Actuating component of vehicle interior door handle assembly and its manufacturing method

Abstract

The present invention relates to an actuating member (14) of a vehicle interior door handle assembly, particularly a handle element, wherein the actuating member (14) has a carrier substrate (20) preferably formed of plastic and a decorative layer (21) at least partially covering the surface of the carrier substrate (20). The decorative layer (21) has: a visible area (22) forming the visible side of the actuating member (14) particularly in the intended installed state and particularly in the unacted state; at least one gate region (2) formed particularly in a gate lip or gate lug (4); and at least one edge region or arcuate region (25, 26) preferably continuously connected to the visible area (22) of the decorative layer (21) via the at least one edge region or arcuate region.

Description

[0001] This invention generally relates to interior components of vehicles, and more particularly to interior door handle assemblies of vehicles. Interior door handle assemblies of the type contemplated herein generally have a housing and an actuating member arranged or hinged to the housing.

[0002] The present invention relates in particular to an actuating member for an interior door handle assembly for a vehicle, especially an actuating member in the form of a handle element, and a corresponding method for manufacturing such an actuating member.

[0003] The actuating member according to the invention can be, for example, a handle element. This handle element can be, for example, a handle lever pivotally or hingedly supported on the housing of an inner door handle assembly. The actuating member can be designed to be grasped or otherwise manipulated by vehicle occupants to open and / or close the door from the inside.

[0004] In such interior door handle assemblies, the housing and actuating component are typically made of plastic. However, for aesthetic reasons, it is often desirable for at least the actuating component to have a metallic appearance.

[0005] Therefore, it is generally known from the prior art that actuating components (such as the handle element of an interior door handle assembly) are chrome-plated or otherwise surface-treated. This method allows for the production of high-quality surfaces, while the substrate of the actuating component with the chrome layer can be made of durable plastic. However, chrome plating, especially using chrome IV, is problematic for health and environmental reasons.

[0006] An alternative to chrome plating is to manufacture the actuators using injection molding of plastic with a metallic appearance (Mould In Metal Colour, MIMC). This achieves an appearance similar to chrome plating.

[0007] However, the problem with the MIMC process lies particularly in surface defects caused by material shrinkage, such as streamlines and dents. Furthermore, the plastics used for this process do not always possess sufficient durability, especially not always the required maximum breaking load. In terms of force transmission, this applies not only to the actuating components of the inner door handle assembly but also to the corresponding housing.

[0008] Based on this, the basic objective of the present invention is to provide an actuating member, particularly a handle element, for a vehicle interior door handle assembly, and a method for manufacturing such an actuating member, wherein a high-quality surface of the actuating member is achieved in a cost-effective manner with a large degree of design freedom and good durability.

[0009] With regard to the actuation member, the fundamental problem of the present invention is solved by the subject matter of independent claim 1, wherein advantageous improvements to the actuation member according to the invention are given in the dependent claims.

[0010] Regarding the manufacturing method, the fundamental problem of the present invention is solved by the subject matter of the parallel independent claims 15.

[0011] Accordingly, the present invention particularly relates to an actuating member of a vehicle interior door handle assembly, preferably implemented in the form of a handle element, wherein the actuating member has a carrier substrate preferably formed of plastic and a decorative layer that at least partially covers the surface of the carrier substrate.

[0012] According to the invention, the decorative layer has a visible area that forms the so-called "A side" of the actuating member, that is, the visible side of the actuating member is formed particularly in the intended installed state of the actuating member and also particularly in the unacted state of the actuating member. Furthermore, the decorative layer has at least one gating region (Angussbereich), particularly formed in the gating lip or gating lug, and at least one edge region or arcuate region, through which the gating region is continuously connected to the visible area of ​​the decorative layer.

[0013] The decorative layer is preferably formed of a plastic material, which may in particular be different from the plastic material of the carrier substrate forming the actuating component.

[0014] The decorative layer is integrally and preferably adhesively bonded to the carrier substrate. At least in the installed state, the visible side of the decorative layer corresponds to the so-called "A side" of the actuating member and is therefore at least partially visible directly from the vehicle interior. The decorative layer, preferably integrally formed with the carrier substrate of the actuating member, also extends at least partially to the so-called "B side" of the actuating member, that is, to the side opposite to the A side of the actuating member.

[0015] According to the invention, at least the decorative layer of the actuating member is manufactured by injection molding or connected to the carrier substrate of the actuating member. However, it is particularly preferred that the actuating member be manufactured using a two-component injection molding method.

[0016] The present invention is particularly characterized in that the decorative layer of the actuating member has at least one gate region through which heated injection molding compound is introduced into the mold cavity of the injection molding tool through at least one gate channel, the mold cavity at least partially corresponding to the shape of the actuating member and particularly corresponding to the shape of the decorative layer of the actuating member.

[0017] The at least one gate region is formed in particular in the gate lip or gate lug, wherein the gate region is continuously connected to the visible area of ​​the decorative layer via at least one edge region or arcuate region.

[0018] Its advantage is that by injecting into the rear side of the internal area of ​​the mold body, injection marks are not visible on the visible side of the actuating component (that is, on side A of the actuating component). Therefore, no additional removal of injection marks is required during subsequent external surface treatment.

[0019] Because the at least one gate region is formed in the gate lip or gate lug, and the gate region is continuously connected to the visible area of ​​the decorative layer via at least one edge region or arcuate region, homogenization of the heated injection molding compound can be achieved when the heated injection molding compound is supplied to the mold cavity. This allows the melt (heated injection molding compound) in the mold cavity to flow from the gate region (i.e., from the gate lip or gate lug) via the at least one edge region or arcuate region to the visible area of ​​the decorative layer at a reduced volumetric flow rate without local densification. This enables the heated injection molding compound to reach the visible area of ​​the decorative layer via at least one "gentle" transition.

[0020] By first smoothing and homogenizing the heated injection molding compound in an area different from the visible area of ​​the actuating component when it is introduced into the mold cavity, and because the heated injection molding compound thus homogenized continuously reaches the area of ​​the mold cavity (corresponding to the visible area of ​​the decorative layer), the decorative layer can be formed by using a plastic material with integrated pigments without the risk of forming undesirable flow lines in the visible area of ​​the decorative layer.

[0021] This measure should be taken into particular consideration when using plastic materials with embedded pigments to form decorative layers, as the pigments do not form a continuous mass in the melt (i.e., in the heated injection-molded compound). Correspondingly, it must be ensured that the melt with embedded pigments does not densify in the visible areas of the actuating component, as localized densification of the melt can lead to pigment densification, which may result in corresponding defects (especially lines) in the finished actuating component.

[0022] Therefore, by providing a gate region formed in the gate lip or gate lug (which is continuously connected to the visible area of ​​the decorative layer via at least one edge region or arcuate region), the volumetric flow of the melt can be stabilized when the heated injection molding compound is introduced into the mold cavity, that is, before or during the flow of the melt from the gate region to the visible area of ​​the decorative layer. This results in higher surface quality, which can be further enhanced by subsequent treatments such as painting.

[0023] With regard to the gate lip or gate lug in which at least one gate area is formed, it should be noted that the gate lip or gate lug exhibits a relatively small volume area in which the heated injection molding compound is supplied to the mold cavity via the corresponding gate channel.

[0024] By subsequently connecting the relatively small volume area formed by the gate lip or gate lug continuously through at least one edge region or arcuate region to the visible area of ​​the final forming actuation component of the mold cavity via volumetric flow, the melt is gently deflected and pressure is uniformly released as it flows from the gate region to the visible area of ​​the actuation component, thus effectively preventing localized densification of the melt in the visible area of ​​the decorative layer.

