Actuating section for a vehicle door handle arrangement and method for producing such an operating section and door handle arrangement of a vehicle

Abstract

Actuating section (1) for a vehicle door handle assembly, in particular an interior door handle assembly, wherein the actuating section (1) is manufactured in a multi-component injection molding process, in particular a three-component injection molding process, and wherein the actuating section (1) comprises a carrier section (4) formed by co-injection injection molding with a core (9) and an outer layer (10) and a decorative section (5) in particular integrally connected with the carrier section (4), wherein the outer layer (10) of the carrier section (4) formed by co-injection consists at least partially of a plastic with a cool-touch effect, and wherein the carrier section (4) is manufactured in a first co-injection step using a first mold half and a second mold half, resulting in a first molded part.and wherein the decorative section (5) is produced in a second injection molding shot onto the first molded part after a change of the first mold half and / or the second mold half, resulting in a second molded part, while the first molded part remains in the first or second mold half until the second molded part has been injected onto it; or wherein the decorative section (5) is produced in a first injection molding shot using a first mold half and a second mold half, resulting in a first molded part, and wherein the carrier section (4) is produced in a second co-injection step onto the first molded part after a change of the first mold half and / or the second mold half, resulting in a second molded part, while the first molded part remains in the first or second mold half until the second molded part has been co-injected onto it.

Description

[0001] The present invention relates to actuating sections for a vehicle door handle assembly, in particular an interior door handle assembly. The invention further relates to a vehicle door handle assembly, in particular an interior door handle assembly, with a corresponding actuating section, and a method for producing such an actuating section.

[0002] The actuating portion of the type considered here can, for example, be a handle portion. It can, for example, be a handle lever pivotably mounted on a housing of the door handle assembly. The actuating portion can be designed to be grasped by a vehicle occupant in order to open and / or close a vehicle door from the inside.

[0003] The housing and the actuating section of such a door handle assembly, especially interior door handle assemblies, are often made of plastic. For aesthetic reasons, a metallic appearance of the actuating section is usually desired. For this purpose, the current state of the art typically involves chrome plating the handle lever. This allows for high-quality surfaces to be created, while at the same time, the base body of the actuating section, coated with the chrome layer, can be manufactured from a durable plastic.

[0004] However, chrome plating, especially using chromium VI, is problematic for health and environmental reasons.

[0005] An alternative to chrome plating is the production of the actuating section using an injection molding process with a plastic with a metallic look (Mold-In-Metal-Color - MIMC). This can achieve a look similar to chrome plating. However, surface defects such as flow lines or depressions, particularly due to material shrinkage, are problematic. In addition, the plastics used for this purpose are not always sufficiently resilient, in particular, they do not always have the required maximum breaking load. This also applies, in a metaphorical sense, to the housing of the vehicle door handle assembly.

[0006] The document DE 100 01 009 A1 relates to a plastic molded part and a method for producing such a plastic molded part. The plastic molded part is coated with a coloring substance on a visible outer side. The plastic molded part has at least one inner layer made of a dimensionally stable plastic and an outer layer made of an electrically conductive plastic, arranged at least in the region of the visible outer side. The outer, electrically conductive plastic is directly coated with the coloring substance.

[0007] The document EP 1 810 811 A1 relates to a method for producing a molded part from at least two different plastics, which method comprises the following steps: a1) plasticizing a first plastic material; a2) injecting the plastic mass into a first cavity of a first plastics tool to produce a preform; a3) opening the first plastics tool, wherein the produced preform remains on one of the tool halves of the tool; b) moving the tool half carrying the preform into a position that enables a cooperative connection with a tool half of a second plastics tool; c) applying a further plastic to the preform (4), wherein the further plastic is polyurethane or comprises polyurethane.

[0008] The document EP 2 851 174 A1 relates to a method for producing a plastic component, wherein gas in a supercritical state is introduced into a molten plastic material and, after the plastic material has been introduced into a mold and foamed in the mold, the plastic material is cooled.

[0009] The document DE 10 2019 111 328 A1 relates to an interior door handle arrangement of a vehicle, comprising a housing and a fastening section arranged on the housing, wherein the fastening section has a carrier section made of a first plastic and a decorative section made of a second plastic that is integrally connected to the carrier section, wherein the actuating section has been produced using a two-component injection molding process.

[0010] The document DE 102 11 662 A1 relates to an actuating lever comprising an axle mount, a linkage for force transmission, and a handle. The actuating lever is made of a single piece of plastic, with a core comprising the axle mount and the linkage being made of a material of higher strength than the handle.

[0011] The invention is based on the object of specifying an actuating section, in particular a handle element, of a vehicle door handle arrangement and a method for producing such an actuating section, wherein high-quality surfaces of the actuating section are made possible in a cost-effective manner with great design freedom and, at the same time, good load-bearing capacity.

