Loading flap arrangement for a motor vehicle and method for manufacturing such a loading flap arrangement

Abstract

The invention relates to a loading flap assembly for a motor vehicle, comprising a pivot arm that is connected or connectable to a loading flap cover, an axle receptacle formed on the pivot arm, and a drive shaft that is axially extendable from the drive shaft receptacle, wherein the pivot arm together with the drive shaft receptacle is injection-molded from a plastic material, and wherein an inner contour of the drive shaft receptacle is formed by overmolding the drive shaft with the plastic material as a geometric negative mold of an outer contour of the drive shaft. The invention further relates to a method for manufacturing such a loading flap assembly.

Description

The invention relates to a loading flap arrangement for a motor vehicle and a method for manufacturing such a loading flap arrangement. The charging port of battery-electric vehicles is typically concealed behind a charging port cover. This cover pivots around an axis between an open and a closed position. In the open position, the charging port is accessible. In the closed position, the charging port cover conceals it. In prior art solutions, the loading flap cover is connected to a pivot arm that has an axle mount which interacts with a drive shaft. For mounting on the vehicle, the drive shaft is inserted axially through a vehicle-mounted axle mount into the axle mount of the pivot arm. The object of the invention is to provide a method for manufacturing a loading flap assembly and a loading flap assembly that offer advantages over the prior art. This problem is solved by providing a method with the features of claim 1 and a loading flap arrangement with the features of claim 4. Advantageous embodiments are specified in the dependent claims. The wording of the claims is incorporated herein by reference. The method according to the invention serves to manufacture a loading flap arrangement for a motor vehicle, wherein the loading flap arrangement has a pivot arm, an axle receptacle formed on the pivot arm, and a plug-in axle which, in a state of the loading flap arrangement mounted on the motor vehicle, is axially inserted into the axle receptacle of the pivot arm.The method according to the invention comprises the following steps: providing an injection mold for injection molding the swivel arm from a plastic material; providing the plug-in axle; applying a release agent to the plug-in axle; positioning the plug-in axle provided with the release agent in the injection mold; injection molding the swivel arm by injecting the plastic material into the injection mold, wherein the plug-in axle is overmolded with the plastic material to form the axle receptacle, wherein an inner contour of the axle receptacle is formed as a geometric negative shape of an outer contour of the plug-in axle, and wherein the release agent forms a separating layer between the inner contour of the axle receptacle and the outer contour of the plug-in axle, which allows axial withdrawal of the plug-in axle from the axle receptacle. The invention is based on the understanding that tolerance-related problems can occur with solutions known from the prior art. Due to geometric tolerances of the axle mount on the one hand and the drive shaft on the other, a tolerance-compliant mating often cannot be achieved. This results in excessive play in the connection between the drive shaft and the axle mount. This excessive play can cause the tailgate cover to assume an imprecisely defined position when closed. Furthermore, the play can cause the tailgate cover to strike the surrounding vehicle body during driving, which can lead to undesirable noises (rattling). The solution according to the invention counteracts all of this in a simple yet particularly effective manner. The method according to the invention allows for a virtually play-free mating between the axle mount and the drive shaft.This virtually play-free fit is achieved by overmolding the drive shaft with the plastic material during the injection molding of the swivel arm, thereby forming a negative geometric mold for the inner contour of the shaft receptacle. The release agent applied before the drive shaft is positioned in the injection mold forms a separating layer between the shaft receptacle and the drive shaft during injection molding, allowing the drive shaft to be manually pulled out of the receptacle after injection molding. The drive shaft is therefore not permanently encased and embedded in the swivel arm. Suitable release agents are known to those skilled in the art. In this embodiment of the invention, the plug-in shaft is positioned in the injection mold in a defined axial orientation relative to an axial reference alignment, with the positioning being effected by means of an adjustable positioning device of the injection mold. The adjustable positioning relative to the axial reference alignment allows the gap and flushness of the loading flap cover in the closed position to be optimized in a particularly