METHOD FOR MANUFACTURING A COVERING DEVICE AND COVERING DEVICE

Abstract

Method for manufacturing a cover device (100), in particular a flap, preferably a fuel filler flap or loading flap for vehicles, wherein the cover device (100) comprises: - a base body (110) configured to cover an opening or surface to be covered in or on a vehicle; - a plurality of fastening elements (130, 130', 130") for attaching the cover device (100) to the opening or surface to be covered; and - at least one rib (120, 120', 120") by means of which the plurality of fastening elements (130, 130', 130") is arranged on the base body (110), wherein the method for manufacturing the cover device (100) comprises the following manufacturing steps: - a first manufacturing step for manufacturing at least the base body (110);and- a second manufacturing step, separate from the first manufacturing step, for producing at least the plurality of fastening elements (130, 130', 130"), wherein the first manufacturing step and the second manufacturing step are at least partially injection molding steps.;

Description

The invention relates to a method for producing a covering device, in particular a flap, preferably a fuel filler flap or charging flap for vehicles. The invention further relates to a covering device, in particular a flap, preferably a fuel filler flap or charging flap for vehicles.The document DE 10 2017 120 018 A1 discloses a method for producing a covering device, in particular a flap, preferably a fuel filler flap or charging flap for vehicles, wherein the covering device has the following:a base body which is designed to conceal an opening or surface to be concealed in or on a vehicle;a plurality of fastening elements for fastening the covering device to the opening to be concealed or to the surface to be concealed; andat least one rib, by means of which the plurality of fastening elements is arranged on the base body, wherein the method for producing the covering device comprises a first production step for producing at least the base body.U.S. Pat. No. 9,010,829 B2 relates to expandable barriers. Expandable barriers are typically barriers made of an expandable material and shaped to fit within a cavity. After placement in a cavity, stretchable barriers generally undergo an activation process in which the stretchable barrier expands to fill the cavity and form a physical barrier. By using different extrusion methods to produce an extensible barrier, tooling costs can be reduced while allowing more flexible barrier designs. Such designs may be tailored specifically to a particular cavity or cavities to ensure that the barrier fills the cavity after expansion.Covering devices are used at various locations in the vehicle. In principle, these serve to conceal or cover an opening or surface to be concealed in or on a vehicle. In particular, covering devices are used, for example, for tank, charging, water or other service flaps. For example, fuel flaps or charging flaps cover a fuel tank (or charging tank), which serves for fueling a vehicle with fuel or, for example, a urea solution or for charging the battery of an electric or hybrid motor vehicle.Flaps of this type are typically connected to a hinge arm which then forms the corresponding flap such that it can be pivoted between an open position which opens up the opening and a closed position which closes the opening.The flap is usually supported, i.e. fastened, on the hinge arm via shoe elements. For the sake of simplicity, the shoe elements required for fastening are manufactured in one piece with the flap. In particular, inclined slides are used during production in order to demold the undercuts produced on account of the shoe elements. After demolding, the flap can then be pushed onto the hinge arm.However, in the known manufacturing methods of the flaps, there is a problem in that during a cooling phase in the tool the shoe elements shrink in the direction of the inclined slide arranged for demolding. Since the inclined slides now hold the shoe elements in a position against shrinkage, stresses arise in the component, i.e. in the flap, which can lead to visible stress markings (sink marks) on the visible side of the flap.Therefore, in the known manufacturing methods, a high reject and advertisement rate occurs, which leads to high costs.Proceeding from the state of the art explained, the object of the invention is to specify a method for producing a covering device, in particular a flap, preferably a fuel filler flap for vehicles, which eliminates the aforementioned problems and disadvantages of the state of the art. In particular, it is the object of the present invention to specify a method in which the problems associated with shrinkage of the shoe elements no longer occur during production.In addition, the object of the invention is to specify a covering device, in particular a flap, preferably a fuel filler flap for vehicles, in which stresses in the component which can lead to stress markings on the visible side of the covering device are effectively prevented.With regard to the method, the object on which the invention is based is achieved by the subject matter of independent patent claim 1, advantageous developments of the method being specified