[0012] With regard to the actuating section, the object underlying the invention is achieved by the subject matter of independent patent claim 1, and with regard to the manufacturing method, by the subject matter of independent patent claim 9, wherein advantageous developments of the actuating section and the manufacturing method are specified in the corresponding subclaims. Furthermore, the object is achieved by a door handle assembly of a vehicle according to the features of patent claim 13.

[0013] Accordingly, the invention relates in particular to an actuating portion for a vehicle door handle arrangement, in particular an interior door handle arrangement, wherein the actuating portion has a carrier portion formed by co-injection with a core and an outer layer and a decorative portion integrally connected to the carrier portion, wherein the actuating portion has been produced in a multi-component injection molding process, in particular in a three-component injection molding process.

[0014] In particular, the invention provides that the decorative section has a visible area, which forms the so-called "A-side" of the actuating section. The A-side of the actuating section forms the visible side of the actuating section in the intended installed state of the actuating section and, in particular, in the non-actuated state of the actuating section.

[0015] The decorative section is preferably formed from a plastic material, which may in particular be different from the plastic material from which the support section of the actuating section is formed.

[0016] In particular, the decorative section is integrally connected, preferably by a material bond, to the support section. At least in the installed state, the visible side of the decorative section corresponds to the aforementioned A-side of the actuating section and is thus at least partially visible directly from the vehicle interior when the actuating section is used for an interior door handle arrangement of a vehicle. At least in some areas, the decorative section, which is preferably formed integrally with the support section of the actuating section, also extends to the so-called "B-side" of the actuating section, i.e., to the side facing away from the A-side of the actuating section.

[0017] According to the invention, the actuating portion is formed by a co-injection process and has a core and an outer layer.

[0018] In other words, the plastic components (melts) forming the support section are injected sequentially from the same injection point into the same mold (co-injection). For flow and cooling reasons, the first injected plastic component is positioned against the wall of the injection mold and thus against the surface of the injection-molded part (support section). Accordingly, this process creates an injection-molded part with a core and an outer layer.

[0019] Unlike dual injection, in which the plastic components are injected simultaneously from different injection points into the same mold cavity, co-injection does not produce a weld line, which typically weakens the injection-molded part. By forming the support section using co-injection, a particularly resilient injection-molded part is created.

[0020] For the purposes of this disclosure, the terms "co-injected," "co-injection," or "co-injection process" are not intended to refer solely to the known co-injection in the narrow sense. Rather, co-injection is also intended to encompass all similar or equivalent processes in which two or more plastic components are injected successively through a nozzle or injection point. Also worth mentioning in this context is the monosandwich process, as described, for example, in DE 39 32 416 A1.

[0021] The invention utilizes the above-described co-injection process for producing the carrier section of the actuating section in a novel way. Only one of the plastic components used is injected in sufficient quantity to reach and fill the outer layer of the carrier section in the injection mold. The at least one other plastic component, in contrast, is sized in such a way that it remains in the core of the carrier section. This creates a corresponding core-shell structure.

[0022] The decorative section is sprayed onto this core-shell structure of the carrier section formed by co-injection.

[0023] According to embodiment variants, the decorative section is connected to the carrier section at least partially or in regions by a positive connection, in particular by an interlocking of at least one first connection partner provided on the decorative section and at least one second connection partner provided on the carrier section.

[0024] The decorative section can be connected to the support section via a purely positive connection.

[0025] According to the invention, the carrier section is produced in a first co-injection step using a first mold half and a second mold half, resulting in a first molded article with a core-shell structure. The decorative section is produced in a separate, second injection molding shot onto the first molded article after changing the first mold half and / or the second mold half. This forms a second molded article. The first molded article, i.e., the carrier section with the core-shell structure, remains in the mold cavity at least until the plastic component of the decorative section has been shot into the second injection molding shot onto the first molded article.

[0026] Alternatively, the invention provides that firstly the decorative section is produced in a first injection molding shot using a first mold half and a second mold half, resulting in a first molded article, wherein the carrier section is produced in a subsequent (second) co-injection step onto the first molded article after a change of the first mold half and / or the second mold half, resulting in a second molded article, while the first molded article remains in the first or second mold half of the mold cavity until the second molded article has been co-injected onto it.

[0027] In the co-injection step for forming the carrier section of the actuating section, as already explained, first the plastic component of the outer layer of the carrier section and then the plastic component of the core of the carrier section are injected into the mold cavity one after the other from the same injection point.

[0028] In this context, it is conceivable that during or after the injection of the plastic component of the core of the carrier section, a gaseous injection medium is preferably also injected.

[0029] In other words, when injecting the plastic component of the core of the support section, a gas injection technique can be used, in particular, to make the core of the support section hollow or foam-like, at least in some areas. This gas injection technique can be used with cooled gas (Cool Gas GIT). Alternatively, a gas injection technique followed by gas purging or a gas injection technique followed by purging with cooled gas is also conceivable.

[0030] In order to ensure the load-bearing capacity of the actuating section, it is provided according to preferred embodiments that the core of the carrier section formed by co-injection consists of a first plastic component, in particular of a glass fiber reinforced plastic component, wherein the outer layer of the carrier section formed by co-injection consists of a second plastic component different from the first plastic component.

