Furthermore, the optics of the rod are improved, creating a high-quality impression for the user. Rheological simulations using suitable simulation tools (such as Mold Flow®) have demonstrated the effectiveness of using interlocking to reduce or prevent warping.

[0014] The interlocking structure provides high stability and torsional rigidity, particularly in the operating section. This results in a stabilizing or shape-retaining effect on the overhanging features. Consequently, warping of the material during cooling can be prevented or at least reduced. This results in reduced production scrap and, consequently, lower manufacturing costs.

[0015] In this disclosure, a paddle shifter, paddle shifter, or rocker switch refers to an operating element, such as in a vehicle. Specifically, as previously described, the lever can be used for shifting gears. However, this disclosure is not limited to paddle shifters. Rather, the present disclosure or invention can be applied to any switch component or control element having an overhanging feature, such as a paddle shifter.

[0016] The paddle shift lever, in particular the base part with the insert part and the housing part, can be made of a plastic material, in particular a thermoplastic material. Suitable materials are, for example, polycaprolactam (PA6, nylon 6 or nylon 66) or polyamide 66 (PA66) or other suitable plastic materials for lever production.

[0017] Preferably, the base component may include an opening for a lighting element for the steering handle. The lighting opening may be located in the connecting portion of the base component. The lighting element may be mounted behind the opening or pushed through or into the lighting opening. This allows for illumination, such as backlighting of a paddle shifter.

[0018] The present disclosure also includes embodiments providing features that offer additional technical advantages.

[0019] In one embodiment, the insert and housing components are assembled, attached, or connected by overmolding. Overmolding is a well-known manufacturing technique, particularly for plastics. By overmolding, a previously manufactured injection-molded component, a so-called pre-molded component (here, for example, the insert), is overmolded or coated with a second melt (here, for example, the housing component) in a further process step. Overmolding belongs to a category of injection molding processes known as multi-material injection molding.

[0020] The injection molding process enables the production of high volumes with consistent quality, ensuring high process stability. All process steps can be automated using injection molds, which further reduces costs and ensures reproducible component quality. Compared to traditional injection molding, multi-material molding (such as overmolding) can provide even lower costs, higher quality products, a significant reduction in assembly operations, and reduced cycle times.

[0021] In one embodiment for implementing or providing an interlocking structure, the insert component includes a first interlocking element, and the housing component includes a corresponding second interlocking element. The first interlocking element forms a recess into or within the bulk of the insert component. This means that the insert component provides a recessed nut or an open slit. The second interlocking element forms a protrusion into or within the bulk of the housing component. This means that the housing component provides a slit or fin.

[0022] In order to form the interlocking structure, the first interlocking element and the second interlocking element can be connected in a form-fitting manner. Form-fitting or form-closure or form-locking fitting is a standard joining or connection technology in mechanical engineering. The interlocking elements are formed accordingly, which means that they can be connected in a form-fitting manner. In order to connect the interlocking elements, the protrusion or the slit can be pierced or inserted or pushed through the recess and thus through the corresponding groove. In the installed position, the protrusion can be completely pierced or pushed through the recess. Alternatively, the protrusion can be partially inserted into the recess. This means that the protrusion overlaps on at least one side of the recess, or the protrusion can end or terminate in the volume body of the inserted component and thus end or terminate in the recess.

[0023] In one embodiment, the ratio of the recess to the wall thickness and / or the ratio of the protrusion to the wall thickness, respectively, is in the range of 50% to 60% relative to the wall thickness of the base component, particularly the wall thickness of the insert component and / or the shell component. This means that the split can be designed to be 50% to 60% of the nominal wall thickness or material thickness of the base component, insert component, or shell component. Thinner split or recess dimensions do not provide much structure and may be difficult to manufacture. Thicker split or recessed structures are attractive, but they may begin to introduce a dip in the decorative surface.

[0024] Here, "wall thickness" refers to the material thickness of the base component, particularly in the area of ​​the operating section. When assembled on a steering handle, the wall thickness is the distance or thickness measured between the front, or visible, surface of the lever and the rear, or touch surface, of the lever. The visible surface is the surface of the operating section facing the user or driver. The touch surface is the surface facing away from the user.

[0025] In an embodiment, the housing part comprises an upper element and a bottom element, which are attached on opposite sides of the insert part to form the housing. In other words, the housing part has a two-part design.