in dependent patent claims 2 to 9.With regard to the covering device, the object on which the invention is based is achieved by the subject matter of the subordinate patent claim 10, wherein advantageous developments of the covering device are specified in the dependent patent claims 11 to 14.Accordingly, the solution according to the invention consists in particular in specifying a method for producing a covering device, in particular a flap, preferably a fuel filler flap or tailgate for vehicles, wherein the covering device has the following: a base body which is designed to conceal an opening or surface to be concealed in or on a vehicle; a multiplicity of fastening elements for fastening the covering device to the opening to be concealed or to the surface to be concealed; and at least one rib by means of which the multiplicity of fastening elements is arranged on the base body. The method for producing the covering device has, in particular, the following production steps: a first production step for producing at least the base body; and a second production step, which is separate from the first production step, for producing at least the multiplicity of fastening elements.The production method according to the invention is characterized in that the first production step and the second production step are at least partially injection molding steps.In order to conceal the opening or surface to be concealed, the base body is at least substantially planar. The base body has a visible side or visible surface which is visible in a state of the covering device mounted on the vehicle. The opposite surface is the mounting side or mounting surface on which the covering device can be mounted on the opening to be concealed or on the surface to be concealed. Preferably, the cover device is mounted on a hinge arm.For mounting the covering device on the opening to be concealed or on the surface to be concealed, preferably on the hinge arm, the plurality of fastening elements is arranged. In particular, the plurality of fastening elements is arranged on or on the rib, which in turn is arranged on the mounting side of the base body.The first production step (for injection molding) of at least the base body takes place separately, i.e. separately from the second production step (injection molding, preferably a baby plastic method) which serves for producing at least the plurality of fastening elements. This means that the base body and the fastening elements are not produced in a common production step (for example casting step).This has the advantage, on the one hand, that the base body can now be manufactured in a simple "open / close direction" (during injection molding) and (expensive) slides or inclined slides are not necessary, since no undercuts are present any longer in this manufacturing step. On the other hand, the tension markings (sink marks) on the visible side of the covering device (or of the main body thereof) are reliably prevented, since the fastening elements are no longer pressed onto the inclined slides when the main body is shrinking and can thereby cause tensions in the component. During shrinkage of the base body, no fastening elements (or shoe elements) are namely arranged, so that the inclined slides are also omitted.Thus, with the method of producing a cover device according to the invention, the object can be achieved in a satisfactory manner. In particular, it is possible to configure the production method such that no longer need to use inclined slides and no stresses occur in the component which can lead to visible stress markings (sink marks) on the visible side.In the described production method or method for producing, the rib can be (partially) produced both in the first production step and in the second production step. It is therefore possible for the rib to be cast completely together with the base body in the first production step. Alternatively, it is possible that a part of the at least one rib is produced in the first production step for casting at least the base body and the other part is produced together with the plurality of fastening elements, for example, in the second production step. As a further alternative, it is possible that the rib is produced completely in the second production step together with the plurality of fastening elements. It is thus also conceivable for the fastening element including the rib or including a part of the rib to be injection-molded and to be applied later to the base body or the other part of the rib by means of a joining method.Rib is preferably understood to mean a structure which does not form an undercut in the tool opening direction (up / down direction). For the production of the rib (whether it be in the first production step or (alternatively) in the second production step), therefore, no slides are required. By arranging the fastening elements on the base body, a geometry with undercuts then arises overall, so that the base body can be fastened to the opening to be concealed or to the surface to be concealed by means of these undercuts.According to an advantageous development of the invention, the plurality of fastening elements are shoe elements and / or clip elements.Preferably, the fastening elements are