[0025] As described above, the interior door handle assembly is used to open and / or close the vehicle door from inside the vehicle. For this purpose, the interior door handle assembly is installed inside vehicles such as passenger cars (PKW) or commercial freight vehicles (LKW). Correspondingly, the present invention also relates to a vehicle having an interior door handle assembly installed therein.

[0026] The interior door handle assembly includes a housing through which it is secured to the vehicle door. An actuating member is arranged on the housing, which can be manually operated by a vehicle occupant, for example, by grasping it. The actuating member can be movably arranged on the housing, for example, in a pivotable or translational manner. The actuating member can be, for example, a handle element, particularly a handle lever, arranged pivotally on the housing. However, the actuating member can also be, for example, a button or the like, actuated by a vehicle occupant. The actuating member can be designed to be actuated by vehicle passengers to open and / or close the door from the inside.

[0027] The actuating component has, in particular, a carrier substrate formed of a first plastic and a decorative layer that at least partially covers the surface of the carrier substrate. The decorative layer is preferably composed of a material different from that of the carrier substrate.

[0028] The carrier substrate supports the decorative layer, which preferably at least partially defines the visible area of ​​the actuating member, that is, the area of ​​the actuating member that is directly visible from the vehicle interior space and typically faces the vehicle interior. The visible area forms the so-called "A surface," which places particularly high demands on its appearance.

[0029] On the other hand, the carrier substrate at least partially forms a so-called "B surface" and is at least partially not directly visible from the vehicle interior. The carrier substrate may, for example, be arranged on the rear side of the actuating member facing away from the vehicle interior. However, the carrier substrate may also partially form a visible surface facing the vehicle interior and directly visible from the vehicle interior.

[0030] The front of the actuating member is preferably defined by the surface of the actuating member facing the interior of the vehicle when the actuating member is installed in the vehicle and in the resting position. The boundary between the front and back of the actuating member is preferably defined by a surface that is parallel to the vehicle surface and directly surrounds the actuating member when it is installed in the vehicle and in the resting position.

[0031] The surface preferably has a surface facing its reference line (facing outwards away from the material).

[0032] Direct visibility preferably means the absence of any other coatings (e.g., paint or chrome) or covering of the molding portion in the decorative layer. The plastic of the decorative layer is preferably the outermost surface layer of the actuating component in the directly visible area of ​​the decorative layer.

[0033] The description of the "first" material / plastic and the "second" material / plastic does not specify their manufacturing order. The invention includes first manufacturing a carrier substrate (of the first plastic) and then manufacturing a decorative layer (of the second plastic), but also includes first manufacturing the decorative layer and then manufacturing the carrier substrate.

[0034] The decorative layer is particularly integrally connected to the carrier substrate, which preferably means that the materials are bonded together, that is, they are held together by atomic or molecular forces and are inseparable, meaning they can only be separated by destruction. However, this also includes a form-fit connection between the decorative layer and the carrier substrate, wherein the form fit is achieved by injection molding within an injection molding tool. Therefore, bonding by atomic or molecular forces is not necessarily necessary, but merely preferred.

[0035] Since the decorative layer (especially the visible area of ​​the decorative layer) is made of a different material than the carrier substrate according to the present invention, the visible areas of the carrier substrate and the decorative layer, and preferably the carrier substrate and the decorative layer, can be specifically adjusted for the corresponding requirements.

[0036] By bonding materials together, a single-piece component is formed, thus eliminating the need for additional fastening devices to connect the carrier substrate of the actuating component to the decorative layer. This not only improves the visual appearance but also simplifies the manufacturing and assembly of the actuating component of this invention.

[0037] When using actuating components, there are high requirements for their durability, especially in terms of maximum breaking load. According to the present invention, durability can be easily increased by selecting a material with corresponding durability for the carrier substrate. At the same time, a visually high-quality surface can be achieved by selecting other suitable materials for the decorative layer, especially the visible areas of the decorative layer. If materials for this purpose (materials that are generally not durable enough) are not used, the overall durability of the actuating component will be affected.

[0038] Materials with a metallic appearance can be used, for example, for decorative layers, and especially for the visible areas of the decorative layer. This eliminates the need for (as explained) the problematic chrome plating process for environmental and health reasons.

[0039] The decorative layer, and especially its visible area, can have a much smaller thickness than the carrier substrate. For example, preferably, the maximum thickness of the decorative layer in its visible area can be less than 50% of the minimum thickness of the carrier substrate, and more preferably less than 20% of the minimum thickness of the carrier substrate. This maximizes the stiffness of the actuating member, which is essentially provided by the carrier substrate, while also reducing the likelihood of surface defects forming in the decorative layer, especially in its visible area. In particular, if, for example, only one surface facing the vehicle interior is formed by the decorative layer, and especially its visible area, this represents a simple geometry that can be manufactured without surface defects.

[0040] The decorative layer, and preferably the visible area of ​​the decorative layer, is formed, in particular, by injection molding into a section (gate area) on the carrier substrate of the actuating member.

[0041] In this context, according to the invention, the at least one gate region (through which the material (second material / plastic material) required for forming the decorative layer is injected into the corresponding mold cavity) is formed by a region away from the visible area of ​​the decorative layer, and particularly in the gate lip or gate lug. The region of the gate lip or gate lug, through which the at least one gate region for the second material of the decorative layer is formed, is connected to the visible area of ​​the decorative layer by volumetric flow, wherein the region of the gate lip or gate lug continuously increases in view from the effective volumetric flow cross-section and deflects upon transition to the visible area of ​​the decorative layer. As already explained, homogenization and depressurization of the heated injection molding compound can be effectively achieved during the formation of the decorative layer.

[0042] According to a particularly practical design, the actuating component can be manufactured using a two-component injection molding method. This allows for the particularly simple and cost-effective manufacture of the actuating component.

[0043] Furthermore, according to the present invention, by combining the structures of the carrier substrate and the decorative layer together, and particularly by providing a gate region in a gate lip or gate lug in a region of the decorative layer (which is continuously connected to the visible area of ​​the decorative layer via an edge region or arcuate region), surface defects can be minimized particularly efficiently during manufacturing using a two-component injection molding method. It has been shown that by providing a gate region for the decorative layer in the gate lip or gate lug (which is continuously connected to the visible area of ​​the decorative layer via an edge region or arcuate region), the shrinkage of the plastic material of the decorative layer during curing (which could cause surface defects such as flow lines or depressions) is reduced / minimized in a particularly effective manner.

[0044] By injection molding onto a carrier substrate made of different materials according to the design scheme of the visible area of ​​the decorative layer, and preferably the decorative layer, shrinkage and the resulting surface defects can be minimized. In this way, the carrier substrate can form a stable foundation for the visible area of ​​the injection-molded decorative layer, and preferably the injection-molded decorative layer, thereby significantly reducing shrinkage. Streamlines and depressions can be reliably avoided.

[0045] Furthermore, the above design allows for the fabrication of different decorative layers, preferably visible areas, using only a single injection molding tool. These visible areas can be made of different colored plastics depending on the application, thus further enhancing flexibility.

[0046] As already shown, especially when using plastics with embedded pigments as decorative layer materials, it is preferable to use such materials as heated injection molding materials (melt) to continuously enter the visible area of ​​the decorative layer in a smooth volumetric flow manner.

