Signal generator for car doors

Abstract

A signal generator, in particular an opening switch, for a vehicle door or flap, the signal generator comprising an actuator, in particular an actuator that can be manually actuated and / or gripped by an operator; the signal generator further comprising a plug housing (14) having a switch (22), the switch being received in the plug housing or arranged thereon and having an electrical contact (20) forming part of a plug connection; and the signal generator comprising an actuator housing (12) having the actuator (30), the actuator being movably mounted on the actuator housing (12) and acting on the switch (22), the actuator housing (12) and the plug housing (14) being fixed in position relative to each other, wherein the electrical contact (20) is electrically connected to the switch (22) via an inserted conductor.

Description

Technical Field

[0001] The invention relates to a signal generator for a vehicle door, in particular an opening switch, the signal generator comprising a plug housing with a switch, the switch being received in the plug housing and having electrical contacts forming part of a plug connection, the signal generator further comprising an actuator housing with an actuator, the actuator being movably mounted on the actuator housing and acting on the switch. Background Art

[0002] As an opening switch, a signal generator of the type described above can be used to activate an electric drive which in particular allows a vehicle door to be opened automatically. This can be, for example, a sliding door or a pivoting door. In order to open the vehicle door, an actuator (for example a door operating lever) is moved by an operator into the open position and thereby the electrical connection between the electrical contacts of the switch is closed via the switch. In the case of known opening switches, the switch is usually a microswitch.

[0003] EP 1 677 324 B1 describes an opening switch and a method for producing an opening switch, wherein a microswitch and a connecting part are first connected to each other by a low-pressure process via a polymer molded thereon to form an intermediate body. Then, a cover is integrally formed onto the intermediate body by injection molding, the cover being arranged as a cover in contact with the actuator housing. A seal may be provided between the cover and the actuator housing.

[0004] EP 2 259 279 B1 discloses an opening switch for a vehicle door, in which an electrical unit having a switch is connected to a mechanical unit having an actuating element and is enclosed at the connection point by a seal.

[0005] EP 1 568 053 ​​B1 discloses an opening switch with a tilt actuator having a return spring as an actuating element. The tilt actuator acts on a switch on which a connecting part is integrally formed by injection molding. The connecting part is in turn connected to a cover via a stop element, which is connected to a body with the tilt actuator via a drive. Summary of the invention

[0006] Starting from the prior art discussed, it is an object of the present invention to provide a signal generator which is simpler in construction and / or a simpler method for producing the signal generator.

[0007] The invention achieves this object by a signal generator as claimed in claim 1 and by a method for producing a signal generator as claimed in claim 10. The dependent claims, the description and the drawings relate to advantageous embodiments.

[0008] The signal generator for a vehicle door or flap according to the invention comprises an actuator, in particular an actuator which can be manually actuated and / or gripped by an operator; the signal generator further comprises a plug housing with a switch, the switch being received in the plug housing or arranged on it, and the switch having electrical contacts forming part of the plug connection; and the signal generator comprises an actuator housing with an actuator, the actuator being movably mounted on the actuator housing (preferably movably around a pivot axis) and acting on the switch, wherein an embodiment is preferably such that a pivoting movement of the actuator is converted into switching of the switch, wherein the actuator housing and the plug housing are fixed in position relative to each other, and the electrical contacts are electrically connected to the switch via an inserted conductor.

[0009] Preferably, the plug housing and the actuator housing are integrally formed on each other, and the switch together with the electrical contacts is inserted into the plug housing, which is integrally formed on the actuator housing. Alternatively, the plug housing is preferably fixed to the actuator housing by a detent connection.

[0010] According to the method of the invention for producing a signal generator, the signal generator has a plug housing with a switch which is received in the plug housing and has electrical contacts forming part of a plug connection; and the signal generator has an actuator housing with an actuator which is movably mounted on the actuator housing, preferably movably about a pivot axis, and which acts on the switch, the actuator being in particular an actuator which can be manually actuated and / or gripped by an operator, wherein an embodiment is preferably such that a pivoting movement of the actuator is converted into a switching of the switch, the method comprising the following steps:

[0011] - attaching the plug housing and the actuator housing to each other,

[0012] - inserting the switch with the electrical contacts into or onto the plug housing;

[0013] - Electrically connecting the electrical contact to the switch by inserting a conductor.