shoe elements. Shoe elements are transferred to a fuel filler door in such a way that the fuel filler door (general covering device) can be pushed onto the hinge arm at least substantially perpendicularly to a later operating direction of the fuel filler door. This has the advantage that the fuel filler flap cannot unintentionally become detached from the hinge arm during operation.Alternatively, however, in the cover devices and methods according to the invention, it would also be possible to use fastening elements in the form of clip elements. The mounting direction of the fuel filler door with clip elements is then at least substantially parallel to the later operating direction of the fuel filler door.According to an advantageous development of the invention, a plurality, preferably a plurality, of ribs are formed, by means of which the plurality of fastening elements are arranged on the base body, wherein the ribs are oriented at least substantially parallel to one another in the state arranged on the base body.In particular, the ribs on the base body (i.e. on the mounting side of the base body) extend aligned in a direction which is formed parallel to the main extension direction of the base body. The main extension direction is understood here to mean the direction in which the longest extension of the corresponding element is present.Because the ribs are oriented at least substantially parallel to one another, the covering device can easily be pushed onto the element (for example hinge arm) during later mounting.According to an advantageous development of the invention, in the first production step, the base body and at least a part of the at least one rib, preferably the entire rib, are formed.The ribs extend at least substantially orthogonally from the base body, i.e. from the mounting side of the base body, so that production in the "up / down direction" is also possible. The base body and the ribs can thus be formed well in one step, since no undercut has to be taken into account.Accordingly, joint production can be carried out cost-effectively and easily.According to an advantageous development of the invention, the at least one rib has at least one recess, preferably a plurality of recesses, on which in each case a fastening element of the plurality of fastening elements is arranged, so that the latter or these is or are limited or prevented in its or their movement along the rib by the shaping of the recess.By means of the recesses, a centering possibility of the fastening elements on the rib is thus provided. The fastening elements can thus be arranged at the correct position on the rib and can be fastened there, for example, subsequently.Preferably, all recesses of the ribs are of the same size and accommodate fastening elements of the same size. The fastening elements can thus be designed as identical parts, so that cost-effective production is promoted.Preferably, the fastening elements can be used not only in one flap, i.e. "flap type", but in a plurality of different flaps. The fastening elements (in particular shoe elements) are thus used as a standard part across a plurality of series, so that a method for producing at least two different covering devices is specified, wherein each covering device has a corresponding base body, at least one rib and a plurality of fastening elements, wherein the base bodies and the plurality of fastening elements are formed in production steps which are separate from one another, and wherein the fastening elements in the case of the one covering device and the fastening elements in the case of the at least one other covering device are of identical construction, i.e. of identical shape and size.By means of standard parts, the production can be made correspondingly more favorable. All aspects of the production methods for a covering device described here can be transferred to the method described above.Alternatively to identical parts, however, it is also possible for fastening elements of different dimensions to be used, which fastening elements are received in corresponding recesses of different sizes of the at least one rib. As a result, errors during assembly in the sense of poka yoke can be prevented, since only one (intended) assembly possibility can be predefined.According to an advantageous development of the invention, the plurality of fastening elements is formed in the second production step with a respective groove, wherein the groove is formed in a complementary manner to the at least one rib and preferably has a length which is matched to or smaller than the length of the recess, preferably of the plurality of recesses.By forming a corresponding groove, the above-described centering possibility of the fastening elements relative to the rib is made possible.In this way, in particular a positive precentration of the fastening elements on the rib is possible before the fastening elements are joined to the rib.According to an advantageous development of the invention, the method further comprises the following step: an assembly step for mounting the plurality of fastening elements on the at least one rib, preferably on the plurality of ribs.During the assembly step, the plurality of fastening elements are positioned and