[0047] For this purpose, it is particularly recommended to set up a homogenization zone when forming the decorative layer, in which the plastic material injected into the mold cavity through the gate channel is first stabilized, and then flows as evenly and continuously as possible into the area of ​​the mold cavity, which finally forms the visible area of ​​the decorative layer on the manufactured actuating component.

[0048] In this context, the present invention proposes, in particular, to form a gate region in a gate lip or gate lug, through which heated injection molding material for a decorative layer is injected into a mold cavity, wherein the gate lip or gate lug is continuously connected to the visible area of ​​the decorative layer via at least one edge region or arcuate region as a continuous volume flow.

[0049] Preferably, the melt (the heated injection molding compound) can be continuously increased in the so-called homogenization region into a larger volume region of the mold cavity.

[0050] To achieve this, according to the design of the present invention, a gate lip or gate lug having at least one gate region has a configuration that is at least substantially U-shaped, V-shaped or wedge-shaped when viewed in a top view, wherein the gate lip or gate lug thus formed tapers in the direction from the at least one edge region or arcuate region toward the at least one gate region.

[0051] This embodiment, utilizing a gate lip or gate lug having at least one gate region, effectively achieves the following: during molten metal injection, the melt increases in volume within the mold cavity from a relatively small volume area towards the visible area of ​​the mold cavity where the decorative layer is formed after the actuating component is manufactured. This preferably continuous volume increase smooths the volumetric flow of the melt as it transitions from the gate region to the visible area of ​​the decorative layer.

[0052] It is particularly advantageous that the gate lip or gate lug having the at least one gate region is preferably formed in the end region of the actuating member and especially in the convergent region of the actuating member.

[0053] The "convergence region" of the actuating component can be particularly considered in the corner region at the end of the actuating component, especially the corner region that is pointed or wedge-shaped and tapering.

[0054] By forming a gate lip or gate lug in the end region of the actuating member, and especially in the convergent region of the actuating member, it is more advantageous to continuously widen the source flow (Quellfluss) of the plastic melt when forming the visible area of ​​the actuating member, which has a positive effect on the homogenization of the plastic melt.

[0055] In an alternative to or in addition to the previously mentioned embodiments (where the gate lip or gate lug having at least one gate region has a configuration that is at least substantially U-shaped, V-shaped, or wedge-shaped when viewed from a top view), it is proposed that, in a top view, the gate lip or gate lug has two boundary lines that extend outward relative to each other toward the at least one edge region or arcuate region and adjoin the carrier substrate, and these boundary lines converge particularly continuously and preferably stably over at least one and especially two curved regions having a constant curvature within the at least one gate region.

[0056] In this design of the gate lip or gate lug, a suitable homogenization zone of the heated plastic melt is achieved in a particularly efficient yet still simple manner when forming the decorative layer of the actuating component.

[0057] In this respect, it has proven particularly efficient to form an angle α between these boundary lines extending outward toward the at least one edge region or arcuate region, where 90° > α > 10°. However, other angle ranges can certainly be considered here.

[0058] Preferably, these outwardly extending boundary lines transition into the at least one edge region or arcuate region on curved regions having constant and particularly equal curvature. In the implementation of the actuating member according to the invention, the curvature of the curved region used to transition these outwardly extending boundary lines into the at least one edge region or arcuate region preferably corresponds to the curvature of the at least one curved region used to bring together these boundary lines adjacent to the carrier substrate.

[0059] The homogenization and stabilization of the plastic melt during the formation of the decorative layer, especially in the visible area of ​​the decorative layer, can be carried out in a particularly preferred manner, such that not only is the volume area at the gate area increased in the direction of the visible area of ​​the decorative layer, but the heated plastic melt is also deflected when transitioning to the visible area of ​​the decorative layer.

[0060] For this purpose, it is preferable that the at least one edge region or arcuate region between the at least one gate region and the visible region of the decorative layer is selected such that the decorative layer preferably turns continuously from the at least one gate region to the visible region at an angle β of at least 35° and more preferably at an angle β of at least 45°.

[0061] Alternatively or additionally, according to the design of the present invention, at least one edge region or arcuate region between the at least one gate region and the visible region of the decorative layer is selected such that the decorative layer preferably deflects continuously from the gate region to the visible region by an angle β of up to 155° and more preferably by an angle β of up to 145°.

[0062] In a preferred embodiment of the actuating member according to the invention, it is proposed that a gate lip or gate lug is formed in a region of the decorative layer, which is preferably continuously connected to a visible region of the decorative layer via a single edge region or arcuate region, wherein the decorative layer is continuously deflected from the gate region to the visible region by an angle β of at least 35° and at most 155° via the single edge region or arcuate region, and wherein the gate region is preferably formed by a straight tunnel gate.

[0063] In this context, it is preferred that the area where the decorative layer forms the gate lip or gate lug has a first layer thickness B at least in the edge region or arcuate region, wherein the area where the decorative layer forms the visible region has a second layer thickness A at least in the edge region or arcuate region.

[0064] The thickness of the first layer, B, should be less than that of the second layer, A, in order to achieve effective volumetric flow stabilization and homogenization as the heated plastic melt transitions from the gate area of ​​the decorative layer to the visible area of ​​the decorative layer.

[0065] According to the implementation of the actuating member of the present invention, the second layer thickness A is preferably 0.5 mm to 3.5 mm, at least in the edge region or arcuate region, while the first layer thickness B is preferably 0.4 mm to 3.3 mm, at least in the edge region or arcuate region. However, other orders of magnitude for the first layer thickness and / or the second layer thickness are of course conceivable.

[0066] According to a preferred improvement of the last mentioned embodiment, the gate region is preferably formed as at least substantially circular or elliptical and has an average diameter C, wherein the average diameter C of the gate region is less than the layer thickness B of the area of ​​the decorative layer where the gate lip or gate lug is formed.

[0067] In particular, according to the implementation method mentioned last, the average diameter C of the gate region is preferably 0.3 mm to 3.1 mm, and the thickness B of the region where the gate lip or gate lug is formed in place or attached to the decorative layer is preferably 0.4 mm to 3.3 mm.

[0068] According to an embodiment of the actuating member of the present invention, the gate lip or gate lug transitions through an intermediate region to the visible region of the decorative layer, wherein only the edge region or arcuate region is arranged between the intermediate region and the visible region, and wherein the decorative layer has a layer thickness B in the region of the gate lip or gate lug and in the intermediate region, the layer thickness preferably being in the range of 0.4 mm to 3.3 mm.

[0069] On the other hand, according to an improved embodiment mentioned last, the intermediate region has a length D that is greater than the thickness A of the decorative layer in the visible region (at least in the edge region or arcuate region), wherein the decorative layer has a thickness of preferably 0.5 mm to 3.5 mm in the visible region.

[0070] These dimensions create a homogenization zone where the heated plastic melt is homogenized into a smooth volumetric flow during the formation of the decorative layer, thus preventing localized densification of the melt. This method allows for an exceptionally high surface quality of the decorative layer.

[0071] According to an embodiment of the actuating member of the present invention, the gate region is formed on the side opposite to the visible region of the actuating member.

[0072] In this embodiment, the gate lip or gate lug is formed particularly in the area of ​​the decorative layer, which is connected to the middle area of ​​the decorative layer via a first edge area or arcuate area, wherein the middle area of ​​the decorative layer is preferably connected to the visible area of ​​the decorative layer via a second edge area or arcuate area.

[0073] In the first edge region or arcuate region, the decorative layer is deflected by an angle γ of at least 45° and preferably by an angle γ of about 90°, wherein in the second edge region or arcuate region of the decorative layer, the decorative layer is preferably continuously deflected by an angle β of at least 35° and preferably at most 155°.