[0014] The attachment of the plug housing and the actuator housing to each other is accomplished by integrally forming the plug housing and the actuator housing to each other.

[0015] The signal generator according to the invention is provided for generating an electrical signal in the door region, in particular in a manner triggered by a door opening member as an actuator. The door opening member can be, for example, a door operating lever. For example, the signal generator can be used as an opening switch for opening a door. The signal generator can also control the lowering of a window to ensure, for example, that the window is automatically lowered when the actuator moves. As described in the overview, it can be used for sliding doors or pivoting doors, for example. By moving the actuator by an operator, for example manually (preferably directly actuating the actuator by the operator), the switch is triggered and an electrical connection is thus generated between the electrical contacts. The electric drive connected by the electrical contacts of the signal generator can therefore be activated and thereby perform a function; for example, the door can be opened. The switch can be, for example, a microswitch. The switch can also be formed by one or more, in particular contactless trigger sensors, for example by Hall sensors.

[0016] According to the invention, the electrical contact is electrically connected to the switch by means of an inserted conductor, thereby advantageously enabling an automatable installation.

[0017] The switch (in particular together with its contacts) is received in at least a certain part inserted into the housing. The switch can thereby also at least partially extend out of the plug housing. In the state in which the switch is inserted into the plug housing, the switch can be held on the plug housing, for example, by a stop device. The electrical contacts can, for example, extend from the switch and form the male part of the plug connection. The component to be connected to the plug housing, such as an electric drive, can accordingly have a correspondingly designed female part of the plug connection. However, the electrical contacts of the switch can also basically form the female part of the plug connection, wherein the component to be connected to the plug housing then forms the male part of the plug connection accordingly. Therefore, in both cases, it is preferred that only one conductor component (for example a metal part) is provided for each pole of the switch, which conductor component directly (without other components) forms the contact point (to the wiring harness of the vehicle) of the plug connection at one end and contacts the connection terminal of the switch at the other end.

[0018] In one embodiment, at least one of these electrical contacts, preferably all, is a single piece and forms the contact for the plug connection on one side and is plugged onto the switch on the other side by being plugged onto output contact pins or output contact strips protruding from a housing in which the switch is received as a module. In a further method according to the invention, a corresponding one-piece arrangement with one or more contacts is realized.

[0019] In one embodiment, the switch has a clamping structure, preferably in the form of a female part of a plug connection, in particular in the form of a metal plate with a slot or two opposite pins, as a connection point, and at least one of the electrical contacts is inserted into the clamping structure, preferably with a straight part, preferably with an end of the electrical contact. In a further method according to the invention, the end of at least one of the electrical contacts is correspondingly inserted into the clamping structure of the switch as a connection point.

[0020] As a result of this provision of a clip structure for the switch, the production method is simplified. This is because the clip structure, which is relatively complex to produce, can then be manufactured as part of the switch, which is easier because the switch in any case constitutes a more or less standard part, while the electrical contacts must be manufactured specifically in a manner that depends on the geometry of the signal generator for the door or flap. However, since the contacts only need to have a single area that can be inserted into the clip structure, these contacts are also easy to manufacture.

[0021] According to the invention, the plug housing and the actuator housing are attached to each other, preferably integrally formed on each other, and further the switch is inserted together with the electrical contacts into the plug housing, which is integrally formed on the actuator housing. The plug housing can thereby be formed directly on the actuator housing, for example by injection molding. Here, the device housing and the actuator housing being integrally formed on each other should be understood to mean not only forming the plug housing on the already manufactured actuator housing (for example by injection molding) or forming the actuator housing on the already manufactured plug housing (for example by injection molding), but also that the plug housing and the actuator housing are jointly manufactured into one piece, as will be described in more detail below.