fastened to the at least one rib.The assembly step can preferably take place fully automatically directly on the machine.According to an advantageous development of the invention, the fastening elements are fastened to the at least one rib by means of a joining method.The fastening can be of releasable, non-releasable or conditionally releasable nature, for example. Exemplary non-releasable connections are welded connections, exemplary releasable connections are screw connections, and exemplary conditionally releasable connections are rivet connections.According to an advantageous development of the invention, the fastening elements are fastened to the rib by means of at least one latching device.The latching device can be formed integrally (i.e. integrally; i.e. in the same production step) with the rib and / or the fastening element.The solution according to the invention further consists in specifying a covering device which is produced according to one of the methods already described.Of course, all aspects and advantages described with respect to the production methods can be transferred directly to the covering device.Furthermore, the solution according to the invention consists in specifying a covering device, in particular a flap, preferably a fuel filler flap or tailgate for vehicles, wherein the covering device has the following: a base body which is designed to conceal an opening to be concealed or a surface to be concealed in or on a vehicle; a multiplicity of fastening elements, preferably shoe elements and / or clip elements, for fastening the covering device to the opening to be concealed or to the surface to be concealed (preferably on a hinge arm); and at least one rib, on which the multiplicity of fastening elements are arranged on the base body, characterized in that at least the base body and the multiplicity of fastening elements are designed in production steps which are separate from one another.In this regard, too, the aspects have already been described in the production method, so that it is only pointed out at this point that these aspects and advantages are also intended to apply to the covering device.In particular, the covering device has the advantage that no further stresses exist in the component, which lead to visible sink marks (stress markings) on the visible side of the covering device. This is achieved in particular in that the base body and the plurality of fastening elements are no longer formed in the same production step.It can be seen from the covering device that it has been formed in two production steps which are separate from one another. In particular, the covering device has, for example on account of the joining method for fastening the fastening elements to the base body, visible markings which indicate the separate production. In addition, the lack of sink marks / stress markings (more generally: corresponding stresses) in the component can already indicate production in two production steps which are separate from one another.Consequently, it can be seen from the covering device that it has been formed by means of a production method with separate, i.e. separate production steps.According to an advantageous development, the covering device has a plurality, preferably a plurality, of ribs, wherein the ribs are oriented at least substantially parallel to one another.Since the ribs are oriented at least substantially parallel to one another, the covering device can easily be pushed onto an element during mounting.According to an advantageous development of the invention, the at least one rib has at least one recess, preferably a plurality of recesses, wherein the plurality of fastening elements each have a groove, wherein the groove is formed complementary to the at least one rib and preferably has a length which is matched to or less than the length of the recess, preferably of the plurality of recesses.By means of the recess and the groove, a centering possibility of the fastening elements on the rib is provided. In particular, this allows a positive precentration of the fastening elements on the rib before the fastening elements are joined to the rib.According to an advantageous development, the fastening elements are fastened to the rib by means of a joining method.The fastening can be effected here, for example, by welding, soldering or adhesive bonding.According to an advantageous development of the invention, the fastening elements are fastened to the rib by means of at least one latching device.The latching device can be formed integrally (i.e. integrally; i.e. in the same production step) with the rib and / or the fastening element.Overall, all physical embodiments of the features described in the method for production can of course also be transferred to the latching device.The invention is explained in more detail below on the basis of the description of exemplary embodiments with reference to the attached drawings.The following shows: FIG. 1 shows a schematic illustration of a covering device before the mounting of the fastening elements according to a present embodiment of the invention; FIG. 2 shows a schematic illustration of a covering device 100 after mounting of the fastening elements; FIG. 3 shows an enlarged view of