[0026] The opposing sides may be the visible surface and the touch surface described above. Hereinafter, the visible surface may be referred to as the upper side or top side, while the touch surface may be referred to as the bottom side or underside. To form a housing or cover, the upper and lower elements may be attached or connected to each other. The upper and lower elements may be connected or attached by a material seal.

[0027] The upper and lower elements can be formed using a multi-injection molding process, specifically two-shot overmolding, or 2K overmolding. Multi-injection molding is also known as sequential injection molding. In multi-injection molding, multiple layers of material—in this case, two layers, for example—are created relative to the initial mold. One layer can be the upper element, and the other can be the lower element. In the 2K overmolding process, an insert can be coated with material to form the upper element from the top in a first process step. In a second process step, the insert can be rotated or pivoted, and coated with material to form the lower element from the bottom.

[0028] In one embodiment, to provide a second interlocking element corresponding to the housing components, the upper element includes a first attachment member and the lower element includes a second attachment member. The first and second attachment members are connected by an additional interlocking structure. In other words, the second interlocking element provides an additional or supplemental interlocking structure, as previously described. The additional interlocking structure allows for a stable and secure connection between the upper and lower elements, reducing or preventing warping.

[0029] In one embodiment, the first attachment member forms a protrusion, thereby forming a slit or fin in or onto the bulk volume of the upper element. The second attachment member forms a protrusion, thereby forming a slit or fin in or onto the bulk volume of the bottom element. Furthermore, the protrusion of the first attachment member forms a recess for inserting or accommodating the second attachment member, particularly its protrusion. Both the first and second attachment members are at least partially inserted or inserted into the recess formed by the first interlocking element of the insert component. In other words, their protrusions allow the upper and lower elements to be attached to each other via the recess (first interlocking element) of the insert component. In this way, the paddle shifter can be further stabilized to enhance the anti-warping effect.

[0030] Therefore, the second interlocking element is two-part. These two parts are the first and second attachment members. To connect the insert component and the housing component in the corresponding interlocking structure, the first attachment member can be fully inserted or pushed into the recess of the insert component. This means that the first attachment member may overlap with or protrude from the insert component on at least one side. The second attachment member is preferably only partially inserted into the recess. This means that the second attachment member can terminate in the bulk of the insert component.

[0031] In one embodiment, to limit or adjust the insertion depth of the second attachment member in the recess formed by the first interlocking element of the insert component, the recess includes an abutment edge for the protrusion of the first attachment member. This abutment edge can serve as a bumper or stop to prevent further insertion of the second attachment member. Thus, the abutment edge provides a contact surface along the insertion direction of the first attachment member.

[0032] In one embodiment, the respective interlocking structures include or provide undercuts. In other words, the interlocking elements may include a form or shape characterized by undercuts. The undercuts may be provided by notches or recesses in the material (here, for example, the first and second interlocking elements and the first or second attachment members, respectively), shaped to prevent separation of the workpieces (here, the insert component and the housing component) in a defined direction. Consequently, the degrees of freedom of the housing component and the insert component are reduced. In this way, warping can be successfully prevented.

[0033] In one embodiment, the respective interlocking structure, in particular the respective interlocking element and / or the respective attachment member, proceeds or extends from the connecting portion in the direction of the operating portion. This means that the respective interlocking structure extends in the longitudinal direction of the paddle shifter.

[0034] In one embodiment, the operating portion is no more than 10% longer than the connecting portion, preferably no more than 5%. This reduces overhang of the operating portion and further reduces warping effects. Preferably, the operating portion and the connecting portion are of the same length. Here, "length" refers to the distance from one end to the other of the surface on which the operating portion or the connecting portion is provided, respectively, in the aforementioned longitudinal direction of the rod.

[0035] In one embodiment, the insert and housing components are formed from plastic materials, particularly thermoplastics, with different material properties in terms of surface finish and / or material strength. This allows the two components to be tailored to their respective purposes. Preferably, the upper and lower components are also formed from plastic materials with different material properties in terms of surface finish and / or material strength. For example, the insert component can be formed from a lower-cost plastic material with higher material strength. Material strength here refers, for example, to hardness, rigidity, and / or tensile strength. This creates a sturdy structure for the paddle shifter. In contrast, the housing component can be formed from a material with a specific surface finish, such as a glossy or textured surface effect. For example, the upper component, facing the driver in the installed position, can have a glossy surface effect to enhance visual appeal. In contrast, the lower component can have a textured surface effect to enhance grip on the lever.

