Cover assembly and vehicle with such a cover assembly

Abstract

The invention relates to a cover assembly (1) comprising a shell structure (2), a flap (3), a coupling element, and an actuator (5), wherein the shell structure (2) forms an opening (6), the flap (3) is mechanically connected to the actuator (5) via the coupling element, and the flap (3) is movable between a covered position (P1), in which the flap (3) closes the opening (6), and an open position (P2), in which the flap (3) at least partially releases the opening (6), by actuating the actuator (5). The cover assembly according to the invention is characterized in that - the coupling element is designed as a rack (4); - the actuator (5) is mounted in a fixed position relative to the shell structure (2); - the actuator (5) is configured to transmit a rotary positioning movement via a drive shaft to a gear (7) mounted on the drive shaft; and - the gear (7) is engaged with the rack (4).

Description

[0001] The invention relates to a cover assembly according to the type defined in more detail in the preamble of claim 1 and to a vehicle with such a cover assembly.

[0002] Vehicles with pop-up headlights are well known. Folding the headlights in protects them from external influences such as dirt, damage, moisture ingress, and the like. However, folding the headlights out comes with several disadvantages. For example, folding the headlights increases the vehicle's drag coefficient, thus increasing air resistance, especially at high speeds. This negatively impacts the vehicle's fuel consumption.

[0003] Nowadays, headlights are generally installed that are rigidly attached to the vehicle structure. The vehicle and the headlights are geometrically matched to each other in such a way that the aerodynamic properties of the vehicle are sufficiently supported. To still protect the headlights from these environmental influences, it is common practice to cover them with a flap when not in use. A headlight with a cover flap is known, for example, from DE 10 2019 007 736 A1. However, the solution disclosed therein is structurally complex.

[0004] The present invention is based on the object of providing an improved cover assembly which is characterized by a simple construction.

[0005] According to the invention, this object is achieved by a cover assembly having the features of claim 1. Advantageous embodiments and further developments as well as a vehicle with such a cover assembly emerge from the dependent claims.

[0006] A generic cover assembly comprising a shell structure, a flap, a coupling element and an actuator, wherein the shell structure forms an opening, the flap is in a mechanical operative connection with the actuator via the coupling element and the flap is movable by actuating the actuator between a covering position in which the flap closes the opening and an open position in which the flap at least partially releases the opening, is further developed according to the invention in that - the coupling element is designed as a rack; - the actuator is mounted stationary relative to the shell structure; - the actuator is designed to transmit a rotary actuating movement to a gear mounted on the drive shaft via a drive shaft; and - the gear is in engagement with the rack.

[0007] The cover assembly according to the invention is characterized by a particularly simple structural design. A combination of a rotary drive for imparting the actuating movement and a translationally displaceable rack provides simple, and thus reliable, and robust kinematics. This allows the flap to be moved reliably during operation to open or close the opening. Due to its simplicity, the cover assembly according to the invention can also be designed in a space-saving manner, thus efficiently utilizing the installation space available on a higher-level structure.

[0008] The individual components of the cover assembly can consist of or include a wide variety of materials, such as metal, a metal alloy, plastic or even a lightweight material such as a fiber-reinforced plastic, for example GRP or CFRP.

[0009] Additional sealing elements such as a sealing lip, an O-ring or the like can also be provided on the flap or the shell structure in order to prevent moisture from entering through the opening when the flap is in the closed position.

[0010] The actuator is mounted stationary relative to the shell structure, although it does not necessarily have to be attached to the shell structure itself. For example, the actuator can also be attached to the structure above the cover assembly. The stationary relationship of the actuator relative to the shell structure allows for a reliable movement sequence, since if the actuator itself were to move, it could easily tilt, which could lead to it becoming jammed. In addition, special measures would be required to carry a connecting cable of the actuator for supplying a control signal and control energy, such as current or pressure, during the movement of the actuator relative to the shell structure. All common types of actuators are suitable, such as electric motors, hydraulic motors, and the like.