[0031] The decorative section of the actuating section preferably consists of a third plastic component different from the first and second plastic components.

[0032] A front side of the actuating portion is preferably defined by the surfaces of the actuating portion facing the vehicle interior when the actuating portion is installed in the vehicle in an interior door handle arrangement and is in a rest position. The boundary between the front and rear sides of the actuating portion is preferably defined by the surfaces that are parallel to the surface of the vehicle surface that directly surrounds the actuating portion when installed in the vehicle and in a rest position.

[0033] Preferably, a surface direction points in its normal (outwards away from the material).

[0034] Directly visible preferably means that there is no additional coating (e.g., paint, chrome) or overmolding of the decorative section. The plastic of the decorative section is preferably the outermost surface layer of the actuating section in the directly visible areas of the decorative section.

[0035] The decorative section is integrally connected to the carrier section, which preferably means "materially bonded," meaning that they are held together by atomic or molecular forces and are inseparable, separable only by destruction. However, this definition also encompasses a positive connection between the decorative section and the carrier section, with the positive connection being created by the injection molding process within an injection molding tool. Bonding by atomic or molecular forces is therefore not absolutely necessary, but preferred.

[0036] By using a different material for the decorative section, preferably the visible section, which is particularly critical in terms of visual requirements, than for the support section, the support section and the decorative section, preferably the visible section, can be specifically adapted to the respective requirements. The integral connection simultaneously forms a one-piece component, so no additional fastening means are required. This not only improves the visual appearance but also facilitates the manufacture and assembly of the actuating section.

[0037] According to one aspect, the solution according to the invention is particularly characterized in that the decorative section of the actuating section has at least one sprue area, via which the heated injection molding compound is introduced into a mold cavity in an injection molding tool via at least one sprue channel, which at least partially corresponds to the shape of the actuating section and in particular to the shape of the decorative section of the actuating section.

[0038] The at least one sprue area is formed in particular in a sprue lip or sprue tab, wherein the sprue area is continuously connected to the visible area of ​​the decorative section via at least one edge area or arcuate area.

[0039] This has the advantage that, due to the rear injection into the interior of the molded body, no injection mark is visible on the visible side of the actuating section, i.e., on the A-side of the actuating section. This eliminates the need for additional removal of the injection mark, even with subsequent external surface treatment.

[0040] By forming the at least one sprue area in a sprue lip or sprue tab, wherein this sprue lip or sprue tab is continuously connected to the visible area of ​​the decorative section via at least one edge area or arcuate area, a homogenization of the heated injection molding compound can be brought about when the heated injection molding compound is fed into the mold cavity, so that in the mold cavity the melt (the heated injection molding compound) can flow at a reduced flow velocity and without local compaction from the sprue area (i.e. from the sprue lip or the sprue tab) via the at least one edge area or arcuate area to the visible area of ​​the decorative section. This ensures that the heated injection molding compound reaches the visible area of ​​the decorative section via at least one "smooth" transition.

[0041] By initially calming and homogenizing the heated injection molding compound in an area different from the visible area of ​​the actuating section when it is introduced into the mold cavity, and by subsequently continuously introducing the heated injection molding compound homogenized in this way into the area of ​​the mold cavity that corresponds to the visible area of ​​the decorative section, it is possible to use a plastic material with integrated pigments to form the decorative section without the risk of undesirable flow lines occurring in the visible area of ​​the decorative section.

[0042] This measure is particularly important when a plastic material with embedded pigments is used to create the decorative section, since the pigments do not form a continuum in the melt (i.e., in the heated injection molding compound). Therefore, appropriate care must be taken to ensure that the melt with the embedded pigments does not compact in the visible area of ​​the actuating section, as local compaction of the melt would lead to compaction of the pigments, which would generate corresponding defects (particularly lines) in the finished actuating section.

[0043] Thus, by providing a sprue area formed in a sprue lip or sprue tab, which is continuously connected to the visible area of ​​the decorative section via at least one edge or curved area, the flow of the melt can be stabilized when the heated injection molding compound is introduced into the mold cavity, either before or during the melt flow from the sprue area to the visible area of ​​the decorative section. This achieves a higher surface quality, and an optionally provided surface finish can also be improved during subsequent treatment, e.g., by painting.

[0044] With regard to the sprue lip or the sprue tab in which the at least one sprue area is formed, it should be noted that this sprue lip or sprue tab is a relatively small volume area into which the heated injection molding compound is fed to the mold cavity via corresponding sprue channels.

[0045] Because this relatively small volume area forming the sprue lip or the sprue tab is then continuously fluidically connected via at least one edge area or arcuate area to the area of ​​the mold cavity, which ultimately represents the visible area of ​​the actuating section, the melt is gently deflected and evenly relaxed as it flows from the sprue area to the visible area of ​​the actuating section, as a result of which local compaction of the melt in the visible area of ​​the decorative section is effectively prevented.