a rib of the covering device during the mounting of a fastening element; FIG. 4 is an enlarged view of the rib of FIG. 3 after mounting of the fastening element; and FIG. 5 shows a schematic illustration of a covering device in which the fastening element is connected to the rib via a latching device.FIG. 1 shows a schematic illustration of a covering device 100 without mounted fastening elements. The covering device 100 illustrated here is in particular a fuel filler flap, so a fuel filler flap 100 is also mentioned below.The fuel filler flap 100 has a base body 110 which is at least substantially planar and is designed in its size and shape such that it can cover a fuel tank opening. The base body 110 has a visible side and a mounting side. The fuel filler flap 100 shown in FIG. 1 is shown lying on its visible side. Accordingly, the visible side cannot be seen directly in FIG. 1.The surface visible in FIG. 1 is the mounting surface with which the fuel filler flap 100 can be fastened, for example, to a hinge arm.Fuel filler door 100 includes three ribs 120, 120', and 120". However, this is exemplary, so the fuel filler door 100 may also have a different number of ribs 120. The ribs 120, 120', 120" extend at least substantially orthogonally to the mounting surface of the base body 110 on which the ribs 120, 120'. 120". The ribs 120, 120' and 120" extend at least substantially parallel to each other. In addition, these extend at least substantially parallel to a main extension direction of the fuel filler flap 100.The fuel filler flap 100 shown in FIG. 1 with the base body 110 and ribs 120, 120', 120" can be produced in a common (injection) casting step. Thus, the element shown in Figure 1 is the product of a common casting process. Alternatively, it would also be conceivable for only a part of the ribs 120, 120' and 120" to be produced in a common casting process with the main body 110.FIG. 2 shows the fuel filler flap 100 of FIG. 1, wherein in the latter shoe elements have already been mounted as fastening elements 130 (shoe elements 130 will also be mentioned below). By way of example, in FIG. 2, three shoe elements 130, 130' and 130" are provided with reference numerals. These are all located on the rib 120. However, it will also be appreciated that the rib 120" and the rib 120' include corresponding shoe elements 130.In particular, three shoe elements 130, 130' and 130" are arranged on the rib 120, preferably at equal distances.The rib 120 is disposed toward a first outer side of the fuel filler door 100. The rib 120'' is arranged towards an opposite outer side of the fuel filler flap 100 and here has, for example, the same length as the rib 120. Accordingly, the rib 120" also receives three shoe elements 130.Between the rib 120 and the 120'' there is a small rib 120' which receives only one shoe element 130.Alternatively, however, a different arrangement of ribs 120 would be possible here.FIG. 3 shows an enlarged view of a rib 120 of the fuel filler door 100, wherein a shoe element 130 is also shown, which is to be arranged on the rib 120. The shoe element 130 is here at least substantially cuboidal in design, wherein it has a groove 131 on an underside thereof. The lower side here refers to the side which is oriented toward the rib 120.The cuboidal configuration of the shoe element 130 is merely exemplary. In particular and preferably, the shoe element 130 can have a T-shaped cross section, wherein the groove is then arranged, for example, "at the bottom" of the T.As can likewise be seen in FIG. 3, the rib 120 has a recess 121, wherein the recess 121 or the rib 120 and the groove 131 or the shoe element 130 are formed complementary to one another (in terms of their size or length) in such a way that the shoe element 130 is arranged centered on the rib 120 when it is plugged onto the rib 120.FIG. 4 shows the shoe element 130 in a state in which it is plugged onto the rib 120. In the interface between rib 120 and shoe element 130, the shoe element can be fastened to rib 120 by means of a joining method. For example, the shoe member 130 may be bonded or welded.FIG. 5 shows a fuel filler door 100, in which the shoe element 130 and the rib 120 are connected by means of a latching device 140. In particular, it can be seen that the rib 120 has a latching structure with a plurality of hooks. The shoe element 130 has a complementary detent structure such that the hooks of the rib 120 can engage the shoe element 130.During assembly, the shoe element 130 can be pressed onto the rib 120 in a simple manner and is held there securely by the latching device 140. Alternatively, it would also be possible here, in addition to the latching device 140, to secure the fastening by means of another joining method.List of reference characters100 Cover device / fuel filler flap 110 Base body 120, 120', 120'' Rib 121 Recess 130, 130', 130'' Fastening element 131 Groove 140 Latching device

Claims