[0011] In general, it would also be conceivable to use a gear system consisting of several gears instead of a single gear, allowing the ratio of the actuator's drive shaft to the rack to be precisely adjusted. This allows a specific actuating force or torque and / or a specific actuating speed to be achieved. The gear system can be shiftable and have multiple gears.

[0012] An advantageous development of the cover assembly according to the invention provides that the shell structure forms at least one guide slot, the flap forms at least one guide pin, and the guide pin is movably received by the guide slot. This allows the kinematic sequence of the flap's movement to be designed even more reliably. Thus, the flap is guided relative to the shell structure during the movement sequence, which can also prevent the flap from tilting and thus wedging. Particularly preferably, several pairs of respective guide slots and guide pins are provided.

[0013] Particularly preferably, the guide slot is designed such that, during the opening process, the flap is first moved away from the opening in a first direction to release it, and then moved away from the opening in a second direction to stow the flap. This prevents the flap from "catching" on a border of the opening.

[0014] According to a further advantageous embodiment of the cover assembly according to the invention, a sleeve, in particular supported by at least one rolling bearing, is mounted on the guide pin, wherein the sleeve is arranged so as to be rollable within the guide slot. This further improves the kinematic sequence of the actuating movement. This reduces the friction between the guide pin and the guide slot, i.e. the shell structure. A lubricant, such as oil, grease, graphite particles or the like, can be applied between the sleeve and the guide slot. Friction can be reduced even further, in particular, if the sleeve is supported on the guide pin via a rolling bearing. This can be any common type of rolling bearing, such as ball bearings, spherical roller bearings, cylindrical roller bearings and the like.Generally, it can also be another bearing type, such as a plain bearing, air bearing, magnetic bearing, or similar. However, rolling bearings are particularly distinguished by their simplicity, robustness, and low cost. The outer diameter of the sleeve is adapted to the width of the guide slot, allowing the sleeve to move, particularly roll, within the guide slot.

[0015] A further advantageous embodiment of the cover assembly according to the invention further provides that the actuator is connected directly or indirectly to the shell structure via an intermediate support. This allows the cover assembly to be designed as a continuous assembly, which allows particularly easy installation on a higher-level structure. In addition, no or only minimal installation tolerances need to be provided for the attachment of the actuator in order to ensure reliable alignment of the actuator, gear, and rack. The intermediate support is a support element which is geometrically designed to hold the actuator in a suitable position. For example, it can be a plate-shaped structure which is connected to the shell structure, for example by plugging in, clipping in, screwing, riveting, or the like. The actuator can then be attached to the intermediate support.All common mounting methods are possible. The intermediate support can be made of or comprise any conceivable material, such as plastic, metal, a metal alloy, a lightweight material, and the like.

[0016] According to a further advantageous embodiment of the cover assembly according to the invention, the rack is connected to the flap via a rotary joint. If the rack is rigidly connected to the flap, a comparatively limited movement sequence is possible. If, on the other hand, the rack is connected to the flap via a rotary joint, the flap can perform a rotational movement relative to the rack when the rack is moved translationally. This makes it possible to realize a more complex movement sequence, so that the cover assembly according to the invention can be designed with even more efficient installation space. During operation, additional components can protrude into the movement trajectory of the flap, past which the flap can be pivoted by the rotary movement. The desired trajectory is imposed on the flap in particular by correspondingly geometrically adapted guide slots.

[0017] A further advantageous embodiment of the cover assembly according to the invention further provides that the flap forms a lever extension and the rack is connected to a free end of the lever extension. The rack can be connected to the lever extension rigidly or via said pivot joint. This allows the designer of the cover assembly even greater flexibility in designing the kinematic movement sequence. Thus, as already mentioned, during later use of the cover assembly, other components can be arranged between the actuator and the flap, around which the rack must be guided. With the help of the lever extension, the connection point of the rack to the flap can be relocated to a different location, thus addressing this problem accordingly.

[0018] According to a further advantageous embodiment of the cover assembly according to the invention, the rack is curved. This also allows for even greater potential for designing the kinematic movement sequence. Particularly preferred is a combination of a curved rack and the connection of the rack to the free end of the lever extension via a swivel joint. This ensures a particularly space-efficient design of the cover assembly and a space-saving movement sequence.