[0074] In order to achieve the best possible homogenization of the melt poured through the gate area, it is preferred in this embodiment that the area where the decorative layer is formed has a visible area with a layer thickness A at least along the edge area or arcuate area, wherein the middle area of ​​the decorative layer has a layer thickness B at least along the edge area or arcuate area, wherein the layer thickness B is less than the layer thickness A.

[0075] Thus, for example, it can be envisioned that the thickness B of the decorative layer in the middle area is between 0.6 and 1.4 mm, while the thickness A of the decorative layer in the visible area (at least along the edge area or curved area) is between 0.8 and 1.6 mm.

[0076] In this way, the liquid melt increases in size as it transitions from the intermediate region to the visible region of the decorative layer, thus stabilizing the melt and preventing localized densification within the melt.

[0077] In this context, it is particularly preferred that the gate region is formed in a shape that is at least substantially circular or elliptical and has an average diameter C, wherein the average diameter C of the gate region is smaller than the layer thickness B of the middle region of the decorative layer. For example, the average diameter C of the gate region can be in the range of 0.4 mm to 1.2 mm.

[0078] According to an embodiment of the invention, a carrier base or decorative layer is manufactured in a first injection molding process using a first mold half and a second mold half, thereby producing a first molded portion. Then, in a second injection molding process onto the first molded portion, preferably a decorative layer or carrier base is manufactured on the outer surface of the first molded portion, that is, especially after replacing the first and / or second mold half, thereby producing a second molded portion, while the first molded portion remains in one of the first and second mold half until the second molded portion has been cast onto the first molded portion.

[0079] This allows for a well-defined boundary between the first and second plastics and achieves a particularly high-quality surface, because each of the carrier substrate and the decorative layer is gated for this optimized geometry and the position of the first molded portion is exactly where it should be for the second injection molding pass.

[0080] According to the embodiment, the second plastic in the region where the edge region or arcuate region is formed has an increased thickness compared to the second plastic in the region farther from the gate region. This makes it possible to create the edge or arcuate region using a second material without the need for undercutting. Therefore, manufacturing can be simplified.

[0081] By setting a corresponding homogenization region for the second plastic melt, the quality of the surface appearance can be improved, especially when a high gloss and / or metallic surface appearance is desired, because the second plastic can flow over a wide surface area in the region that becomes the front surface of the actuating component.

[0082] According to an embodiment, the at least one edge region or arcuate region of the second plastic extending from the front side of the actuating member to the back side of the actuating member extends over at least 25%, preferably at least 40%, particularly preferably at least 70%, and most preferably 99% of the boundary between the front and back sides of the actuating member, and preferably extends along at least the upper region of the actuating member.

[0083] This can further improve the appearance of the actuating component as observed from the vehicle's interior space, since the trim layer extends primarily rearward. For example, when the upper region of the actuating component (typically installed in the door) is formed by a rearward-extending first component, vehicle occupants might not notice that the actuating component is composed of two materials.

[0084] According to a preferred embodiment, the decorative layer has a constant thickness over at least 70%, preferably at least 80%, of its visible area, that is, in the case of uncertainty, the deviation is less than 30%, preferably less than 20%, of the average thickness.

[0085] This further improves the appearance of the decorative layer by improving the volume flow of the second plastic material.

[0086] The preferred carrier substrate has a variable thickness in areas where the decorative layer has a constant thickness, meaning that the deviation is greater than 30%, preferably greater than 50%, of the average thickness in uncertain cases. This thickness is preferably measured from the front to the back, specifically along a surface reference line.

[0087] According to an embodiment of the actuating member of the present invention, the decorative layer has a thickness in the range of 0.5 to 3.5 mm, and preferably in the range of 0.7 mm to 1.7 mm, over 70% of its visible area.

[0088] This further improves the appearance of the decorative layer by improving the volumetric flow of the second plastic material during its formation. Regarding thickness, we have determined that to avoid obstructions, the thickness should not be less than a specified range (preferably, even more preferably), and to avoid zebra stripes, the thickness should not exceed the specified range, thereby minimizing the risk of these undesirable effects.

[0089] According to the design of the actuating component of the present invention, the decorative layer has a surface roughness RA of less than or equal to 2 μm, preferably less than or equal to 1.1 μm, or preferably a gloss of at least 60 gloss measured at 60°, preferably at least 70 gloss measured at 60°, on 70% or more of its visible area.

[0090] This further improves the appearance of the decorative layer. It has been found that the present invention is particularly suitable for high-gloss surfaces that are highly sensitive to volumetric turbulence and material shrinkage during the formation of the decorative layer.

[0091] According to another design, the decorative layer constitutes at least 90%, and preferably at least 99%, of the visible area of ​​the actuating component.

[0092] Furthermore, the carrier substrate can be made of reinforced plastic, especially glass fiber reinforced plastic. This allows for particularly good carrier properties. A wide variety of material combinations for the carrier substrate and decorative layer are theoretically conceivable. Only a few possible material combinations are given exemplarily below:

[0093] ●Carrier-based reinforced PA6 / Decorative layer decorative PA6

[0094] ●Carrier base PA6 with a cool touch effect / Decorative layer PA6

[0095] ●Reinforced carrier substrate SAN / decorative layer PC-ABS or ABS

[0096] ●Reinforced carrier substrate POM / decorative layer decorative POM.

[0097] According to other design schemes, the carrier substrate and the decorative layer can be composed of the same plastic base material, wherein the plastic of the carrier substrate is preferably reinforced, especially reinforced with glass fiber. This further simplifies the two-component injection molding process.

[0098] Furthermore, the first and second plastics can be identical, preferably both reinforced with filler (e.g., glass fiber). In this case, it is preferable that the surface of the decorative layer is granular. Other techniques exist for manufacturing granular, near-surface actuating components, which typically require specific construction of gas-assisted injection molding or carrier substrates to avoid a large plastic proportion (which leads to shrinkage that may even be visible on the granular surface). However, this new technique with a two-layer (or multi-layer) configuration makes it less necessary or even unnecessary to use specific designs of gas-assisted injection molding or carrier substrates, because the decorative layer itself is thin enough to avoid shrinkage and is formed in a single pour.

[0099] The decorative layer can be a different color from the substrate. This allows for a great deal of design freedom. However, in principle, the decorative layer and the substrate can also be the same color.

[0100] According to another design, the visible area of ​​the decorative layer, and preferably the decorative layer, can be composed of a plastic with a metallic appearance. Such plastics with a metallic appearance (metallic molding, MIMC), which can be manufactured particularly by plastic injection molding, are known per se. These plastics have a surface finish similar to chrome plating, but without the environmental and health problems associated with chrome plating. Furthermore, as already explained, such plastics with a metallic appearance typically lack the required durability. This problem is solved by the actuation member structure according to the invention.

[0101] According to another design, the carrier substrate can be composed at least partially of a plastic with a cool-touch effect.

[0102] Mineral fillers or metal particles, especially ferromagnetic metal particles, can be embedded in the plastic substrate. By embedding mineral fillers or metal particles in the plastic, a cool feel associated with metal surfaces is typically achieved, even when using plastic materials that can be processed accordingly in plastic injection molding processes.

[0103] For example, the carrier substrate can form the back of the actuating component, which is gripped by vehicle occupants to actuate the door and is away from the vehicle interior. By forming the back of the component with a plastic having a cool-touch effect, combined with a metallic-looking plastic for the decorative layer (and preferably the visible area of ​​the decorative layer) forming the front of the actuating component facing the vehicle interior, the vehicle occupants are given the visual and tactile impression of a metal handle.