simple and cost-effective manner. In prior art solutions, this often requires a complex modification of the injection mold for this purpose. Such modifications are time-consuming and expensive. The adjustable positioning of the plug-in shaft significantly simplifies the adjustment of the gap and flush.The defined axial alignment of the drive shaft simultaneously determines the resulting axial alignment of the shaft mount. Axial alignment can be understood as the alignment of the longitudinal axis of the drive shaft and thus of the shaft mount. In a further embodiment of the invention, the drive shaft is positioned in the injection mold in a defined longitudinal rotation position relative to a rotational reference orientation. This defined longitudinal rotation position of the drive shaft differs from its later nominal longitudinal rotation position when the loading flap assembly is assembled. In other words, in this embodiment of the invention, the drive shaft is positioned in the injection mold rotated about its longitudinal axis relative to its later assembly position and relative to the shaft mount. This rotation allows for the creation of a preload, such as that required for four-joint components. This is achieved by ensuring that the production position no longer corresponds to the design position and can be adjusted after testing. During injection molding, the drive shaft assumes the defined longitudinal rotation position.For mounting on the vehicle, the axle shaft is pulled out of the axle mount and inserted into the axle mount in a different longitudinal rotation position, the aforementioned nominal longitudinal rotation position. The charging flap assembly according to the invention is intended for a motor vehicle, in particular a battery-electric vehicle, and comprises a pivot arm, an axle mount, and a drive shaft. The pivot arm is connected to, or connectable to, a charging flap cover. The axle mount is formed on the pivot arm. The drive shaft is axially extendable from the axle mount. The pivot arm, together with the axle mount, is injection-molded from a plastic material. An inner contour of the axle mount is formed by overmolding the drive shaft with the plastic material as a negative geometric shape of an outer contour of the drive shaft. For the advantages arising from the charging flap assembly according to the invention, reference is made to the disclosure of the inventive method, and express reference is made to it. What is disclosed therein also applies mutatis mutandis to the charging flap assembly according to the invention.In one embodiment, the loading flap cover is connected to the pivot arm and is therefore part of the loading flap assembly. In another embodiment, the loading flap cover and the pivot arm are injection-molded together from the plastic material. In yet another embodiment, the loading flap cover is not part of the loading flap assembly. In one embodiment, a separating layer formed by a release agent is present between the inner contour of the axle receptacle and the outer contour of the drive axle. In another embodiment, a retention device is provided by means of which the drive axle is detachably and securely held to the pivot arm. Preferably, the retention device is injection-molded from the plastic material, for example, in the form of a film bond, a thin plastic strut, or the like.The locking mechanism can be easily released manually during the assembly of the loading flap assembly by pulling the plug shaft axially out of the shaft receptacle, thereby mechanically overloading the locking mechanism and causing it to fail. In a further embodiment of the invention, the inner contour of the axle receptacle and the outer contour of the drive shaft interact in a form-fit manner in the circumferential direction of the drive shaft. This form-fit prevents the drive shaft from rotating within the axle receptacle. To enable this form-fit, the outer contour of the drive shaft is preferably provided with a profile. During the injection molding of the swivel arm, this profile is transferred as a negative geometric shape to the inner contour of the axle receptacle. This results in a particularly full-surface form-fit. In a further embodiment of the invention, the axle shaft has an assembly code that specifies a nominal longitudinal rotational position of the axle shaft during the installation of the loading flap assembly on the vehicle. The assembly code allows for angularly accurate installation of the axle shaft in accordance with the requirements, with respect to the axle mount and / or the vehicle-mounted axle bracket. The assembly code can also be referred to as a mounting lock. Such mounting locks are also known by the Japanese term "Poka-Yoke". In a further embodiment of the invention, the swivel arm is designed in the form of a swan-neck boom, which has a first end and a second end and is extended longitudinally at an angle between the first and second ends. Such a design of the swivel arm has proven to be particularly advantageous. In a further embodiment of the invention, the axle mount