[0019] A further advantageous embodiment of the cover assembly further provides that the shell structure is designed as an outer skin element for a vehicle. Such an outer skin element can be a part of the vehicle body, such as a bumper, the hood, the radiator grille, a fender, and the like, or parts thereof. This enables easy integration of the cover assembly into a vehicle, such as a passenger car.

[0020] Preferably, the opening forms a light exit opening for a vehicle lighting device, in particular a headlight. With the help of the cover assembly, the vehicle's headlights can be protected from environmental influences by opening and closing the cover. Furthermore, the visual appearance of the vehicle can be improved, as the headlights are concealed when not in use.

[0021] In particular, a control signal to activate the actuator is sent simultaneously when the vehicle's headlights are activated or deactivated. This allows the flap to be opened and closed at the correct time to ensure the headlights function properly.

[0022] According to the invention, a vehicle comprising at least one such cover assembly is thus also part of the invention. The vehicle can be a road vehicle such as a car, truck, van, bus, or the like. Generally, it could also be a rail vehicle, watercraft, or aircraft. Advantageously, both headlights of the vehicle are protected from environmental influences by such a cover assembly according to the invention.

[0023] Further advantageous embodiments of the cover assembly according to the invention and of the vehicle according to the invention also emerge from the exemplary embodiments which are described in more detail below with reference to the figures.

[0024] Showing: Fig. 1 is a schematic side view of a cover assembly according to the invention with a straight rack; Fig. 2 a schematic rear view of the cover assembly according to the invention, in which the rack is connected to a flap via a pivot joint; Fig. 3 a schematic rear view of the cover assembly according to the invention with a curved rack during the movement process from a cover position to an open position; Fig. 4 a schematic rear view of the cover assembly according to the invention from Fig. 3 in the open position; and Fig. 5 a schematic front view of a vehicle according to the invention.

[0025] With the aid of a cover assembly 1 according to the invention shown in the figures, lighting devices of a Fig. 5 from environmental influences such as contamination, damage, wetting with moisture and the like. Fig. 1 shows a first embodiment of the cover assembly 1 according to the invention.

[0026] The cover assembly 1 comprises a shell structure 2, a flap 3, a coupling element designed as a rack 4 and an actuator 5. The flap 3 can be switched between a Fig. 1 shown cover position P1 and one in Fig. 4 shown open position P2.

[0027] The shell structure 2 forms an opening 6, in particular in the form of a light exit opening for a headlight of the vehicle 15. Advantageously, such a cover assembly 1 can be provided for each headlight. The shell structure 2 forms, as Fig. 5 shows an outer skin element 14 of the vehicle 15.

[0028] In Fig. 1, the rack 4 is straight and rigidly connected to the flap 3 or even formed in one piece with it. The actuator 5 is designed, for example, as an electric motor, with a gear 7 mounted on or attached to a drive shaft of the actuator 5 (not shown in detail). The toothing of the rack 4 and the gear 7 is in Fig. 1 by a thick line. The gearing allows the rotational movement emitted by the actuator 5 to be converted into a translational movement indicated by a double arrow. The actuator 5 can be connected to the shell structure 2 via an intermediate support 11. In general, the actuator 5 can also be connected directly to the shell structure 2. The actuator 5 could also be arranged detached from the shell structure 2 and, for example, be connected to a higher-level structure of the cover assembly 1, for example, to a structure of the vehicle 15.

[0029] The cover assembly 1 according to the invention is characterized by its geometric simplicity and straightforward kinematic movement sequence. This ensures reliable movement of the flap 3 from the cover position P1 to the open position P2 and back. Furthermore, the cover assembly 1 can be installed in the vehicle 15 in a space-efficient manner.