[0046] As already indicated, the actuating section is subject to considerable demands regarding its load-bearing capacity, particularly its maximum breaking load. These requirements can be easily met according to the invention by selecting a material with appropriate strength for the support section. At the same time, by selecting a suitable, different material for the decorative section, preferably the visible section, a particularly high-quality surface can be achieved without the material used for this, which is often not sufficiently strong, compromising the overall load-bearing capacity of the actuating section.

[0047] For example, a material with a metallic look is possible for the decorative section, preferably the visible section. Chrome plating, which is problematic for environmental and health reasons, can be omitted.

[0048] The decorative section, preferably the visible section, can have a significantly smaller thickness than the support section. For example, the greatest thickness of the decorative section, preferably the visible section, can be less than 50% of the smallest thickness of the support section, preferably less than 20% of the smallest thickness of the support section. This maximizes the rigidity of the actuating section, provided by the support section, while simultaneously reducing the tendency for surface defects in the decorative section, preferably the visible section. In particular, if, for example, only one surface facing the vehicle interior is formed by the decorative section, preferably the visible section, this creates a simple geometry that can be produced without surface defects.

[0049] The support section, and in particular the core of the support section, can be made of a reinforced plastic, particularly a glass-fiber-reinforced plastic. This allows for particularly good support properties. In principle, a wide variety of material combinations are conceivable for the support section and the decorative section. Some possible material combinations are listed below as examples only: • Core and / or outer layer of the carrier section PA6 reinforced / decorative section PA6 decor • Outer layer of the carrier section PA6 with cool-touch effect / decorative section PA6 decor • Core / outer layer of the carrier section SAN reinforced / decorative section PC-ABS or ABS • Core / outer layer of the carrier section POM reinforced / decorative section POM decor

[0050] The decorative section can have a different color than the outer layer of the carrier section. This allows for a particularly high degree of design freedom. However, the decorative section and, in particular, the outer layer of the carrier section can also, in principle, have the same color.

[0051] According to a further embodiment, the decorative section and preferably the visible area of ​​the decorative section can be made of a plastic with a metallic appearance. Such metallic-look plastics, which can be produced in particular using plastic injection molding processes (Mold-In-Metal-Color - MIMC), are known per se. They have a surface quality similar to chrome plating, but without the environmental and health problems associated with chrome plating. As explained, such metallic-look plastics often lack the required resilience. This problem is solved by the inventive design of the actuating section and, in particular, by the support section formed by co-injection.

[0052] According to the invention, the outer layer of the actuating section consists, at least in part, of a plastic with a cool-touch effect.

[0053] A mineral filling or metal particles, particularly ferromagnetic metal particles, can be embedded in the plastic, particularly in the outer layer of the carrier section. Embedding a mineral filling or metal particles in the plastic achieves the coolness typically associated with metal surfaces, even though a plastic material is used that can also be processed in a plastic injection molding process, particularly in a co-injection process.

[0054] For example, the support section, and in particular the outer layer of the support section, can form the rear side of the actuating section facing away from the vehicle interior, which a vehicle occupant grasps to operate the vehicle door. Because this is made of a plastic with a cool-touch effect, in combination with a plastic with a metallic look for the decorative section forming the front side of the actuating section facing the vehicle interior and preferably the visible area of ​​the decorative section, a vehicle occupant visually and haptically perceives a metal handle.

[0055] To enhance the cool-touch effect, the outer layer and / or the core of the support section can be made of a plastic with good thermal conductivity. Within the scope of this invention, a plastic preferably exhibits the cool-touch effect if the value measured with 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 an equivalent of the perceived haptic temperature, with steel having a value of 0, glass a value of 10, and PTFE a value of 20. These values ​​are based on a "HapTemp" device from 2012 (serial no. 12.11.1), software version 16.2.8, last calibrated in January 2019.

[0056] According to a further embodiment, the core of the carrier section can be formed as a cavity, at least in some areas. Plastics with a cool-touch effect or plastics with embedded mineral filling or metal particles generally have a high density. To counteract this, a cavity can be formed in the core of the carrier section. For example, in a plastic injection molding process, this can be achieved by injecting gas (CO2 or nitrogen) into the still-flowing plastic to displace the corresponding material. The formation of such a cavity would also be possible, for example, with a plastic such as PA6-GF30.

[0057] According to a further embodiment, the decorative section and in particular the visible area of ​​the decorative section can be connected to the carrier section in an in-mold painting process.

[0058] In this context, the in-mold painting process is treated as an injection molding process. The manufacturing method essentially corresponds to the two-component injection molding process, whereby the cavity of the injection mold forming the decorative section is very thin. For example, the cavity can have a thickness of less than 1 mm, preferably less than 0.3 mm. The component forming the decorative section (paint) is pressed into the cavity for the decorative section after the carrier section has been co-injected and, after curing, forms a surface similar to a paint finish. This allows for further design freedom with regard to the color of the decorative section while maintaining high surface quality.