[0022] After such attachment of the plug housing and the actuator housing to each other or on each other, preferably integrally formed, the switch is inserted into the plug housing. The switch can be inserted into the plug housing together with its electrical contacts. It is also possible, for example, to insert the electrical contacts first and then insert the switch. In particular, as an alternative to a conductor inserted separately, the electrical contacts can be formed on the switch. After the switch or the electrical contacts are inserted, the plug housing can be closed by a cover. As described above, the switch is inserted into the plug housing at least in a specific part, in particular so that the electrical contacts of the switch are located in the plug housing. Therefore, according to the present invention, it is preferably provided that the plug housing and the actuator housing are integrally formed on each other, and only then the switch, the electrical contacts and other possible components that are conducive to the function of the signal generator are inserted into the plug housing. The production of the signal generator can be greatly simplified thereby. The known prior art always provides for the separate production of the plug housing and the actuator housing and / or the use of cables, wherein the two housings are then connected to each other by, for example, an adhesive or a stopper. Here, it is usually the case that the switch, the electrical contacts and possibly other components have been inserted or injection molded into the plug housing before the plug housing is connected to the actuator housing, as described in the overview. Such production is not only more cumbersome, but also results in a less secure connection between the plug housing and the actuator housing. In one embodiment, the plug housing and the actuator housing are integrally formed on each other by injection molding. Accordingly, the method can provide a step of integrally forming the plug housing and the actuator housing on each other by injection molding. This integral formation can be particularly easily, efficiently and reliably accomplished by the injection molding process. The plug housing and the actuator housing can be made in particular of the same plastic. In one embodiment, the actuator housing is first produced and then the plug housing is integrally formed on the plug housing. Accordingly, the method can include the steps of producing the actuator housing and then integrally forming the plug housing on the actuator housing. Therefore, in this embodiment, the actuator housing can first be manufactured, in particular by injection molding. The plug housing can then be integrally formed on the actuator housing, in particular by injection molding. In an alternative embodiment, the plug housing is first produced and the actuator housing is subsequently formed integrally on the plug housing. Accordingly, the method may include the steps of producing the plug housing and subsequently forming the actuator housing integrally on the plug housing. Such production may be technically simpler because fewer complex injection molding tools are required. In an alternative embodiment, the plug housing and the actuator housing are integrally formed on each other by jointly manufacturing the plug housing and the actuator housing into one piece. The method may thus include the step of integrally forming the plug housing and the actuator housing on each other by jointly manufacturing the plug housing and the actuator housing into one piece. In particular, the plug housing and the actuator housing may be jointly manufactured into one piece by injection molding.Although it may be necessary to first produce a relatively complex injection molding tool for this purpose, it is particularly simple and efficient to subsequently produce the two housings in one piece. As already mentioned in the overview, in this case, production in one piece is also understood to mean that the plug housing and the actuator housing are integrally formed on each other. By this integral formation, a simple and secure connection between the plug housing and the actuator housing is achieved. By arranging the electrical contacts in the plug housing directly on the actuator housing, additional cables, in particular wiring harnesses, can be further omitted. In this way, too, it is possible to arrange the components activated by the signal generator directly on the plug housing and therefore on the actuator housing, as will be described in more detail below.

[0023] In one embodiment, the signal generator has a carrier element on which the switch and / or an electrical contact electrically connected to the switch via an inserted conductor is mounted, the carrier element being arranged in or on the plug housing. In a further method according to the invention, the switch and the electrical contact are pre-mounted on the carrier element, and the carrier element is then arranged in or on the plug housing.

[0024] In this way, the production method is simplified, since the machine for mounting the switches and the electrical contacts on the carrier element no longer has to be adapted to different actuator housings. A plurality of switches are preferably pre-mounted on the carrier element, so that different functions of the signal converter can be covered. The plug housing is preferably formed by the carrier element, wherein in this case the plug housing is then attached to the actuator housing at a later point in time by a latching connection.

[0025] In one embodiment, a potting compound is introduced for the purpose of sealing the switch in the plug housing. Therefore, the method may include a step of introducing a potting compound into the plug housing for the purpose of encapsulating the switch in the plug housing. Here, the potting compound seals the switch in at least a specific part of the plug housing. Here, the potting compound can also be used to fix the switch (in particular together with the electrical contact) in the plug housing. In particular, the electrical contact of the switch is sealed by the potting compound. In particular, the receiving part of the plug housing for receiving the switch and / or the electrical contact can be completely filled with the potting compound. If the electrical contact forms the convex part of the plug connection, the contact can be completely received in the potting compound (except for the part to be connected to the concave part of the plug connection, for example, of the electric drive). The potting compound can in particular replace a cover that closes the plug housing at least in a specific part. This further simplifies the production process and leads to an even more secure connection.