[0104] To enhance the cold-touch effect, the carrier substrate can be made of plastic with good thermal conductivity. In the context of this invention, the plastic preferably exhibits a cold-touch effect when the value measured by the "HapTemp" device developed for this purpose by "ZIEGLER-Instruments GmbH" is equal to or less than 19, preferably equal to or less than 15. This instrument is capable of measuring the equivalent value of the perceived tactile temperature, where steel has a value of 0, glass has a value of 10, and Teflon has a value of 20. These values ​​are based on the "HapTemp" device manufactured in 2012 (serial number 12.11.1), with software version 16.2.8, as of January 2019.

[0105] According to another design approach, cavities can be formed within the carrier substrate. Plastics with a cold-touch effect, or those with embedded mineral fillers or metal particles, have high density. To counteract this effect, cavities can be formed within the carrier substrate. For example, in plastic injection molding processes, this can be achieved by injecting gas into still-flowable plastic to cause displacement of the corresponding material. Such cavities could also be envisioned in plastics such as PA6-GF30.

[0106] According to another design scheme, the decorative layer, and especially the visible area of ​​the decorative layer, has been bonded to the carrier substrate using an in-mold coating method. In this context, in-mold coating is considered an injection molding method. This manufacturing method essentially corresponds to a two-component injection molding method, wherein the cavity of the injection molding tool for forming the decorative layer has a very small thickness. For example, the thickness of this cavity can be less than 1 mm, preferably less than 0.3 mm. The component (color) forming the decorative layer is pressed into the cavity for the decorative layer after injection molding the carrier substrate and forms a surface similar to a paint layer after curing. In this way, the design freedom of the decorative layer in terms of color can be further improved while maintaining high surface quality.

[0107] The present invention also addresses the aforementioned problems by providing a method for manufacturing an inner door handle assembly according to the invention, wherein the inner door handle assembly is manufactured at least partially using a multi-component injection molding method, such as a two-component injection molding method or a three-component injection molding method. As already described, this allows for the production of exceptionally high-quality surfaces using a manufacturing design approach, while simultaneously achieving high durability.

[0108] According to an embodiment, the injection molding method includes manufacturing the actuating component according to at least the following steps:

[0109] A) Manufacture one of the following:

[0110] -The carrier substrate is made of the first plastic, and

[0111] - In the case of using a first mold half and a second mold half that define the first cavity, a decorative layer is manufactured from a second plastic in the first injection molding process, thereby producing the first molded portion.

[0112] B) After replacing the second mold half and / or the second mold half to define the second cavity, a corresponding other carrier base and decorative layer are preferably manufactured on the outer surface of the first molded portion during the second injection molding process, thereby creating the second molded portion, while the first molded portion remains in one of the first mold half and the second mold half until the second molded portion has been injected onto the first molded portion, wherein the first molded portion is preferably held in the corresponding cavity by means of a slider or by means of the undercut geometry of the corresponding cavity, the slider being preferably a slider that blocks the bore for the rotation axis of the actuating component, thereby thereby subsequently ejecting the component from the mold, preferably by means of a forced demolding mechanism.

[0113] This allows for the design of the surface and parting line between the two plastics, thereby improving the appearance quality of the decorative layer. The method preferably includes a further tool change during the first injection molding process, thereby creating a third region, specifically by injecting a third plastic onto the first and / or second molding portions to produce the third molding portion. The third plastic is preferably softer and / or has a cool-touch effect than the first and / or second plastics. "Obscuration" is preferably understood herein as covering a volume, while "removal of obscuration" is understood as releasing the obscured volume.

[0114] According to one embodiment of the manufacturing method of the present invention, the decorative layer is, or will be, at least partially visible directly from and facing the vehicle interior, wherein the actuating member has a front facing the vehicle interior and a back facing away from the vehicle interior space, wherein preferably the carrier substrate is manufactured in the first injection molding process and the decorative layer is manufactured in the second injection molding process, wherein a second plastic is injected into the cavity in which the decorative layer is to be formed in the first cavity and the second cavity as follows:

[0115] A) Injection is made at the location of the back area where it should be the actuating component, such that the second plastic flows along at least one concave mold edge (preferably the front edge when installed below the head position of the driver in a seated vehicle) or along at least one concave arcuate mold area facing the front of the actuating section, or

[0116] B) Injection is performed at a location covered by a housing (e.g., covered by a housing wall between the vehicle interior space and the location where the actuating member should be movably arranged).

[0117] According to one design, the second plastic flows around the edge of the at least one mold or the at least one curved mold area over a width of at least 5 mm, preferably at least 10 mm.

[0118] This improves surface quality by better balancing the flow of the second plastic material. It also allows the material of the carrier substrate to be concealed from other viewing angles or when the actuating member is activated.

[0119] According to the present invention, in this manufacturing method, a second plastic melt first flows through a homogenization region and then forms a visible area of ​​the decorative layer. This homogenization region is formed by stabilizing the plastic melt during its flow and continuously allowing it to flow into the cavity, and this region forms a visible area of ​​at least the decorative layer in the finished actuating member.

[0120] This allows for the direct acquisition of a high-gloss surface from the mold, and a high-quality appearance can be achieved without further surface treatment by using the special two-component design according to the invention.

[0121] The embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0122] In the attached diagram:

[0123] Figure 1 An exemplary embodiment of the inner door handle assembly according to the present invention is shown schematically and in isometric view;

[0124] Figure 2 The enlarged view schematically illustrates, and in an isometric view, the data according to... Figure 1 The actuating component or handle element of the inner door handle assembly;

[0125] Figure 3 Side A of an exemplary embodiment of the actuating member according to the present invention is shown schematically and in top view;

[0126] Figure 4 Schematic and shown in cross-section according to Figure 3 Exemplary embodiments of the actuation component of the present invention;

[0127] Figure 5A Schematic and detailed illustrations show the data based on... Figure 4 An area of ​​the actuating component is shown to illustrate an exemplary implementation of the gate area;

[0128] Figure 5B Schematic and top view shown in accordance with Figure 5A The gate area in an exemplary embodiment;

[0129] Figure 6AThe gate region of an actuating member according to another embodiment of the invention is schematically shown in cross-section; and

[0130] Figure 6B Schematic and top view showing according to Figure 6A The gating area.

[0131] Unless otherwise stated, the same reference numerals in the accompanying drawings denote the same objects.

[0132] Figure 1 The interior door handle assembly shown includes a housing 10 through which the interior door handle assembly can be installed on the door of a vehicle (e.g., a car or van).

[0133] The housing 10 has a handle recess 12, in which an actuating member 14 (in this example, a handle element 14) is received. Figure 1 The resting position is shown. From this resting position, the handle element 14 can pivot about, for example, a vertical pivot axis. Figure 1 The free end on the right side pivots out from the handle recess 12. The door is unlocked by pivoting the handle element 14 out via a corresponding connection, allowing the door to be opened by the vehicle occupant. To pivot the handle element 14 out, the vehicle occupant reaches into the handle recess 12 and grasps the handle element 14 from behind. The handle element 14 forms a handle lever in the illustrated example. Furthermore, a speaker 16 is integrated into the housing 10, surrounded by a bezel 18.

[0134] exist Figure 2 As can be seen in the enlarged view, the handle element 14 has a carrier base 20 facing away from the vehicle interior in the rest position and a decorative layer facing the vehicle interior, particularly the visible area 22.