[0059] The door handle assembly, designed in particular as an interior door handle assembly, serves in particular for opening and / or closing a vehicle door from the vehicle interior. For this purpose, the interior door handle assembly is mounted in the interior of a vehicle, such as a car or truck. Accordingly, the invention also relates to a vehicle having an interior door handle assembly mounted therein.

[0060] The interior door handle assembly comprises a housing with which it is attached to a vehicle door. An actuating section is arranged on the housing, which a vehicle occupant can manually actuate, for example, grasp. The actuating section can be movably mounted on the housing, for example pivotably or translationally movable. It can, for example, be a handle element, in particular a handle lever, pivotably mounted on the housing. However, the actuating section can also be, for example, a button or the like actuated by a vehicle occupant. The actuating section can be designed to be actuated by a vehicle occupant in order to open or close a vehicle door from the inside.

[0061] The decorative section and preferably the visible area of ​​the decorative section can be formed in particular by a section (sprue area) which is injection-molded in particular onto the carrier section of the actuating section.

[0062] According to the invention, in this context it can be provided in particular that the at least one sprue area, via which the material (plastic material) required to form the decorative section is injected into the corresponding mold cavity, is formed in an area facing away from the visible area of ​​the decorative section and in particular in a sprue lip or sprue tab.

[0063] The area in which the sprue lip or sprue tab of the at least one sprue area for the material of the decorative section is formed is fluidly connected to the visible area of ​​the decorative section. The area of ​​the sprue lip or sprue tab continuously expands in terms of the effective flow cross-section and is deflected at the transition to the visible area of ​​the decorative section. This effectively homogenizes and relaxes the heated injection molding compound during the formation of the decorative section.

[0064] At the same time, by combining the structure according to the invention comprising a carrier section and a decorative section and, in particular, by providing the sprue area in a sprue lip or sprue tab in a region of the decorative section which is continuously connected to the visible area of ​​the decorative section via an edge region or arcuate region, surface defects can be minimized particularly efficiently during production in a multi-component injection molding process.

[0065] It has been shown that by providing the sprue area for the decorative section in a sprue lip or sprue tab, which is continuously connected to the visible area of ​​the decorative section via an edge area or arcuate area, shrinkage of the plastic material of the decorative section during curing of the plastic material of the decorative section can be reduced / minimized to a particular extent, which would lead to surface defects such as flow lines or depressions.

[0066] By molding the decorative section, and preferably the visible area of ​​the decorative section, onto the carrier section made of a different material according to the aforementioned design, shrinkage and the associated surface defects are minimized. Thus, the carrier section, and in particular the outer layer of the carrier section, forms a stable base for molding the decorative section, and preferably the visible area of ​​the decorative section, which can significantly reduce shrinkage. Flow lines and depressions can be reliably avoided.

[0067] At the same time, the aforementioned design allows the production of different decorative layers, preferably visible areas, e.g., from plastics of different colors, using a single injection mold, depending on the specific application. This further increases flexibility.

[0068] According to embodiments, the plastic in the region in which the edge region or arcuate region is formed has a greater thickness than the thickness of the plastic of the decorative section in a region located further from the sprue area. This makes it possible to create an edge or an arcuate region through the material of the decorative section without creating an undercut. This is therefore easier to manufacture.

[0069] By providing a corresponding homogenization area for the melt of the plastic of the decorative section, the quality of the surface appearance can be improved, especially when a high-gloss and / or metallic-looking surface is desired, since the second plastic can flow over a wide area into the area that becomes a surface on the front side of the actuating section.

[0070] According to embodiments, the at least one edge region or arcuate region of the plastic material of the decorative portion, which extends from a front side of the actuating portion to the rear side of the actuating portion, extends over at least 25%, preferably at least 40%, particularly preferably at least 70%, and most preferably 99% of the boundary between the front side and the rear side of the actuating portion, preferably along at least an upper region of the actuating portion.

[0071] This can further enhance the appearance of the operating section from the perspective of the vehicle interior, as the decorative section extends largely rearward. For example, the fact that the operating section is made of three materials may not be noticeable to a vehicle occupant if the upper part of the operating section, when conventionally installed in the vehicle door, is formed by the plastic material of the decorative section extending rearward.

[0072] According to preferred embodiments, the decorative section has a constant thickness over at least 70%, preferably at least 80% of its visible area, ie in case of doubt with a deviation of less than 30%, preferably less than 20% of the average thickness.

[0073] This further improves the appearance of the decorative section as the flow of the plastic material of the decorative section is improved.

[0074] Preferably, the carrier section has a variable thickness in the areas where the decorative section has a constant thickness, i.e., in case of doubt, with a deviation of more than 30%, preferably more than 50% of the average thickness. The thickness is preferably measured from the front side to the back side, along a surface normal.

[0075] According to embodiments of the actuating portion according to the invention, the decorative portion has a thickness in a range of 0.5 to 3.5 mm and preferably in a range of 0.7 mm to 1.7 mm over 70%, preferably at least 80% of its visible area.