[0026] In one embodiment, the electrical contacts are formed by a lead frame. For the method, it can be provided that the electrical contacts are formed by a lead frame, which is cut off after the lead frame is inserted into the plug housing to form separate electrical contacts. Alternatively, the contacts can also be disconnected and inserted into the plug housing separately. The lead frame can be inserted into the plug housing together with the switch. The lead frame can also be inserted into the plug housing before or after the switch is inserted. The lead frame allows simple production of the electrical contacts, in particular forming the convex part of the plug connection.

[0027] In one embodiment, the plug connection is designed to be directly connected to the electric drive. A system consisting of an electric drive and a signal generator according to the present invention can be provided, wherein the electric drive is directly connected to the plug housing. Accordingly, the method can provide, in particular as a final step, docking the electric drive to the plug housing. Here, the electric drive establishes a connection with an electrical contact arranged in the plug housing. As already described in the overview, the electrical contact of the plug housing of the signal generator and the contact of the correspondingly designed electric drive thus form a plug connection. In particular, the electrical contact of the plug housing can form the convex part of the plug connection, and the contact of the electric drive can form the concave part of the plug connection. Since the switch is inserted into the plug housing together with the electrical contact, the connection to the electric drive can be directly realized. Here, directly means that the plug connection in question is formed in particular without an additional cable extending between the electric drive and the plug housing. Therefore, according to the present invention, the electric drive can be easily attached to or mounted on the plug housing. In particular, it is advantageous to form the electrical contact by a lead frame. Therefore, in particular, additional cables can be omitted, and the electric drive can be arranged directly on the plug housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Embodiments of the present invention will be discussed below based on the accompanying drawings, in which:

[0029] Figure 1 An actuator housing of a signal generator according to the present invention is shown, the actuator housing having a plug housing integrally formed thereon,

[0030] Figure 2 The view from above shows Figure 1 The diagram in

[0031] Figure 3 Shows Figure 2 A view of the lead frame being inserted into the plug housing,

[0032] Figure 4 Shows Figure 3 , in which the electrical contacts are produced by cutting through the lead frame,

[0033] Figure 5 Shows Figure 4 An illustration of a switch being inserted into a plug housing,

[0034] Figure 6 Shows Figure 5 , wherein the door operating rod is inserted into the actuator housing,

[0035] Figure 7 Shows Figure 6 , in which the potting compound is introduced into the receiving part of the plug housing,

[0036] Figure 8 Shows Figure 7 , where the door operating lever is deflected,

[0037] Fig. 9 Another view shows Figure 8 The diagram in , and

[0038] Fig.10 A further view shows Figure 8 .

[0039] Unless otherwise specified below, the same reference numerals are used to refer to the same objects. DETAILED DESCRIPTION

[0040] Figure 1 An actuator housing 12 of a signal generator according to the present invention is shown, which has a plug housing 14 formed thereon. The plug housing 14 includes a receiving portion 16 for receiving a switch 22 having an electrical contact 20, and includes a connecting portion 18 into which the electrical contact extends to connect to, for example, an electric drive, as will be described in more detail below. The plug housing 14 can be formed on the actuator housing 12, in particular in an injection molding process. Likewise, the actuator housing 12 can be formed on the plug housing 14. This can be done by forming the plug housing 14 integrally after the actuator housing 12 is produced, or by forming the actuator housing 12 integrally after the plug housing 14 is produced, or by manufacturing the actuator housing 12 and the plug housing 14 in one piece, in particular by injection molding.

[0041] Figure 2 The figure in also shows that Figure 1 The unit visible in the figure (which consists of the plug housing 14 and the actuator housing 12) is shown only in certain parts and in different plan views. Figures 3 to 7The further production of the signal generator is described. In the present embodiment of the method, after the plug housing 14 and the actuator housing 12 are integrally formed on each other, a lead frame 19 made of metal is first inserted into the receiving part 16 of the plug housing 14. The lead frame 19 has two electrical contacts 20, but these are still connected to each other by a cross bar 21. The lead frame 19 is inserted into the receiving part 16 of the plug housing 14 so that the electrical contacts 20 protrude into the connecting part 18 ( Fig.10 In subsequent production steps ( Figure 4 As can be seen), the transverse strip 21 is severed and separate electrical contacts 20 are produced thereby.