[0135] The carrier base 20 forms the back of the handle element 14 for vehicle occupants to grip from the rear, while the visible area 22 of the trim layer forms the front of the handle element 14 directly visible from inside the vehicle. Figure 2 The left end of the handle element 14 has a support device 24, by means of which the handle element 14 can pivot on the housing 10.

[0136] The visible area 22 of the decorative layer is bonded to the carrier substrate 20 by means of material adhesion. In the example shown, the visible area 22 of the decorative layer has been injected onto the carrier substrate using a two-component injection molding method.

[0137] The carrier substrate 20 is made of plastic, such as reinforced plastic, like glass fiber reinforced plastic. The plastic may have embedded mineral fillers or embedded metal particles, such as ferromagnetic metal particles, so that vehicle occupants feel a cool surface and thus a metallic impression when they grip the carrier substrate 20 from the rear to pivot the handle element 14 out of the handle recess 12 of the housing 10.

[0138] Correspondingly, the visible area 22 of the decorative layer can be composed of plastic with a metallic appearance (metallic molding, MIMC).

[0139] However, the visible area 22 of the decorative layer may also be composed of other plastics, such as plastics of different colors. The visible area 22 may also have been bonded to the carrier substrate 20 by in-mold coating.

[0140] In the example shown, the bezel 18 of the speaker 16 has also been injected into the housing 10 using a two-component injection molding process. The bezel 18 may, for example, be composed of the material used for the visible area 22 of the decorative layer.

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

[0142] The following is for reference Figures 3 to 5B The illustrations in the figure provide a detailed description of an exemplary embodiment of the actuating member or handle element 14.

[0143] Specifically, Figure 3 Side A of an exemplary embodiment of the actuating member or handle element 14 is shown schematically and in top view, while Figure 4 The diagram illustrates the following based on Figure 3 Longitudinal cross-sectional view of the actuating component or handle element 14.

[0144] As shown, the actuating member or handle element 14 of the present invention includes a carrier substrate 20 formed of a first plastic material and a decorative layer 21 that at least partially covers the surface of the carrier substrate 20. It is particularly noted here that the decorative layer 21 includes not only the visible area 22 (in...) Figure 3 As can be seen from the image, it also includes the edge region 23 of the actuating component or handle element 14.

[0145] Specifically, the edge region 23 is connected to the visible region 22 of the decorative layer 21 via the edge region or arcuate region 25, such as from... Figure 4 This was obtained from the cross-sectional view.

[0146] The actuating member or handle element 14 according to this exemplary embodiment is preferably manufactured by a two-component injection molding process. In particular, it is mentioned here that the plastic material of the decorative layer 21 is at least partially coated onto the surface of the carrier substrate 20 and bonded to the carrier substrate 20 by means of material bonding.

[0147] In order to manufacture the actuating component or handle element 14 and especially to form a decorative layer 21 on these areas of the surface of the carrier base 20, it is proposed that the plastic material of the decorative layer 21 be injected as a heated injection molding compound into the corresponding mold cavity via a gating channel, wherein the mold cavity is partially constrained by the carrier base 20 and at least one tool plate (not shown in the figure).

[0148] For this purpose, an injection molding tool with at least one distribution channel leading to the gate region 2 is used. In particular, at least one point gate is provided in the embodiment of the invention so as to form a decorative layer 21 at least partially on the carrier substrate 20.

[0149] As will be described in detail below, the present invention particularly includes an underflur-anguss system, such as a so-called banana-shaped gate, to form a decorative layer 21 on the carrier substrate 20. The decorative layer 21 is injected such that the heated injection molding compound of the plastic material of the decorative layer 21 is homogenized in the mold cavity corresponding to the decorative layer 21 and the volumetric flow is smooth. The heated injection molding compound is then brought to a region of the mold cavity, which corresponds to the visible region 22 of the manufactured actuating member or handle element 14.

[0150] The following is for reference. Figure 5A and Figure 5B The diagram in the figure illustrates an exemplary implementation of possible gating methods.

[0151] Specifically, in Figure 5A The enlarged diagram illustrates the situation in... Figure 4 The edge region or curved region 25 shown is (specifically, together with the sprue channel 3 of the injection molding tool). The sprue channel 3 terminates here in a region of the mold cavity that is not part of side A of the manufactured actuating member or handle element 14. The sprue channel 3, however, terminates in a side region or edge region 23, which is connected to the visible region 22 of the actuating member or handle element 14 via the edge region or curved region 25.

[0152] As in Figure 5AAs shown in the schematic cross-sectional view, the gate channel 3 preferably has a cross-sectional shape that converges in the direction of the gate region 2, so that the heated injection molding melt of the plastic material for the decorative layer 21 can be injected into the side region or edge region 23 of the mold cavity accordingly.

[0153] exist Figure 5B The top view schematically shows the data according to... Figure 5A The gating area 2 of the gating channel 3.

[0154] In summary, the gate region 2 is formed in the gate lip or gate lug 4, wherein the gate region 2 is continuously connected to the visible area 22 of the decorative layer 21 via the edge region or arcuate region 25.

[0155] In particular, it is advantageous that the gate lip or gate lug 4 forming the gate region 2 is shown in the top view (see [see image]). Figure 5B The gate has a design that is at least substantially U-shaped, V-shaped, or wedge-shaped. Here, the gate lip or gate lug 4 tapers from the edge region or arcuate region 25 toward the gate region 2.

[0156] In other words, in Figure 5B In the top view of the gate lip or gate lug 4 shown, the gate lip or gate lug 4 has two boundary lines 5 that extend outward from each other and are adjacent to the carrier substrate 20 in the direction of the edge region or arcuate region 25, wherein these two boundary lines 5 converge continuously within the gate region 2.

[0157] With this implementation of the gate region 2, a corresponding homogenized region is formed in the mold cavity corresponding to the decorative layer 21 in an effective manner. Advantageously, it is proposed that an angle α be formed between the boundary lines 5 extending outward in the direction of the edge region or arcuate region 25, wherein this angle is between 10° and 90°.

[0158] However, other angle ranges can certainly be considered here.

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

[0160] exist Figure 5A and 5BIn the illustrated embodiment, a gate lip or gate lug 4 is formed in a region of the decorative layer 21, which is continuously connected to the visible region 22 of the decorative layer 21 via a single edge region or arcuate region 25, wherein the decorative layer 21 is deflected from the gate region 2 to the visible region 22 by a minimum angle β of 35° via the edge region or arcuate region 25. Here, the gate region 2 is preferably formed by a straight tunnel gate (gate channel 3).

[0161] In order to form a corresponding homogenized area in the mold cavity of the decorative layer 21 including the actuating member or handle element 14, it is preferably proposed that the area of ​​the decorative layer 21 where the gate lip or gate lug 4 is formed has a first layer thickness B at least in the edge area or arcuate area 25, wherein the area of ​​the decorative layer 21 where the visible area 22 is formed has a second average layer thickness A at least in the edge area or arcuate area 25.

[0162] It is particularly noted that, at least in the edge region or arcuate region 25, the thickness B of the first layer is less than the thickness A of the second layer. According to a preferred embodiment, at least in the edge region or arcuate region 25, the thickness A of the second layer is preferably 0.5 mm to 3.5 mm, while the thickness B of the first layer is preferably 0.4 mm to 3.3 mm.

[0163] Furthermore, in order to achieve the most efficient homogenization of the second plastic material melt when pouring it into the mold cavity, it is advantageous that the gate region 2 is preferably formed as at least substantially circular or elliptical (see [reference]). Figure 5B (Top view) and has an average diameter C, as shown in Figure 5A As shown in the image.