[0036] According to another aspect, the present disclosure or invention provides a steering handle for a vehicle, in particular a motor vehicle including a paddle shifter as described above. In the mounted position of the lever, the operating portion of the lever at least partially protrudes beyond or overlaps the gripping area of ​​the steering handle. Thus, the lever, in particular the operating portion of the lever, is visible to a user (e.g., the driver). Considering the steering handle as a steering wheel, the gripping area may be the rim of the steering wheel. In this context, "within the gripping area" refers to the surface or portion of the steering handle that a user grips or touches when operating the vehicle. The motor vehicle is preferably a passenger car or bus, in particular a truck or a moped.

[0037] According to another aspect, the present disclosure or invention provides a method for manufacturing a paddle shifter as described above. In particular, the disclosed method describes an overmolding process for manufacturing a paddle shifter as described above. The method can be performed using a molding tool. This means that a corresponding molding tool can be programmed or implemented to perform the described method. The method comprises the following steps: providing an insert component and overmolding the insert component with a housing component in a molding tool. By doing so, a base component is formed with an operating portion for operating the lever and a connecting portion for connecting the lever to the steering handle. The insert component thus includes a connecting element in the region of the connecting portion and a protruding element that forms a protrusion relative to the connecting element in the region of the operating portion. The housing component covers the insert component at least in the region of the operating portion, wherein the insert component and the housing component are connected by an interlocking structure in the region of the operating portion.

[0038] Thus, the described method can be used to manufacture a paddle shift lever as described above. When implementing this method, a lever is manufactured. In this method, the connecting element of the insert component can be a mold-contacting surface in a molding tool. This means that the insert component can be held or secured by the connecting element during overmolding. The molding tool can be a conventional overmolding machine. The insert component can be manufactured by injection molding in a previous step or in a separate molding process.

[0039] In one embodiment of this method, the insert component is overmolded with the housing component in a two-shot overmolding process. In the first shot, the insert component is overmolded with the upper element of the housing component on a first side (the upper side), and in the second shot, the insert component is overmolded with the bottom element of the housing component on a second side (the bottom side). The upper and lower elements form a housing for the insert component, with the first and second sides being opposing sides of the insert component. In other words, the paddle shifter is manufactured using a 2K, or two-step, overmolding process.

[0040] For use cases or usage situations that may occur in the method and are not explicitly described here, it can be provided that, according to the method, error messages and / or prompts for user feedback are output and / or default settings and / or predetermined initial states are set.

[0041] Further embodiments of the steering handle and / or method according to the invention follow directly from the various embodiments of the paddle shifter according to the invention, and vice versa. In particular, the individual features and corresponding explanations and advantages associated with the various embodiments of the paddle shifter according to the invention can be transferred analogously to the corresponding embodiments of the steering handle and / or method according to the invention.

[0042] Other features of the present invention are apparent from the claims, the drawings, and the accompanying descriptions. The features and feature combinations mentioned above in the specification, as well as the features and feature combinations mentioned below in the description of the drawings and / or shown in the drawings, may be encompassed by the present invention not only in the respective combinations described, but also in other combinations. In particular, embodiments and feature combinations that do not possess all of the features of the initially formulated claims may also be encompassed by the present invention. Furthermore, the present invention may include embodiments and feature combinations that go beyond or deviate from the feature combinations set forth in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Hereinafter, the present invention will be explained in detail with reference to specific exemplary embodiments and corresponding schematic diagrams or figures. In the accompanying drawings, identical or functionally identical elements may be represented by the same reference numerals. The description of identical or functionally identical elements is not necessarily repeated with respect to different drawings.