[0042] Subsequently, the switch 22 is inserted into the receiving portion 16 of the plug housing 14, as shown in FIG. Figure 5 . Here, the switch 22 has in particular a trigger element 24 that protrudes from the receiving part 16. However, at least the electrical contacts 20 of the switch 22 are completely received in the plug housing 14, partly in the receiving part 16 and partly in the connecting part 18. The electrical contacts 20 are electrically connected to the switch 22 by inserting conductors. The contacts 20 are each a single piece and, firstly, form the contacts for the plug connection and, secondly, are plugged onto the switch 22 by being plugged onto output contact strips 23 that protrude from the housing in which the switch 22 is received as a module. The switch 22 has each a clip structure 23.1 at these connection points 23 and the electrical contacts 20 are plugged into the respective clip structures 23.1.

[0043] Next, a door operating rod 30 as an actuator is inserted into the actuator housing 12. The door operating rod 30 is mounted in the actuator housing 12 so that it can pivot about the rotation axis D and acts on the switch 22 in a manner as will be described in more detail below. Fig. 9 The door operating rod 30 can be clearly seen in FIG.

[0044] Finally, the receiving portion 16 of the plug housing 14 is filled with a potting compound 26, such as Figure 7 As can be seen, the contact 20 of the switch 22 is thus fixed and sealed in the plug housing 14. In particular, the potting compound does not enter the connecting part 18 here. With such a potting compound, a cover closing the receiving part 16 can be omitted.

[0045] exist Figure 6 and Figure 7 In the embodiment of the present invention, the door operating lever 30 is in an undeflected state. The actuating portion 32 of the door operating lever 30 thus does not actuate the switch 22. The switch 22 is thus in the off position. As a result of pivoting the door operating lever 30 out of the plug housing 14 about its rotation axis D (e.g., Figures 8 to 10As can be seen), the actuating portion 32 of the door operating lever 30 is adjusted toward the switch 22 and thereby pushes the trigger element 24 into the switch 22. In this way, the switch 22 is closed and an electrical connection is produced between the electrical contacts 20.

[0046] The production of the signal generator is simplified relative to known signal generators due to the fact that the plug housing 14 and the actuator housing 12 are integrally formed on each other according to the invention and the switch is subsequently inserted together with the electrical contacts into the plug housing 14. Since the electrical contacts are located in the plug housing, it is easier to mount or insert the electrical actuator to be connected to the signal generator directly into the plug housing.

[0047] List of Reference Numerals

[0048] 12 Actuator housing

[0049] 14 Plug housing

[0050] 16 Acceptance section

[0051] 18 Connection part

[0052] 19 Lead frame

[0053] 20 Electrical contact

[0054] 21 horizontal stripe

[0055] 22 Switch

[0056] 23 Output contact

[0057] 23.1 Clip structure

[0058] 24 Trigger element

[0059] 26 Potting mixture

[0060] 30 Door operating lever

[0061] 32 Actuation part

Claims

1. A signal generator for a vehicle door or flap, the signal generator comprising an actuator, the actuator being configured to be manually actuated and / or gripped by an operator; the signal generator further comprising a plug housing (14) having a switch (22), the switch being received in the plug housing or arranged thereon, and the switch having an electrical contact (20) forming part of a plug connection; and the signal generator comprising an actuator housing (12) having the actuator, the actuator being movably mounted on the actuator housing (12) and acting on the switch (22), wherein the actuator housing (12) and the plug housing (14) are fixed in position relative to each other, and the electrical contact (20) is electrically connected to the switch (22) via an inserted conductor, wherein The actuator comprises a door operating lever (30) which is pivotally mounted on the actuator housing (12) and acts on the switch (22).

2. The signal generator as claimed in claim 1, wherein at least one of the electrical contacts (20) is a single piece and forms a contact for the plug connection on one side and is plugged onto the switch (22) on the other side by being plugged onto output contact pins or output contact strips (23), wherein the output contact pins or output contact strips (23) protrude from a housing in which the switch (22) is received as a module.