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

[0165] According to a conceivable implementation of the actuating member or handle element 14 of the present invention, the average diameter C of the gate region 2 is preferably 0.3 mm to 3.1 mm, and the thickness B of the decorative layer 21 in the region where the gate lip or gate lug 4 is formed is preferably 0.4 mm to 3.3 mm. However, other dimensions corresponding to the diameter or thickness are of course conceivable.

[0166] exist Figure 6A and Figure 6B An alternative embodiment of the actuating member or handle element 14 is shown.

[0167] Also compared with previous references Figures 3 to 5B Similar to the embodiment shown in the figure, the embodiment of the gate region 2 for the decorative layer 21 shown in Figure 6 is set in a region of the corresponding mold cavity, which is different from the visible region 22 of the decorative layer 21.

[0168] Especially in Figure 6A In the embodiment shown, the second plastic material of the decorative layer 21 is poured into the corresponding mold cavity through the banana-shaped gate 6.

[0169] exist Figure 6A The implementation methods shown are the same as Figure 5A The difference in the illustrated embodiment lies particularly in that the gate region 2 is formed in the gate lip or gate lug 4, which is formed in a region of the decorative layer 21. This region is connected to the central region 27 of the decorative layer 21 via a first edge region or arcuate region 26, wherein the central region 27 of the decorative layer 21 is preferably continuously connected to the visible region 22 of the decorative layer 21 via a second edge region or arcuate region 25. By providing such a central region 27, particularly efficient homogenization of the plastic melt can be achieved when the plastic melt is poured into the mold cavity.

[0170] The first edge region or arcuate region 26 is preferably formed such that the decorative layer 21 is deflected by an angle γ of at least 45° and preferably by an angle γ of about 90° in the first edge region or arcuate region 26, wherein in the second edge region or arcuate region 25 of the decorative layer 21, the decorative layer 21 is deflected by an angle β of 35° and by a maximum angle β of 155°.

[0171] exist Figure 6B The top view shows the data according to... Figure 6A The gate lip or gate lug 4 of the gate region 2 in an exemplary embodiment.

[0172] Also with Figure 5B Similar to the gate lip or gate lug 4 shown schematically, in accordance with Figure 6B In one embodiment, the gate lip or gate lug 4 forming the gate region 2 has a design that is at least substantially U-shaped, V-shaped, or wedge-shaped in a top view, wherein the gate lip or gate lug 4 extends from the first edge region or arcuate region 26 toward the gate region 2.

[0173] Specifically, in the top view of the gate lip or gate lug 4 (see...) Figure 6B In the first edge region or arcuate region 26, the gate lip or gate lug 4 has two boundary lines 5 that extend outward from each other and are adjacent to the carrier substrate 20 in the direction of the first edge region or arcuate region 26, and these boundary lines converge continuously within the gate region 2.

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

[0175] The actuating component or handle element 14 is preferably manufactured by a multi-component injection molding process through the following steps:

[0176] A) In the first injection molding process, a carrier substrate 20 of the first plastic is manufactured using a first mold half and a second mold half that define the first cavity, thereby producing the first molded portion;

[0177] B) After replacing the second mold half to define the second cavity, a decorative layer 21 is formed on the outer surface of the first molded portion during a second injection molding process onto the first preform, thereby creating the second molded portion, while the first molded portion remains in the first mold half until the second molded portion has been cast onto the first molded portion. The first molded portion is preferably held in the corresponding cavity by a slider, for example, covering a hole for the rotation axis of the handle element.

[0178] In the second injection molding process, the heated injection molding compound of the second plastic is first injected into a homogenization region in the mold cavity defined by the first molding portion and the second mold half, wherein the homogenization region is selected to homogenize the melt and smooth the volumetric flow of the melt.

[0179] The molten plastic then flows toward the visible side of the actuating member through at least one edge region or arcuate region 25, thereby forming the molten plastic in the visible region 22.

[0180] The present invention particularly provides an interior door handle / method for manufacturing such a door handle (actuating element). The door handle has at least two plastic layers, specifically a first plastic layer formed by a carrier substrate 20 and a second plastic layer formed by a decorative layer 21, wherein the two plastic layers are bonded together by injection molding. The first layer forms the back side of the actuating element or handle element 14, while the second layer forms the visible front side.

[0181] Preferably, the first layer is formed through 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 the region of the first cavity.

[0182] By injecting a second layer into the tool cavity to homogenize the plastic melt before it flows into the visible area of ​​the actuation component / handle element, a surface structure of the visible area with special quality can be obtained.

[0183] The invention is not limited to the embodiments shown in the accompanying drawings, but is derived from an overview of all the features disclosed herein.

[0184] List of reference numerals

[0185] 2. Gating area

[0186] 3. Gating channel

[0187] 4. Gate lip / gate lug

[0188] 5. Boundary Line

[0189] 6. Banana-shaped gate

[0190] 10. Shell

[0191] 12 Handle Grooves

[0192] 14 Actuating components / handle elements

[0193] 16 speakers

[0194] 18. Pinning

[0195] 20 Carrier substrate

[0196] 21 Decorative Layer

[0197] 22 Visible area of ​​the decorative layer

[0198] 23 Edge area of ​​decorative layer

[0199] 24 Supporting devices

[0200] 25 Edge area / curved area

[0201] 26 Edge Area / Curved Area

[0202] 27. Middle area of ​​the decorative layer

Claims

1. An actuating member (14) of an interior door handle assembly of a vehicle, wherein the actuating member (14) has a carrier substrate (20) formed of plastic and a decorative layer (21) at least partially covering a surface of the carrier substrate (20), wherein a back face of the actuating member is formed by the carrier substrate and a front face of the actuating member is formed by the decorative layer, the front face being opposite to the back face, wherein the decorative layer (21) has: - a visible area (22) on the front face, which forms a visible side of the actuating member (14) in an intended mounted state of the actuating member (14) and further in an unactuated state of the actuating member (14); - at least one gate area (2) formed in a gate lip or gate lug (4); and - at least one edge or arc area (25, 26) via which the gate lip or gate lug (4) is continuously connected with the visible area (22) of the decorative layer (21); wherein a boundary line is formed by an edge portion of the decorative layer, which is visible adjacent to a surface of the carrier substrate; wherein, viewed in a top view of the gate lip or gate lug, the gate lip or gate lug has two boundary line sections which, relative to each other, flare out towards the at least one edge or arc area and adjoin the carrier substrate, the two boundary line sections converging continuously and over at least two curved areas with constant curvature in a direction towards a distal end of the gate lip or gate lug, such that an end of the gate lip or gate lug is defined by a curved boundary area of the boundary line.

2. The actuating member (14) according to claim 1, wherein the gate lip or gate lug (4) in which the at least one gate area (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 an angle a is formed between the boundary line sections which flare out in the direction of the at least one edge or arc area (25, 26), wherein 90° > a > 10°.

4. The actuating member (14) according to claim 1, wherein the at least one edge or arc area (25, 26) is located between the at least one gate area (2) and the visible area (22) of the decorative layer (21) such that the decorative layer (21) continuously deflects by a minimum angle β of 35° from the at least one gate area (2) towards the visible area (22).

5. The actuating member (14) according to claim 1, ​ ​ ​ ​ ​ ​ ​ ​ wherein the gate lip or gate tab (4) is formed in a region of the decorative layer (21) which is continuously connected to the visible region (22) of the decorative layer (21) via a single edge region or arc region (25), wherein the decorative layer (21) is deflected via the single edge region or arc region (25) by an angle β of at least 35° and at most 155° from the at least one gate region (2) to the visible region (22).