[0076] This further improves the appearance of the decorative section by improving the flow of the plastic material of the decorative section during its formation. It was determined that the thickness should be neither smaller to avoid obstructions nor larger to avoid zebra patterns than the specified interval, and preferably even the preferred interval to minimize the risk of these undesirable effects.

[0077] According to embodiments of the actuating section according to the invention, the decorative section 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 units measured at 60°, preferably 70 gloss units measured at 60°, over 70%, preferably at least 90% of its visible area.

[0078] This further improves the appearance of the decorative section. It was found that the invention is particularly suitable for high-gloss surfaces, which are very sensitive to flow turbulence and material shrinkage during the formation of the decorative section.

[0079] According to a further embodiment, the decorative section makes up at least 90% and preferably at least 99% of the visible area of ​​the actuating section.

[0080] The invention also achieves the aforementioned object by a method for producing an actuating portion for a vehicle door handle assembly, in particular an interior door handle assembly, wherein the actuating portion comprises a carrier portion formed by co-injection with a core and an outer layer, and a decorative portion integrally connected to the carrier portion. The actuating portion is produced using a multi-component injection molding process, in particular a three-component injection molding process. As already explained, this allows particularly high-quality surfaces to be produced with simultaneous high load-bearing capacity in a technically simple manner.

[0081] According to the invention, the manufacturing process comprises at least the following steps: • the carrier section is produced in a first co-injection step using a first mold half and a second mold half, resulting in a first molding, and • the decorative section is produced in a second injection shot onto the first molding after a change of the first mold half and / or the second mold half, resulting in a second molding, while the first molding remains in the first or second mold half until the second molding has been shot onto it.

[0082] Alternatively, the manufacturing method according to the invention comprises at least the following steps: • the decorative section is produced in a first injection molding shot using a first mold half and a second mold half, resulting in a first molding, and • the support section is produced in a second co-injection step onto the first molding after a change of the first mold half and / or the second mold half, resulting in a second molding, while the first molding remains in the first or second mold half until the second molding has been co-injected onto it.

[0083] In the method according to the invention, it is particularly provided that in the co-injection step, first the plastic component of the outer layer and then the plastic component of the core are injected into the mold one after the other from the same injection point, wherein during or after the injection of the plastic component of the core, a gaseous injection medium is preferably also injected.

[0084] Preferably, the outer layer of the carrier section formed by co-injection consists, at least in part, of a plastic with a cool-touch effect. Alternatively or additionally, the core of the carrier section formed by co-injection is formed, in particular, by gas injection and foamed, at least in part.

[0085] The core of the carrier section formed by co-injection consists in particular of a first plastic component, in particular of a glass fiber reinforced plastic component, wherein the outer layer of the carrier section formed by co-injection consists of a second plastic component different from the first plastic component.

[0086] In the following, embodiments of the invention are explained in more detail with reference to the accompanying drawings.

[0087] They show: Fig. 1 schematically and in an isometric view an exemplary embodiment of an interior door handle arrangement with an actuating portion designed as a handle element according to an exemplary embodiment of the invention; Fig. 2 schematically and in an isometric view of the operating section or the handle element of the interior door handle arrangement according to Fig. 1 in an enlarged view; Fig. 3 schematically and in a plan view of the A-side of an exemplary embodiment of the actuating section according to the invention; and Fig. 4 schematically and in a sectional view the exemplary embodiment of the actuating section according to the invention according to Fig. 3.

[0088] Unless otherwise stated, the same reference symbols in the figures refer to the same objects.

[0089] The Fig. The interior door handle assembly shown in Figure 1 comprises a housing 11 with which it can be attached to a door of a vehicle, such as a car or truck.

[0090] The housing 11 has a grip recess 12 in which an actuating section 1 designed as an actuating element, in the present example a grip element, in the Fig. 1 shown resting position.

[0091] From this rest position, the handle element 1 can be pivoted about a pivot axis which, in the assembled state, is vertical, for example, with its Fig. 1 right-hand free end can be swung out of the handle recess 12. Via a corresponding connection, the vehicle door is unlocked by swung out the handle element 1, so that it can then be opened by a vehicle occupant. When the handle element 1 is swung out, the vehicle occupant engages the handle recess 12 and grasps behind the handle element 1. In the example shown, the handle element 1 forms a handle lever. Also integrated into the housing 11 is a loudspeaker 2, which is surrounded by a frame 3.

[0092] In the enlarged view of the Fig. 2 it can be seen that the handle element 1 has a support section 4 which, in the rest position, faces away from the vehicle interior and a decorative section 5, preferably the visible area 6, facing the vehicle interior.

[0093] The carrier section 4 forms the rear side of the handle element 1 which is to be grasped by a vehicle occupant and the visible area 6 of the decorative section 5 forms the front side of the handle element 1 which is directly visible from the vehicle interior. The carrier at its in Fig. 2 left end has bearing means 7 with which the handle element 1 can be pivotally mounted on the housing 11.