3. The signal generator according to claim 1, wherein: The switch (22) has a clamping structure (23.1) as a connection point, and at least one of the electrical contacts (20) is inserted into the clamping structure (23.1).

4. The signal generator according to claim 1, wherein: The plug housing (14) and the actuator housing (12) are integrally formed on each other, and the switch (22) is inserted into the plug housing (14) together with the electrical contact (20).

5. The signal generator according to claim 4, wherein: The plug housing (14) and the actuator housing (12) are integrally formed on each other by injection molding.

6. The signal generator according to claim 4, wherein: The actuator housing (12) is first produced and the plug housing (14) is subsequently formed integrally on the actuator housing (12), or the plug housing (14) is first produced and the actuator housing (12) is subsequently formed integrally on the plug housing (14).

7. The signal generator according to claim 4, wherein: The plug housing (14) and the actuator housing (12) are integrally formed on each other by jointly manufacturing the plug housing (14) and the actuator housing (12) as a single piece.

8. The signal generator according to claim 1, wherein: The signal generator has a carrier element on which the switch (22) is mounted and / or the electrical contact (20) which is electrically connected to the switch (22) via an inserted conductor, the carrier element being arranged in or on the plug housing (14).

9. The signal generator according to claim 1, wherein: A potting compound (26) is introduced to seal the switch (22) within the plug housing (14).

10. The signal generator according to claim 1, wherein: The electrical contact (20) is part of the lead frame (19).

11. The signal generator according to claim 1, wherein: The door operating lever is mounted within the actuator housing, wherein the plug housing and the switch are located outside the actuator housing, wherein the actuator housing includes a wall having an opening aligned with the switch, wherein when the door operating lever is pivoted, a portion of the door operating lever protrudes from the opening to act on the switch.

12. The signal generator according to claim 1, wherein: The plug housing (14) is configured to be directly connected to an electric drive.

13. A system consisting of an electric drive and a signal generator as claimed in any one of the preceding claims, wherein: The electric drive is directly connected to the plug housing (14).

14. A method for producing an opening switch for a vehicle door, the opening switch having a plug housing (14) having a switch (22), the switch being received in the plug housing and having an electrical contact (20) forming part of a plug connection; and the opening switch having an actuator housing (12), the actuator housing having an actuator movably mounted on the actuator housing (12) and acting on the switch (22), wherein the actuator is configured to be manually actuated and / or gripped by an operator, wherein: The actuator comprises a door operating lever (30) which is pivotally mounted on the actuator housing (12) and acts on the switch (22), the method comprising the following steps: - attaching the plug housing (14) and the actuator housing (12) to each other, - inserting the switch (22) having the electrical contact (20) into or onto the plug housing (14); and - electrically connecting the electrical contact (20) to the switch (22) by inserting a conductor.

15. The method of claim 14, wherein: The plug housing (14) and the actuator housing (12) are attached to each other by integrally forming the plug housing (14) and the actuator housing (12) on each other.

16. The method of claim 15, wherein: The plug housing (14) and the actuator housing (12) are integrally formed on each other by injection molding.

17. The method of claim 15, comprising: producing the actuator housing (12) and subsequently forming the plug housing (14) integrally on the actuator housing (12), or The plug housing (14) is produced and the actuator housing (12) is subsequently integrally formed on the plug housing (14).

18. The method of claim 15, wherein the plug housing (14) and the actuator housing (12) are integrally formed to each other by jointly manufacturing the plug housing (14) and the actuator housing (12) as a single piece by injection molding.

19. The method of claim 14, comprising introducing a potting compound (26) into the plug housing (14) to seal the switch (22) in the plug housing (14).

20. The method of claim 14, wherein: The electrical contact (20) is a part of a lead frame (19), which is cut off after the lead frame (19) is inserted into the plug housing (14) to form separate electrical contacts (20).

21. The method of claim 14, wherein the door operating lever is mounted within the actuator housing, wherein the plug housing and the switch are located outside the actuator housing, wherein the actuator housing includes a wall having an opening aligned with the switch, wherein when the door operating lever is pivoted, a portion of the door operating lever protrudes from the opening to act on the switch (22).

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