[0044] The accompanying drawings show:

[0045] Figure 1 is a schematic diagram of a paddle shifter according to a preferred embodiment;

[0046] Figure 2 A schematic diagram of the paddle shifter is shown in the exploded view;

[0047] Figure 3 is a schematic diagram of different examples of interlocking structures for paddle shifters; and

[0048] Figure 4 is an exemplary flow chart of a method for manufacturing a paddle shifter according to a preferred embodiment. DETAILED DESCRIPTION

[0049] Figure 1 A schematic diagram of a paddle shift lever 1, hereinafter referred to as lever 1, is shown. The lever 1 can be mounted on a steering handle, such as the steering wheel of a motor vehicle. In this configuration, the lever 1 can be used for gear shifting, particularly for manual shifting of an automatic transmission. Conventional vehicles typically use two corresponding levers 1 for manual shifting. These are typically mounted on the left and right side of the steering handle, particularly behind the handle. Here, "behind" refers to the side of the steering handle facing away from the driver. To operate the corresponding lever 1, the driver can, for example, pull the corresponding lever. Pulling one of the levers downshifts, while pulling the other upshifts.

[0050] like Figure 1 As shown, the paddle shift lever 1 includes a base member 2 having a connecting portion 3b and an operating portion 3a. The operating portion 3a is the area or surface of the lever 1 that a user uses or touches to operate the lever 1. The connecting portion 3b is the area or surface of the lever 1 that is used to connect the lever 1 to the steering handle. In the installed position, the operating portion 3a of the lever 1 can at least partially protrude or overlap a grip area, such as the edge of the steering handle. Therefore, the operating portion 3a can be an area of ​​the lever 1 that is visible to the user. Figure 1 In the exemplary embodiment of the present invention, the base member 2 provides an L-shaped form or body. However, various other forms or body types are also possible.

[0051] As in Figure 1 As can be seen in the embodiment of FIG, the rod 1 can provide an illumination opening 6 for a steering handle or an illumination element of the vehicle. The illumination opening 6 can be used for backlighting or illumination of the rod 1.

[0052] In the installed position, lever 1 presents two opposing or opposite sides, one facing the driver and the other facing away from the driver. The side facing away from the driver is referred to as top side T of lever 1. The opposite side, thus facing the driver, is referred to as bottom side B. Top side T may be the side or surface that the driver touches to pull lever 1. Bottom side B may be the side or surface for engraving symbols representing the function performed when lever 1 is operated.

[0053] As in accordance with Figure 2 As can be seen in the exploded view of the lever 1, the base component 2 includes an insert or inlay component 4 and a housing component 5. The insert component 4 includes a connecting element 4a. The connecting element 4a can be a physical connection for connecting the lever 1 to the steering handle. The connecting element 4a is located or positioned in the area of ​​the connecting portion 3b. The insert component 4 also includes a protruding element 4b, which forms a protrusion or overhanging feature relative to the connecting element 4a in the area of ​​the operating portion 3a. The protruding element 4b is located in the operating portion 3a.

[0054] The housing part 5 provides a housing or an enclosure or a cover for the insert part 4. This means that the housing part 5 covers the insert part 4 at least in the region of the operating section 3a. Figure 1 and Figure 2 An embodiment of the lever 1 is shown in which the housing part 5 covers the insert part 4 in the region of the operating part 3a and in the region of the connecting part 3b. The housing part 5 thus comprises a connecting opening 7 for leading the connecting element 4a out of the housing to the outside.

[0055] The base component 2 is preferably made of a thermoplastic material, such as PA6 or PA66. The base component 2 can be manufactured by injection molding, in particular multi-material injection molding. Generally, (multi-material) injection molding is a well-known standard method for manufacturing plastic components or parts. The corresponding component is produced by injecting a molding material into or onto a predetermined mold. Preferably, the insert component 4 and the housing component 5 are assembled, attached, or manufactured by overmolding. Overmolding is a type of multi-material injection molding in which a previously manufactured injection-molded component, a so-called pre-molded component, here, for example, the insert component 4, is overmolded or coated with a second melt, here, for example, the housing component 5, in a further process step. Overmolding preferably results in a material connection between the insert component 4 and the housing component 5.

[0056] Since injection molding uses molded or viscous materials that cool to their final state, an effect that can occur in the manufactured component is so-called warping. This means that the resulting workpiece is deformed and therefore differs from the previously desired or intended form.

[0057] The paddle shift lever 1, in particular the operating portion, can be susceptible to warping. In order to stabilize the base part 2 and prevent warping, in particular during cooling, the insert part 4 and the housing part 5 are connected in the region of the operating portion 3a by means of an interlocking structure 10. Figure 2 In the embodiment of FIG. 1 , the interlocking structure is realized by a first interlocking element 11 of the insert component 4 and a second interlocking element 12 of the shell component 5. The first interlocking element 11 forms a recess or groove in the bulk of the insert component 4. The second interlocking element 12 forms a protrusion or break from the bulk of the shell component 5. In the assembled or installed position of the base component 2, the protrusion can be pushed through the recess or inserted into the recess to form the interlocking structure 10.