[0094] The visible area 6 of the decorative section 5 is integrally connected to the carrier section 4. In the example shown, the visible area 6 of the decorative section 5 has been molded onto the carrier section 4 using a multi-component injection molding process.

[0095] The support section 4 is made entirely of a plastic and is divided into a core 9 and an outer layer 10, for example a reinforced plastic such as a glass-fiber-reinforced plastic, which surrounds the core 9 at least in part. It can have an embedded mineral filling or embedded metal particles, for example ferromagnetic metal particles, so that a vehicle occupant perceives a cool surface and thus the impression of metal when reaching behind the support section 4 to pivot the handle element 1 out of the grip recess 12 of the housing 11.

[0096] Accordingly, the visible area 6 of the decorative section 5 can consist of a plastic with a metallic appearance (Mold-In-Metal-Colour - MIMC).

[0097] However, the visible area 6 of the decorative section 5 could also be made of other plastics, for example, differently colored plastics or the like. The visible area 6 of the decorative section 5 could also be bonded to the carrier section 4, and in particular to the outer layer 10 of the carrier section 4, using an in-mold painting process.

[0098] In the example shown, the surround 3 of the loudspeaker 2 has also been molded into the housing 11 using a multi-component injection molding process. The surround 3 can, for example, be made of the material used for the visible area 6 of the decorative section 5.

[0099] The decorative section 5 and in particular the viewing area 6 of the decorative section 5 is intended to be at least partially directly visible from the vehicle interior and to face the vehicle interior, wherein the handle element 1 has a front side facing the vehicle interior and a rear side facing away from the vehicle interior.

[0100] The following is based on the illustrations in Fig. 3 to Fig. 4 an exemplary embodiment of the actuating or gripping element 1 according to the invention is described in more detail.

[0101] As shown, the actuating or gripping element 1 according to the invention comprises a carrier section 4 and a decorative section 5 covering at least part of the surface of the carrier section 4. In this case, it is particularly provided that the decorative section 5 not only covers the viewing area (recognizable in Fig. 3), but also forms an edge region of the actuating or gripping element 1.

[0102] In detail, the edge area is connected to the visible area of ​​the decorative section 5 via an edge area or arcuate area, as shown in the sectional view in Fig. 4 can be removed.

[0103] The sectional view in Fig. 4 further shows that the carrier section 4 has a core or core region 9 and an outer layer 10, wherein the carrier section 4 has been formed by co-injection.

[0104] The actuating or gripping element 1 according to the exemplary embodiment shown in the drawings is preferably manufactured using a three-component injection molding process. In particular, it is provided that the plastic material of the decorative section 5 is applied at least partially to the surface of the outer layer 10 of the carrier section 4 and is integrally bonded to the outer layer 10.

[0105] To produce the support section 4 of the actuating or gripping element 1, it is provided that the support section 4 is formed by co-injection. Preferably, the outer layer 10 of the support section 4 is formed, at least in some areas, from a plastic with a cool-touch effect. The core of the support section 4 can be formed by gas injection and foamed, at least in some areas.

[0106] To form the decorative section 5 on the areas of the surface of the outer layer 10 of the carrier section 4, it is provided in particular that the plastic material of the decorative section 5 is injected as a heated injection molding compound via sprue channels into a corresponding mold cavity, wherein this mold cavity is delimited, for example, by the carrier section 4 and at least one tool plate (not shown in the drawings).

[0107] For this purpose, an injection molding tool is preferably used, which has at least one distribution channel leading to a gate area. In particular, in the exemplary embodiment of the actuating or gripping element 1 according to the invention, a point gate is provided to form the decorative section 5 on the outer layer 10 of the carrier section 4, at least in some areas.

[0108] This makes it possible to design surfaces and dividing lines between the plastics in such a way that the optical quality of the decorative section 5 is improved.

[0109] In particular, an underfloor sprue system, such as the so-called banana sprue, can be provided for forming the decorative section 5 on the outer layer 10 of the carrier section 4, wherein the injection molding of the decorative section 5 takes place in such a way that in the mold cavity corresponding to the decorative section 5, the heated injection molding compound of the plastic material of the decorative section 5 is homogenized and its flow is calmed before the heated injection molding compound reaches the area of ​​the mold cavity which corresponds to the visible area in the finished actuating or gripping element 1.

[0110] This improves the surface quality because the flow of the plastic mass is better balanced.