is formed at the first end of the gooseneck boom and the second end of the gooseneck boom is connected or connectable to the loading flap cover. Further advantages and features of the invention will become apparent from the claims and from the following description of preferred embodiments of the invention, which are illustrated with reference to the drawings. Figure 1 shows a schematic block representation of an embodiment of a method according to the invention for manufacturing a loading flap assembly for a motor vehicle; Figure 2 shows a truncated side view of a motor vehicle in the area of ​​a loading flap cover, which is pivotably mounted on the motor vehicle between an open position and a closed position by means of an embodiment of a loading flap assembly according to the invention; Figure 3 shows a schematic perspective view of the loading flap assembly according to Figure 2; Figure 4 shows a schematic perspective view and simplified block representation of an exemplary situation during the manufacture of the loading flap assembly; Figures 5 and 6 show a truncated perspective view of the loading flap assembly in the area of ​​a pivot arm, which has an axle receptacle at one end in which a plug-in axle, temporarily overmolded with plastic during the manufacture of the loading flap assembly, is retractably arranged; and Figure 6 shows the loading flap assembly in the area of ​​a pivot arm, which has an axle receptacle at one end in which a plug-in axle, temporarily overmolded with plastic during the manufacture of the loading flap assembly, is arranged to be pulled out.Figure 7 shows an exemplary situation in a cropped perspective view during the assembly of the loading flap assembly on the motor vehicle. According to Fig. 1, a method 100 for manufacturing a loading flap arrangement 1 (see Fig. 3) for a motor vehicle F is provided (see Fig. 2). The loading flap arrangement 1 shown in detail in Fig. 3 has a pivot arm 10, an axle mount 11 and a plug axle 20. The swivel arm 10 can be connected to a loading flap cover 30, which is shown in Fig. 2 in a situation mounted on the motor vehicle F. In the illustrated embodiment, a cover support 40 is provided for connecting the pivot arm 10 to the loading flap cover 30; the cover support 40 is fixedly connected to the pivot arm 10 at one end. The cover support 40 is optional and not present in all embodiments. The axle mount 11 is formed on the swivel arm 10. The plug-in axle 20 is axially removable from the axle receptacle 11 and is temporarily overmolded with a plastic material K in a manner described in more detail, wherein the entire swivel arm 10 together with the axle receptacle 11 is injection molded from the said plastic material K. An inner contour 12 of the axle mount 11 (see Fig. 6) is formed by the aforementioned overmolding of the plug-in axle 20 as a geometric negative form N of an outer contour 21 of the plug-in axle 20. By temporarily overmolding the drive shaft 20 to form the inner contour 12 of the axle receptacle 11, a particularly precise, virtually play-free fit between the axle receptacle 11 and the drive shaft 12 is achieved. This play-free fit enables a particularly precise alignment of the tailgate cover 30, especially in the closed position shown in Fig. 2. The play-free fit promotes uniform gap dimensions and a flush alignment of the tailgate cover 30 with the surrounding body of the vehicle F (gap and flush). Furthermore, it prevents the tailgate cover 30 from striking the body during driving due to excessive play and causing rattling noises. In the method 100 provided for the manufacture of the loading flap arrangement 1 according to Fig. 1, steps 110, 120, 130, 140 and 150 are provided. Step 110 involves providing an injection mold 50 for injection molding the swivel arm 10 from the aforementioned plastic material K. The injection mold 50 is shown schematically in a highly simplified form in Fig. 4. Step 120 involves providing the stub axle 20. In one version, the stub axle 20 is made of metal. In another version, the stub axle is also injection-molded as a plastic component. Step 130 involves applying a release agent TM to the plug-in shaft 20. The release agent TM prevents the plug-in shaft 20 from forming a permanent bond with the plastic material K during injection molding. In principle, any suitable release agent can be used for this purpose. Preferably, a release agent that is usable up to at least 200 °C is used. Step 140 involves positioning the plug-in shaft 20, coated with the release agent TM, in the injection mold 50. This positioning is shown schematically in Fig. 4. In the situation shown there, the plug-in shaft 20 is arranged in the injection mold 50. A positioning device 51 is provided for positioning purposes; in this case, it is a component of the injection mold 50. The positioning device 51 allows for adjustable positioning of the plug-in shaft 20. It should be understood that the positioning device 51 is shown schematically in a highly simplified manner in Fig. 4. Furthermore, Fig. 4 shows an open state of the positioning device 