[0058] Figure 1 An exemplary embodiment is shown having a total of two interlocking elements. However, interlocking structures having a plurality of interlocking elements, in particular more than two interlocking elements, such as two or more first interlocking elements and two or more corresponding second interlocking elements, are also possible.

[0059] Another measure to prevent warping may be to provide the operating portion 3a and the connecting portion 3b with the same length, such as Figure 1 This ensures that the lever arm provided by the operating part 3a is kept as small as possible in order to achieve an optimal touch surface for the driver on the one hand and to avoid warping as much as possible on the other hand.

[0060] In accordance with Figure 2 In an embodiment of the present invention, the shell component 5 includes two elements or two parts: an upper element 5a and a bottom element 5b. The upper element 5a and the bottom element 5b are attached on opposite sides of the insert component 4 to form a shell. Here, the upper element 5a can be attached to the upper side T, thereby providing the surface of the upper side T for the base component 2. The bottom element 5b can be attached to the bottom side B, thereby forming a surface for the bottom side B of the base component 2. The upper element 5a and the bottom element 5b can be attached to the insert component 4 in a two-step overmolding process. Two-step or 2K overmolding is a well-known injection molding technology, in which the insert component 4 can first be coated with one element, such as the upper element 5a, and then turned and coated with another element, such as the bottom element 5b.

[0061] Preferably, the upper element 5a and the bottom element 5b are connected in a materially bonded manner. This means that the materials of the upper element 5a and the bottom element 5b are merged or molded together at the corresponding contact surfaces. Similar to the housing component 5, the second interlocking element 12 is also provided in two parts. Thus, the upper element 5a includes a first attachment member 12a, and the bottom element 5b includes a second attachment member 12b. The first and second attachment members 12a, 12b are also connected by an additional interlocking structure 10'.

[0062] In order to provide an additional interlocking structure 10', the first attachment member 12a forms a protrusion or a break from the volume of the upper element 5a. The second attachment member 12b forms a protrusion or a break from the volume of the bottom element 5b. In addition, the protrusion of the first attachment member 12a forms or provides a recess for inserting or accommodating the second attachment member 12b. Figure 2 To interlock or connect the insert component 4 and the housing component 5 , both the first and second attachment members 12 a and 12 b are at least partially inserted or fitted into the recess formed by the first interlocking element 11 of the insert component 4 .

[0063] In a preferred embodiment, if Figure 2 As shown, the second attachment member 12b can be fully inserted or pushed into the recess (first interlocking element 11) of the insert component 4. This means that the second attachment member 12b can overlap with or protrude from the insert component 4 on at least one side (here, the upper side T). The first attachment member 12a can be only partially inserted into the recess (first interlocking element 11) of the insert component 4. This means that the first attachment member 12a ends in the main volume of the insert component 4. To adjust the insertion depth of the first attachment member 12a, the recess formed by the first interlocking elements 11 of the insert component 4 includes an abutment edge 11a. The abutment edge 11a can provide a buffer or contact surface for the protrusion of the second attachment member 12b. This means that in the assembled position, the first attachment member 12a can contact the abutment edge 11a.

[0064] like Figure 2 As shown, the first interlocking element 11 and the second interlocking element 12, in particular the first attachment member 12a and the second attachment member 12b, are designed as slits or grooves, which extend from the connecting part 3b in the direction of the operating part 3a. This means that the corresponding interlocking structures 10, 10' extend in the longitudinal direction of the rod 1.

[0065] Preferably, the insert member 4 and the housing member 5, in particular the upper element 5a and the lower element 5b, can be formed from different plastic materials having different material properties in terms of surface finish or material strength. The upper element 5a, which may be the driver's touch surface, can have a textured surface to enhance the grip for operating the lever 1. In contrast, the lower element 5b can have a glossy surface finish to enhance the optical quality of the lever 1.