[0111] The invention, in particular, presents an interior door handle / method for manufacturing such a door handle (actuating element). This comprises at least three plastic layers or regions, namely a first plastic layer formed by the outer layer 10 of the support section 4, a second plastic region formed by the core 9 of the support section 4, and a third plastic layer formed by the decorative section 5, wherein the plastic layers / regions are connected by injection molding. The first layer forms a rear surface, and the third layer forms a visible front surface of the actuating or handle element 1. List of reference symbols 1 operating section / operating element / handle element 2 speakers 3 Border 4 support section 5 Decorative section 6 Visible area of ​​the decorative section 7 Storage resources 8 Edge area / arched area 9 Core / core area of ​​the support section 10 Outer layer of the carrier section 11 housings 12 recessed grip

Claims

[1] Actuating section (1) for a vehicle door handle assembly, in particular an interior door handle assembly, wherein the actuating section (1) has been produced in a multi-component injection molding process, in particular in a three-component injection molding process, and wherein the actuating section (1) has a carrier section (4) formed by co-injection injection molding with a core (9) and an outer layer (10) and a decorative section (5) which is in particular integrally connected to the carrier section (4), wherein the outer layer (10) of the carrier section (4) formed by co-injection consists at least in regions of a plastic with a cool-touch effect, and wherein the carrier section (4) has been produced in a first co-injection step using a first mold half and a second mold half, resulting in a first molded article,and wherein the decorative section (5) has been produced in a second injection molding shot onto the first molded article after a change of the first mold half and / or the second mold half, resulting in a second molded article, while the first molded article remains in the first or second mold half until the second molded article has been shot onto it; or wherein the decorative section (5) has been produced in a first injection molding shot using a first mold half and a second mold half, resulting in a first molded article, and wherein the carrier section (4) has been produced in a second co-injection step onto the first molded article after a change of the first mold half and / or the second mold half, resulting in a second molded article, while the first molded article remains in the first or second mold half until the second molded article has been co-injected onto it. [2] Actuating section (1) according to claim 1, wherein in the co-injection step, first the plastic component of the outer layer (10) and then the plastic component of the core (9) are injected into the mold in succession from the same injection point, wherein during or after the injection of the plastic component of the core (9) a gaseous injection medium is preferably also injected. [3] Actuating section (1) according to claim 1 or 2, wherein the core (9) of the carrier section (4) formed by co-injection is formed by gas injection and is foamed at least in regions. [4] Actuating section (1) according to one of claims 1 to 3, wherein the decorative section (5) is connected to the carrier section (4) at least partially or in regions by a positive connection, in particular by an interlocking of at least one first connection partner provided on the decorative section (5) and at least one second connection partner provided on the carrier section (4). [5] Actuating section (1) according to one of claims 1 to 4, wherein the core (9) of the carrier section (4) formed by co-injection consists of a first plastic component, in particular of a glass fiber reinforced plastic component, and wherein the outer layer (10) of the carrier section (4) formed by co-injection consists of a second plastic component different from the first plastic component. [6] Actuating portion (1) according to claim 5, wherein the decorative portion (5) consists of a third plastic component different from the first and second plastic components. [7] The operating portion (1) according to claim 6, wherein the third plastic component forms at least one convex edge or at least one convex arcuate region (8) on a surface of the operating portion (1) such that the third plastic component extends to a rear side of the operating portion (1). [8] The actuating portion (1) according to claim 7, wherein a portion of the surface of the rear side of the actuating portion (1) is formed by the third plastic component which extends from a front side of the actuating portion (1) to the rear side of the actuating portion (1) and forms the at least one edge or the arcuate portion (8). [9] Method for producing an actuating section (1) for a vehicle door handle arrangement, in particular an interior door handle arrangement, wherein the actuating section (1) has a carrier section (4) formed by co-injection with a core (9) and an outer layer (10) and a decorative section (5) integrally connected to the carrier section (4), wherein the actuating section (1) is produced in a multi-component injection molding process, in particular in a three-component injection molding process, wherein the outer layer (10) of the carrier section (4) formed by co-injection consists at least in regions of a plastic with a cool-touch effect, and wherein the carrier section (4) is produced in a first co-injection step using a first mold half and a second mold half, resulting in a first molded article, and wherein the decorative section (5) is produced in a second injection molding shot onto the first molded article after changing the first mold half and / or the second mold half, resulting in a second molded article, while the first molded article remains in the first or second mold half until the second molded article has been shot onto it; or wherein the decorative section (5) is produced in a first injection molding shot using a first mold half and a second mold half, resulting in a first molded article, and wherein the carrier section (4) is produced in a second co-injection step onto the first molded article after a change of the first mold half and / or the second mold half, resulting in a second molded article, while the first molded article remains in the first or second mold half until the second molded article has been co-injected onto it. [10] Method according to claim 9, wherein in the co-injection step, first the plastic component of the outer layer (10) and then the plastic component of the core (9) are injected into the mold one after the other from the same injection point, wherein during or after the injection of the plastic component of the core (9) a gaseous injection medium is preferably also injected. [11] Method according to claim 9 or 10, wherein the core (9) of the carrier section (4) formed by co-injection is formed by gas injection and is foamed at least in regions. [12] Method according to one of claims 9 to 11, wherein the core (9) of the carrier section (4) formed by co-injection consists of a first plastic component, in particular of a glass fiber reinforced plastic component, and wherein the outer layer (10) of the carrier section (4) formed by co-injection consists of a second plastic component different from the first plastic component. [13] Door handle assembly of a vehicle, in particular interior door handle assembly, comprising a housing (11) and an actuating section (1) movably arranged on the housing (11) according to one of claims 1 to 8.

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