51. In the closed state, positioning elements (without reference numerals) of the positioning device 51 are pressed against the plug-in shaft 20, so that it is positioned in a defined position relative to the injection mold 50. Step 150 involves injection molding the swivel arm 10. The plastic material K is injected into the injection mold 50. The drive shaft 20 is (temporarily) overmolded with the plastic material K, forming the shaft receptacle 11. This overmolding creates the inner contour 12 of the shaft receptacle 11 as a negative geometric mold N of the outer contour 21 of the drive shaft 20. The release agent TM forms a release layer TS (see Fig. 5), which allows the drive shaft 20 to be axially withdrawn from the shaft receptacle 11. Fig. 5 shows the loading flap assembly 1 in section. The connecting shaft 20, together with the pivot arm 10 and the shaft receptacle 11, forms a manufacturing unit. In other words, Fig. 5 shows the loading flap assembly 1 as a component removed from the mold, as it is taken out of the injection mold 50 after injection molding, i.e., step 150. The connecting shaft 20 can be manually pulled axially out of the shaft receptacle 11, as shown in Fig. 6. This extraction advantageously takes place only during the actual assembly of the loading flap assembly 1 on the vehicle F. The swivel arm 10, together with the axle mount 11, is arranged in a vehicle-mounted housing G, as shown schematically in Fig. 7. The drive axle 20 is then inserted axially through an axle mount GH of the housing G into the axle mount 11 of the swivel arm 10. In the illustrated embodiment, step 140 provides that the plug-in shaft 20 is positioned in the injection mold 50 in a defined axial orientation relative to an axial reference alignment RA (see Fig. 4). This defined axial orientation can be set using the positioning device 51. In the situation shown in Fig. 4, the plug-in shaft 20 is aligned exactly according to the axial reference alignment RA. The axial reference alignment RA of the plug-in shaft 20 simultaneously and necessarily also determines the axial alignment of the shaft receptacle 11 formed by overmolding the plug-in shaft 20. The axial alignment of the shaft receptacle 11 with respect to the vehicle-mounted shaft receptacle GH of the housing G is particularly important for the gap pattern and the flushness of the loading flap cover 30 in the closed position (see Fig. 2). In the illustrated embodiment, it is also provided that in step 140, the plug-in shaft 20 is positioned in the injection mold 50 in a defined longitudinal rotation position relative to a rotational reference orientation LR (see Fig. 4). This defined longitudinal rotation position of the plug-in shaft 20 differs from its later nominal longitudinal rotation position when the loading flap assembly 1 is assembled (see Fig. 7). In other words, the plug-in shaft 20 is inserted into the injection mold 50 at an angular position about its longitudinal axis relative to the shaft receptacle 11 being formed, which does not correspond to its later angular position in the assembled state. Put another way, the plug-in shaft 20 is inserted into the injection mold 50 rotated relative to the shaft receptacle 11 in relation to the assembly state.Depending on the actuation mechanism of the loading flap assembly, a preload can be achieved, among other things, by this rotation. The aforementioned actuation mechanism can be designed in different ways, is not part of the loading flap assembly 1, and is therefore not shown here. In the illustrated embodiment, the inner contour 12 of the axle receptacle 11 and the outer contour 21 of the drive shaft 20 interact in a form-fitting manner in the circumferential direction of the drive shaft 20. The drive shaft 20 is therefore not rotatable within the axle receptacle 11. However, the drive shaft 20 (together with the pivot arm 10) is rotatable relative to the vehicle-fixed axle receptacle GH of the housing G. In the illustrated embodiment, the aforementioned positive fit is formed by a profile of the outer contour 21. During overmolding with the plastic material K, the profile of the outer contour 21 forms the geometric negative mold for a complementary profile of the inner contour 12 of the axle mount 11. In the illustrated embodiment, the aforementioned profile simultaneously forms an assembly code M. The assembly code M acts as a locking mechanism, ensuring that the plug-in axle 20 can only be mounted in a defined longitudinal rotation position relative to the axle receptacle GH of the housing G. This longitudinal rotation position corresponds to the nominal longitudinal rotation position already mentioned. In the embodiment shown, the swivel arm 10 is designed in the form of a gooseneck boom 13. The gooseneck boom 13 is cranked longitudinally between a first end and a second end. In this case, the axle mount 11 is formed at the first end of the gooseneck boom 13. The second end of the gooseneck boom 13 can be connected to the loading flap cover 30, in this case via the aforementioned optional cover support 40.