Method for producing a covering device (100), in particular a flap, preferably a fuel filler flap or tailgate for vehicles, wherein the covering device (100) has: - a base body (110) which is designed to conceal an opening or surface to be concealed in or on a vehicle; - a plurality of fastening elements (130, 130', 130") for fastening the covering device (100) to the opening to be concealed or to the surface to be concealed; and - at least one rib (120, 120', 120") by means of which the plurality of fastening elements (130, 130', 130") is arranged on the base body (110), wherein the method for producing the covering device (100) has the following production steps: - a first production step for producing at least the base body (110); a second manufacturing step, separate from the first manufacturing step, for manufacturing at least the plurality of fasteners (130, 130', 130"), wherein the first manufacturing step and the second manufacturing step are at least partially injection molding steps.The method for manufacturing a covering device (100) according to claim 1, wherein the plurality of fastening elements (130, 130', 130") are shoe elements and / or clip elements.Method for producing a covering device (100) according to Claim 1 or 2, wherein a plurality, preferably a plurality, of ribs (120, 120', 120") are formed, by means of which the plurality of fastening elements (130, 130', 130") are arranged on the base body (110), wherein the ribs (120, 120', 120") are oriented parallel to one another in the state arranged on the base body (110).Method for producing a covering device (100) according to one of the preceding claims, wherein in the first production step the base body (110) and at least a part of the at least one rib (120, 120', 120"), preferably the entire at least one rib (120, 120', 120"), are formed.Method for producing a covering device (100) according to one of the preceding claims, wherein the at least one rib (120, 120', 120") has at least one recess (121), preferably a plurality of recesses (121), on which a fastening element (130, 130', 130") of the plurality of fastening elements (130, 130', 130") is or are respectively arranged, such that said rib or ribs is or are restricted in its or their movement along the at least one rib (120, 120', 120") by the shaping of the recess (121).Method for producing a covering device (100) according to claim 5, wherein the plurality of fastening elements (130, 130', 130") in the second production step are each formed with a groove (131), wherein the groove (131) is formed complementary to the at least one rib (120, 120', 120") and preferably has a length which is matching or smaller than the length of the recess (121), preferably of the plurality of recesses (121).Method for producing a covering device (100) according to one of the preceding claims, wherein the method further comprises the following step: - an assembly step for mounting the plurality of fastening elements (130, 130', 130") on the at least one rib (120, 120', 120"), preferably on the plurality of ribs (120, 120', 120").Method for producing a covering device (100) according to one of the preceding claims, wherein the fastening elements (130, 130', 130") are fastened to the at least one rib (120, 120', 120") by means of a joining method.Method for producing a covering device (100) according to one of the preceding claims, wherein the fastening elements (130, 130', 130") are fastened to the at least one rib (120, 120', 120") by means of at least one latching device (140).Covering device (100), in particular a flap, preferably a fuel filler flap or a tailgate for vehicles, wherein the covering device (100) has: - a base body (110) which is designed to conceal an opening to be concealed or a surface to be concealed in or on a vehicle; - a plurality of fastening elements (130, 130', 130"), preferably shoe elements and / or clip elements, for fastening the covering device (100) to the opening to be concealed or to the surface to be concealed; and - at least one rib (120, 120', 120") on which the plurality of fastening elements (130, 130', 130") are arranged on the base body (110), wherein at least the base body (110) and the plurality of fastening elements (130, 130', 130") are formed in mutually separated production steps, and wherein the mutually separated production steps are at least partially injection-molding steps.Covering device (100) according to claim 10, wherein the covering device (100) comprises a plurality, preferably a plurality, of ribs (120, 120', 120"), and wherein the ribs (120, 120', 120") are oriented parallel to one another.Covering device (100) according to claim 10 or 11, wherein the at least one rib (120, 120', 120") has at least one recess (121), preferably a plurality of recesses (121), and wherein the plurality of fastening elements (130, 130', 130") each have a groove (131), wherein the groove (131) is formed complementary to the at least one rib (120, 120', 120") and preferably has a length which is matched to or smaller than the length of the recess (121), preferably the plurality of recesses (121).Covering device (100) according to one of Claims 10 to 12, wherein the fastening elements (130, 130', 130") are fastened to the at least one rib (120, 120', 120") by means of a joining method.Covering device (100) according to one of Claims 10 to 13, wherein the fastening elements (130, 130', 130") are fastened to the at least one rib (120, 120', 120") by means of at least one latching device (140).

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