[0066] In order to provide a secure hold between the interlocking elements and / or the attachment members, the respective interlocking structures 10, 10' are realized as so-called undercuts 13. The undercuts are provided by protruding formation elements in the material, which prevent the workpieces (here the insert and housing parts 4, 5) from separating in a defined direction. Figure 3Different examples or embodiments of undercuts 13 are shown for the respective interlocking structures 10, 10'. However, other shapes or forms of undercuts 13 are also possible.

[0067] In a first example, the interlocking structure 10, 10' can be provided by an undercut 13 having a slot structure or slot form 10a. To achieve the slot for 10a, the protrusion (e.g., the second interlocking element 12) and the recess (e.g., the first interlocking element 11) provide a tapered or conical section created by a tapered section.

[0068] In a second example or embodiment, the interlocking structure 10, 10' is provided by an undercut 13 based on a dovetail joint structure 10b. This means that the undercut 13 is realized in the manner of a dovetail joint. In this example, the workpieces (thus the insert part 4 and the housing part 5) are connected by more than one interlocking structure (in particular two interlocking structures). This means that Figure 1 and Figure 2 In contrast to the embodiment shown in , the rod 1 may comprise one or more, in particular two or more, interlocking structures 10 , 10 ′ for connecting the insert part 4 and the housing part 5 .

[0069] In another example or embodiment, the respective interlocking structures 10, 10' show an undercut 13 with an overlapping dovetail joint structure 10c. This means that the protrusion (here, for example, the second interlocking element 12) overlaps the recess or volume body (here, for example, the first interlocking element 11 of the insert part 4).

[0070] A fourth example or embodiment shows a corresponding interlocking structure 10, 10' having an undercut 13 of a plate-like structure. This means that the protrusion (here, for example, the second interlocking element 12) provides a taper or narrowing that expands or weakens into the plate shape. Thus, the plate-like structure 10d provides a T-shape or T-form.

[0071] When providing corresponding interlocking structures 10, 10', the ratio of the recess to the wall thickness and / or the ratio of the protrusion to the wall thickness is preferably in the range of 50% to 60% relative to the wall thickness of the base part 2. This means that the slits or corresponding grooves should be designed to be 50% to 60% of the nominal wall thickness of the base part 2. This results in optimal filling or material filling, with overmolding and optimal anti-warping stability for the base part 2.

[0072] Figure 4A flow chart illustrating an exemplary embodiment of a method for manufacturing a paddle shifter 1 is shown. In step S1 of the method, an insert component 4 is provided. The insert component 4 can be provided by clamping or securing the insert component 4 with the connecting element 4 a to a mold contact surface of a molding tool. The connecting element 4 a can thus serve as a mold contact surface in the molding tool. The molding tool can be a conventional overmolding machine. The insert component 4 can be manufactured in a previous process step prior to step S1, for example, by injection molding. Thus, the plastic material for the insert component 4 can be injected into a corresponding mold. The processing of the insert component 4 can be carried out in another molding tool, for example, a conventional injection molding machine.

[0073] After the insert part 4 has been provided, the method continues with step S2. In step S2, the insert part 4 is overmolded together with the housing part 5 in a molding tool. If the housing part 5 is provided in two parts (see Figure 2 ), the overmolding process can be performed in two shots or in two parts. This means that the insert component 4 is overmolded with the housing component 5 in a two-shot overmolding process. In the first shot, the insert component 4 is overmolded with the upper element 5a of the housing component 5 on a first side, in this case, the top side T. In the second shot, the insert component 4 is overmolded with the bottom element 5b of the housing component 5 on a second side (here, the bottom side B). As described above, the upper element 5a and the bottom element 5b are applied so that they form a housing for the insert component 4.

[0074] In summary, the figures show a preferred embodiment of a mechanical interlock to optimize the warpage of an overmolded component, here a paddle shifter 1. By using the described interlocking structures 10, 10', the reduction in warpage can be verified by rheological simulations, for example using the software tool Mold Flow®.

Claims

1. A paddle shifter (1) for a steering handle, comprising: - a base member (2) having an operating portion (3a) for operating the lever (1) and a connecting portion (3b) for connecting the lever (1) to the steering handle, wherein - the base part (2) comprises an insert part (4) and a housing part (5), wherein - the insert part (4) comprises a connecting element (4a) in the region of the connecting portion (3a), and a protruding element (4b) forming a protrusion relative to the connecting element (4a) in the region of the operating portion (3a), and The housing part (5) covers the insert part (4) at least in the region of the operating section (3a), wherein The insert part (4) and the housing part (5) are connected in the region of the operating portion (3a) via an interlocking structure (10, 10').