Claims

Method (100) for manufacturing a loading flap assembly (1) for a motor vehicle (F), the loading flap assembly (1) comprising a pivot arm (10), an axle receptacle (11) formed on the pivot arm (10), and a plug-in axle (20) which, in a state of the loading flap assembly (1) mounted on the motor vehicle (F), is axially inserted into the axle receptacle (11) of the pivot arm (10), the method (100) comprising the steps: providing (110) an injection mold (50) for injection molding the pivot arm (10) from a plastic material (K); providing (120) the plug-in axle (20); applying (130) a release agent (TM) to the plug-in axle (20); positioning (140) the plug-in axle (20) provided with the release agent (TM) in the injection mold (50);Injection molding (150) of the swivel arm (10) by injecting the plastic material (K) into the injection molding tool (50), wherein the plug-in shaft (20) is overmolded with the plastic material (K) to form the shaft receptacle (11), wherein an inner contour (12) of the shaft receptacle (11) is formed as a geometric negative form (N) of an outer contour (21) of the plug-in shaft (20), and wherein the release agent (TM) forms a release layer (TS) between the inner contour (12) of the shaft receptacle (11) and the outer contour (21) of the plug-in shaft (20), which allows axial withdrawal of the plug-in shaft (20) from the shaft receptacle (11). Method (100) according to claim 1, wherein the plug axis (20) is positioned in a defined axial orientation in the injection mold (50) with respect to an axial reference orientation (RA) relative to the injection mold (50), and wherein the positioning is carried out by means of an adjustable positioning device (51) of the injection mold (50). Method (100) according to claim 1 or 2, wherein the plug-in axis (20) is positioned in a defined longitudinal rotation position in the injection mold (50) with respect to a rotational reference orientation (LR) relative to the injection mold (50), wherein the longitudinal rotation position of the plug-in axis (20) is different from a later nominal longitudinal rotation position assumed in an assembled state of the loading flap assembly (1). Loading flap arrangement (1) for a motor vehicle (F), comprising a pivot arm (10) which is connected or connectable to a loading flap cover (30), an axle mount (11) which is formed on the pivot arm (10), and a plug-in axle (20) which is axially retractable in the axle mount (11), wherein the pivot arm (10) together with the axle mount (11) is injection molded from a plastic material (K), and wherein an inner contour (12) of the axle mount (11) is formed by overmolding the plug-in axle (20) with the plastic material (K) as a geometric negative form (N) of an outer contour (21) of the plug-in axle (20). Loading flap arrangement (1) according to claim 4, wherein the inner contour (12) of the axle receptacle (11) and the outer contour (21) of the plug axle (20) interact in a form-fitting manner in the circumferential direction of the plug axle (20). Loading flap arrangement (1) according to claim 4 or 5, wherein the plug shaft (20) has an assembly code (M) which specifies a nominal longitudinal rotation position of the plug shaft (20) when mounting the loading flap arrangement (1) on the motor vehicle (F). Loading flap arrangement (1) according to one of claims 4 to 6, wherein the pivot arm (10) is designed in the form of a gooseneck boom (13) which has a first end and a second end and is extended longitudinally in a cranked manner between the first end and the second end. Loading flap arrangement (1) according to claim 7, wherein the axle receptacle (11) is formed at the first end, and wherein the second end is connected or connectable to the loading flap cover (30).

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