6. The actuating member (14) according to claim 5, wherein the region of the decorative layer (21) in which the gate lip or gate tab (4) is formed has a first average layer thickness B at least at the edge region or arc region (25), and wherein the region of the decorative layer (21) in which the visible region (22) is formed has a second average layer thickness A at least at the edge region or arc region (25), wherein the first average layer thickness B is smaller than the second average layer thickness A, wherein the second average layer thickness A is 0.5 mm to 3.5 mm, and wherein the first average layer thickness B is 0.4 mm to 3.3 mm.

7. The actuating member (14) according to claim 5, wherein the gate lip or gate tab (4) transitions into the visible region (22) of the decorative layer (21) via an intermediate region (27), wherein the single edge region or arc region (25) is arranged between the intermediate region (27) and the visible region (22), wherein the decorative layer (21) has an average layer thickness B in the region of the gate lip or gate tab (4) and in the intermediate region (27), wherein the average layer thickness B is 0.4 mm to 3.3 mm.

8. The actuating member (14) according to claim 7, wherein the intermediate region (27) has an average length D which is greater than the average layer thickness A of the decorative layer (21) in the visible region (22), wherein the decorative layer (21) has an average layer thickness of 0.5 mm to 3.5 mm in the visible region (22).

9. The actuating member (14) according to claim 1, wherein the gate lip or gate tab (4) is formed in a region of the decorative layer (21) which is connected to an intermediate region (27) of the decorative layer (21) via a first edge region or arc region (26), wherein the intermediate region (27) of the decorative layer (21) is continuously connected to the visible region (22) of the decorative layer (21) via a second edge region or arc region (25), wherein the decorative layer (21) is deflected in the first edge region or arc region (26) by an angle γ of at least 45°, and wherein the decorative layer (21) is deflected in the second edge region or arc region (25) of the decorative layer (21) by an angle β of at least 35° and at most 155°.

10. The actuating member (14) according to claim 9, wherein the intermediate region (27) of the decorative layer (21) has an average layer thickness B, and wherein the visible region (22) of the decorative layer (21) has an average layer thickness A at least at the edge region or arc region (25), wherein the average layer thickness B of the intermediate region (27) of the decorative layer (21) is smaller than the average layer thickness A of the visible region of the decorative layer (21), wherein the average layer thickness B of the intermediate region (27) of the decorative layer (21) is in the range between 0.3 mm and 3.5 mm at least in the edge region or arc region (25), and wherein the average layer thickness A of the visible region of the decorative layer (21) is in the range between 0.4 mm and 3.7 mm at least at the edge region or arc region (25).

11. The actuating member (14) according to claim 1, wherein the decorative layer (21) is made of a plastic material with embedded pigments.

12. A method for manufacturing an actuating member according to claim 1 in a multi-component injection molding process, wherein the method has the following method steps: A) manufacturing the 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 portion; and B) after replacing the second mold half to define a second cavity, manufacturing the decorative layer (21) on the outer surface of the first molded part in a second injection molding shot onto the first molded part, resulting in a second molded part, while the first molded part remains in the first mold half until the second molded part has been cast onto the first molded part, or wherein the method has the following method steps: A) manufacturing the 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) after replacing the second mold half to define a second cavity, manufacturing the carrier substrate (20) on the outer surface of the first molded part in a second injection molding shot onto the first molded part, resulting in a second molded part, while the first molded part remains in the first mold half until the second molded part has been cast onto the first molded part, wherein in the second injection molding shot, a heated injection molding compound of a second plastic is first injected into a homogenization region in the mold cavity defined by the first molded part and the second mold half, wherein the homogenization region is selected such that the melt is homogenized and the volume flow of the melt becomes smooth.

13. An actuating member of a vehicle interior door handle assembly, wherein the actuating member has a carrier substrate formed of a plastic and a decorative layer at least partially covering a surface of the carrier substrate, wherein a back face of the actuating member is formed by the carrier substrate and a front face of the actuating member is formed by the decorative layer, the front face being opposite to the back face, wherein the decorative layer has: - a visible area on the front face, which visible area forms the visible side of the actuation member in the intended mounted state of the actuation member and further in the unactuated state of the actuation member; - at least one gate area formed in a gate lip or gate lug; and - at least one edge area or arcuate area, via which the gate lip or gate lug is continuously connected with the visible area of the decorative layer; wherein, viewed in a top view of the gate lip or gate lug, the gate lip or gate lug has two boundary lines defined by edge portions of the decorative layer, which edge portions are adjacent to the surface visible area formed by the carrier substrate, which two boundary lines diverge from each other towards the at least one edge area or arcuate area and are adjacent to the carrier substrate, which two boundary lines converge continuously and over at least two curved areas with constant curvature in a direction towards the distal end of the gate lip or gate lug.

14. An actuation member of an interior door handle assembly of a vehicle, wherein the actuation member has a carrier substrate formed of plastic and a decorative layer at least partially covering a surface of the carrier substrate, wherein a back face of the actuation member is formed by the carrier substrate and a front face of the actuation member is formed by the decorative layer, the front face being opposite to the back face, wherein the decorative layer has: - a visible area on the front face, which visible area forms the visible side of the actuation member in the intended mounted state of the actuation member and further in the unactuated state of the actuation member; - at least one gate area formed in a gate lip or gate lug; and - at least one edge area or arcuate area, via which the gate lip or gate lug is continuously connected with the visible area of the decorative layer; wherein a boundary line is formed by an edge portion of the decorative layer, which edge portion is adjacent to a surface visible portion of the carrier substrate; wherein, viewed in a top view of the gate lip or gate lug, the gate lip or gate lug has two boundary line sections which diverge from each other towards the at least one edge area or arcuate area and are adjacent to the carrier substrate, which two boundary line sections converge continuously and over at least two curved areas with constant curvature in a direction towards the distal end of the gate lip or gate lug; wherein an angle a is formed between the boundary line sections diverging in the direction of the at least one edge area or arcuate area, wherein 90° > a > 10°.

15. An actuation member of an interior door handle assembly of a vehicle, wherein the actuation member has a carrier substrate formed of plastic and a decorative layer at least partially covering a surface of the carrier substrate, wherein a back face of the actuation member is formed by the carrier substrate and a front face of the actuation member is formed by the decorative layer, the front face being opposite to the back face, wherein the decorative layer has: - a visible region on the front face, the visible region forming a visible side of the actuation member in an intended mounted state of the actuation member and further in a non-actuated state of the actuation member; - at least one gate region formed in the gate lip or gate tab; and - at least one edge region or arcuate region, the gate lip or gate tab being continuously connected with the visible region of the decorative layer via the at least one edge region or arcuate region; wherein a boundary line is formed by an edge portion of the decorative layer, the edge portion being visible adjacent to a surface visible portion of the carrier substrate; wherein, viewed in a top view of the gate lip or gate tab, the gate lip or gate tab has two boundary line sections facing each other outwards towards the at least one edge region or arcuate region and abutting the carrier substrate, the two boundary line sections converging continuously and over at least two curved regions of constant curvature in a direction towards a distal end of the gate lip or gate tab; wherein the at least one edge region or arcuate region is located between the gate lip or gate tab and the visible region of the decorative layer, such that the decorative layer continuously deflects from the gate lip or gate tab towards the visible region by an angle β of at least 35°.

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