2. The paddle shift lever (1) according to claim 1, wherein: The insert component (4) and the housing component (5) are assembled by overmolding.

3. A paddle shift lever (1) according to any one of the preceding claims, wherein: In order to realize the interlocking structure (10, 10'), the insert part (4) comprises a first interlocking element (11) and the housing part (5) comprises a corresponding second interlocking element (12), wherein the first interlocking element (11) forms a recess in the volume body of the insert part (4) and the second interlocking element (12) forms a protrusion in the volume body of the housing part (5).

4. The paddle shift lever (1) according to claim 3, wherein: Relative to the wall thickness of the base part (2), in particular the wall thickness of the insert part (4) and / or the housing part (5), the ratio of the recess to the wall thickness and / or the ratio of the projection to the wall thickness are each in the range of 50% to 60%.

5. A paddle shift lever (1) according to any one of the preceding claims, wherein The housing component (5) comprises an upper element (5a) and a bottom element (5b) which are attached on opposite sides of the insert component (4) to form an outer shell.

6. Paddle shifter (1) according to claim 3 and 5 and / or in combination with any one of the preceding claims, wherein To provide the second interlocking element (12), the upper element (5a) comprises a first attachment member (12a) and the lower element (5b) comprises a second attachment member (12b), the first attachment member (12a) and the second attachment member (12b) being connected by an additional interlocking structure (10').

7. The paddle shift lever (1) according to claim 6, wherein: The first attachment member (12a) forms a protrusion in the volume body of the upper element (5a), and the second attachment member (12b) forms a protrusion in the volume body of the lower element (5b), wherein the protrusion of the first attachment member (12a) forms a recess for inserting the second attachment member (12b), wherein the first attachment member (12a) and the second attachment member (12b) are at least partially inserted into the recess formed by the first interlocking element (11).

8. The paddle shift lever (1) according to claim 6 or 7, wherein: In order to define the insertion depth of the first attachment member (12a) in the recess formed by the first interlocking element (11), the recess comprises an abutment edge (11a) for the projection of the second attachment member (12b).

9. A paddle shift lever (1) according to any one of the preceding claims, wherein: The respective interlocking structures (10, 10') provide an undercut (13).

10. A paddle shift lever (1) according to any one of the preceding claims, wherein The corresponding interlocking structures (10, 10') start from the connecting portion (3b) and advance in the direction of the operating portion (3b).

11. A paddle shifter (1) according to any one of the preceding claims, wherein: The operating portion (3a) is at most 10% longer than the connecting portion (3b), preferably at most 5% longer.

12. A paddle shifter (1) according to any one of the preceding claims, wherein The insert part (4) and the housing part (5) are formed from plastic materials having different material properties with respect to surface finishing and / or material strength.

13. A steering handle for a vehicle comprising a paddle shift lever (1) according to any one of the preceding claims, wherein: In the installed position, the operating portion (3a) of the lever (1) at least partially protrudes beyond the gripping area of ​​the steering handle.

14. A method for manufacturing a paddle shift lever (1), comprising the following steps: - providing an insert part (4), - Overmolding the insert part (4) with the housing part (5) in a molding tool, wherein the base part (2) is formed with an operating portion (3a) for operating the lever and a connecting portion (3b) for connecting the lever to a steering handle, wherein the insert part (4) comprises a connecting element (4a) in the region of the connecting portion (3b) and a protruding element (4b) forming a protrusion relative to the connecting element (4a) in the region of the operating portion (3a), and the housing part (5) covers the insert part (4) at least in the region of the operating portion (3a), wherein the insert part (4) and the housing part (5) are connected in the region of the operating portion (3a) by means of an interlocking structure (10, 10').

15. The method according to claim 14, wherein The insert part (4) is overmolded with the housing part (5) in a two-shot overmolding process, wherein, in a first shot, the insert part (4) is overmolded with an upper element (5a) of the housing part (5) on a first side, and in a second shot, the insert part (4) is overmolded with a lower element (5b) of the housing part (5) on a second side, wherein the upper element (5a) and the lower element (5b) form a housing for the insert part (4), and wherein the first side and the second side are opposite sides of the insert part (4).

Images