[0030] Fig. Figure 2 shows an alternative embodiment of the cover assembly 1, in which the rack 4 is connected to the flap 3 via a pivot joint 12. Furthermore, the shell structure 2 has a plurality of guide slots 8, into which respective guide pins 9 of the flap 3 are movably embedded. Preferably, a sleeve 10 is mounted on each guide pin 9, each of which allows a rolling movement within the guide slots 8.

[0031] The rack 4 can also be movably attached to the intermediate support 11 or mounted relative to it. This improves the movement sequence and ensures a robust adjustment movement. For example, the intermediate support 11 can have a guide channel 17 for guiding the rack 4.

[0032] The flap 3 may have a reinforcement, for example in the form of struts applied in a grid-like manner on the side facing the rack 4, to increase the structural integrity.

[0033] The Fig. 3 and Fig. 4 show an alternative design of the rack 4, in which it is curved. Furthermore, the flap 3 has a lever extension 13, to whose free end the rack 4 is connected via the pivot joint 12. A light module 16 of a headlight of the vehicle 15 can also be seen. This can, for example, be the light module 16 used to generate the high beam or low beam.

[0034] In Fig. 3, the flap 3 is moved from the cover position P1 to the open position P2. In Fig. 4, the flap 3 has reached the open position P2. The Fig. 3 and Fig. 4 also illustrate a possible advantageous geometric design of the guide slots 8. Thus, the guide slots 8 are in the Fig. 3 and Fig. 4, the flap 3 is designed in an S-shape. Thus, the direction of movement of the flap 3 changes during the adjustment process. This allows the flap 3 to first be moved out of the opening 6 and then "quickly" moved away from it in order to stow the flap 3.

[0035] Fig. 5 shows the integration of the cover assembly 1 into the vehicle 15. The shell structure 2 forms the outer skin element 14 of the vehicle 15, such as a bumper, fender or the like. Fig. Figure 5 shows two light modules 16 of the headlight. The flap 3 is in the open position P2, allowing a view of the two light modules 16 through the opening 6. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2019 007 736 A1

[0003]

Claims

[1] Cover assembly (1) comprising a shell structure (2), a flap (3), a coupling element and an actuator (5), wherein the shell structure (2) forms an opening (6), the flap (3) is in a mechanical operative connection with the actuator (5) via the coupling element and the flap (3) is movable by actuating the actuator (5) between a covering position (P1), in which the flap (3) closes the opening (6), and an open position (P2), in which the flap (3) at least partially releases the opening (6), characterized by , that - the coupling element is designed as a rack (4); - the actuator (5) is mounted in a fixed position relative to the shell structure (2); - the actuator (5) is designed to transmit a rotary actuating movement to a gear (7) mounted on the drive shaft via a drive shaft; and - the gear (7) is in engagement with the rack (4). [2] Cover assembly (1) according to claim 1, characterized by that the shell structure (2) forms at least one guide slot (8), the flap (3) forms at least one guide pin (9), and the guide pin (9) is movably received by the guide slot (8). [3] Cover assembly (1) according to claim 2, characterized by that a sleeve (10), in particular supported by at least one rolling bearing, is mounted on the guide pin (9), wherein the sleeve (10) is arranged so as to be rollable within the guide slot (8). [4] Cover assembly (1) according to one of claims 1 to 3, characterized by that the actuator (5) is connected directly or indirectly to the shell structure (2) via an intermediate carrier (11). [5] Cover assembly (1) according to one of claims 1 to 4, characterized by that the rack (4) is connected to the flap (3) via a swivel joint (12). [6] Cover assembly (1) according to one of claims 1 to 5, characterized by that the flap (3) forms a lever extension (13) and the rack (4) is connected to a free end of the lever extension (13). [7] Cover assembly (1) according to one of claims 1 to 6, characterized by that the rack (4) is curved. [8] Cover assembly (1) according to one of claims 1 to 7, characterized by that the shell structure (2) is designed as an outer skin element (14) for a vehicle (15). [9] Cover assembly (1) according to claim 8, characterized by that the opening (6) forms a light exit opening for a vehicle lighting device, in particular a headlight. [10] Vehicle (15), characterized by at least one cover assembly (1) according to one of claims 1 to 9.

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