Unit carrier for a door module

Abstract

Aggregate support (4) for a door module (2), comprising a support plate (6) designed as a plastic injection-molded part, on which at least one vertically upstanding bearing pin (20) with an undercut (22) for a clip element (18), in particular for a clip pulley, is integrally formed, - wherein at least one axial recess (28) is formed in the support plate (6) in the region of the bearing journal (20) in such a way that a separating burr (26) produced during demoulding of the bearing journal (20) is arranged within the recess (28), and - wherein the recess (28) is deeper than 0.1 mm.

Description

[0001] The invention relates to an assembly carrier for a door module of a vehicle door, comprising a carrier plate designed as a plastic injection-molded part, on which at least one vertically upstanding bearing pin for a clip element, in particular for a clip pulley, is integrally formed with an undercut. The invention further relates to a door module with such an assembly carrier and two injection molding tools for producing such an assembly carrier.

[0002] Today, movable vehicle windows are typically moved between a closed and an open position by electrically or electric-motor-operated actuators known as (vehicle) window lifters. Such a window lifter typically comprises an (electric) actuator motor and an actuator mechanism that connects the actuator motor to the window pane, i.e., couples it to the power transmission, and is assigned to a vehicle door or vehicle body.

[0003] For the installation of functional components in a vehicle door, such as the window regulator, drive unit, side airbag module, loudspeaker, control unit, or the like, it is possible to pre-assemble such functional components on an assembly carrier. The assembled assembly carrier can then be placed over an assembly opening in the vehicle door to cover it, particularly to create a wet / dry compartment divider.

[0004] A basic structure of such a door module is shown in the Fig. 1 and explained below.

[0005] The representation of the Fig. Figure 1 shows a top view of a door module 2 for a vehicle door. The door module 2 has an assembly carrier 4 with a carrier plate 6. The assembly carrier 4 is typically designed as an injection-molded part.

[0006] Mounted on the support plate 6 is a two-strand cable window lifter 8 with two (essentially) parallel guide rails 10, each of which has a carrier (rail slider) (not shown in detail) slidably guided on it. The carriers are connected to a traction cable (not shown) as a flexible traction means, which is deflected several times and coupled to an electric actuator 12. The guide rails 10 are preferably integrated into the unit carrier 4; in particular, the guide rails 10 are designed as a single piece, i.e., one-piece or monolithic, with the support plate 6. This means that the guide rails 10 are designed as plastic parts.

[0007] Deflection devices 14, 16 are arranged at the rail end sides (cable deflection areas) of the guide rails 10 to deflect a drive force transmitted via the traction cable for adjusting the window pane. These transmit the drive force from the actuator 12 to the window pane or to the drivers connected to it in order to raise or lower the window pane within the vehicle door. Window lifters with such cable mechanisms are also referred to here and below as cable-operated window lifters or cable window lifters.

[0008] The deflection is achieved by means of deflection elements 18. Preferably, the deflection is achieved by means of cable pulleys provided on the guide rails 10 of the window lifter, which are mounted on the guide rails so that they can rotate about a rotation axis. In other words, rotatably mounted cable pulleys are preferably used as the deflection element. Various fastening elements, such as screws or stepped bolts, are used for the rotatable fastening. These are guided centrally through the cable pulley and about whose central axis the cable pulley can be rotated.

[0009] For example, DE 10 2020 204 027 A1 discloses a deflection device for a cable window lifter in which the cable pulley can be clipped or locked to a raised bearing pin. In the assembled state, a rotatable or pivotable snap connection (snap connection, clip connection) is thus realized, eliminating the need for additional components to hold the cable pulleys.

[0010] The embodiment of the Fig. 1 has, for example, three deflection devices 14 with deflection elements 18 designed as clip-on pulleys ( Fig. 5), which are also referred to below as clip elements 18. The deflection devices 14 are arranged at the top and bottom of the A-side guide rail 10, as well as at the bottom of the B-side guide rail 10.

[0011] The bearing journals 20 ( Fig. 2) are preferably formed from the material of the guide rail 10 or the support plate 6. In other words, the respective bearing pin 20 is formed (molded, demolded) from the support material itself as a cylindrical or hollow-cylindrical shaped body.

[0012] Below is a more typical production of such a bearing journal 20 based on the Fig. 2 to 4 are explained in more detail.

[0013] The unit carrier 4 is manufactured in an injection molding tool, in which the main demolding direction is oriented, for example, approximately perpendicular to the support plate 6. The bearing pin 20 extends substantially perpendicularly upwards from the guide rail 10 or the support plate 6 and is thus oriented, in particular, along the main demolding direction. For the snap-on or clip-on fastening of the clip elements 18, the bearing pin 20 has a circumferential annular groove (locking groove) as an undercut 22. The undercut 22 is realized, for example, by means of two sliders 24 as a radial undercut of the bearing pin 20.

[0014] The slides 24 each have a semicircular receptacle which encompasses the bearing journal 20 and thus forms its outer surface or undercut 22. The slides 24 are guided laterally along a secondary demoulding direction N radially to the bearing journal 20 and are in the closed state ( Fig. 2) adjoin each other at the end face. The secondary demolding direction N is essentially perpendicular to the main demolding direction.

[0015] A parting plane is thus formed between the end faces of the slides 24, so that, due to the manufacturing process, when the slides ( Fig. 3) a separation or demoulding burr 26 remains on the workpiece or on the carrier plate 6 or guide rail 10, which is oriented approximately radially to the bearing journal 20 and protrudes axially from the top side of the workpiece.

[0016] Here and below, a parting or demolding flash refers in particular to irregularly shaped, thin, film-like plastic webs that lie outside the molded part contour. The cause is primarily a lack of tightness between the adjacent demolding tools (slide, collapsible core) due to mold breathing, manufacturing tolerances, or wear. This allows the melt to penetrate into the tool interface areas and solidify.

[0017] Clip pulleys as clip elements 18 are, for example, manually or automatically joined to the bearing journal 20. As can be seen in particular from the illustrations of the Fig. 4 to 7, the separating burr 26 is arranged in the support area of ​​the clip element 18 for manufacturing reasons. If the separating burr 26 becomes too large, the clip element 18 can no longer be clipped or assembled reliably. In particular, it may happen that not all of the locking or clip hooks of the clip element 18 engage completely, which creates the risk that the snap connection could come loose again on its own. If the separating burr 26 is too large, this can also adversely affect the function of the clip element 18 by reducing the installation height and thus blocking the clip element 18. Furthermore, the separating burr 26 can also lead to undesired noise when the cable pulley rotates if the support surface of the clip element 18 slides or drags over the separating burr 26.

[0018] The invention is based on the object of providing a particularly suitable assembly support. Preferably, an assembly support is to be provided in which the essentially unavoidable burrs do not adversely affect the function of a clip element, in particular a clip pulley. The invention is further based on the object of providing a particularly suitable door module and particularly suitable injection molding tools.

[0019] With regard to the assembly carrier, the problem is solved according to the invention with the features of claim 1, with regard to the door module with the features of claim 7, and with regard to the injection molding tools with the features of claims 8 and 9. Advantageous embodiments and further developments are the subject of the dependent claims (subclaims). The advantages and embodiments cited with regard to the assembly carrier are also transferable mutatis mutandis to the door module and / or the injection molding tools, and vice versa.

[0020] The conjunction “and / or” is to be understood here and in the following in such a way that the features linked by this conjunction can be formed both together and as alternatives to one another.

[0021] The present invention is based on the earlier German utility model DE 20 2023 104 437 U1. The content of this utility model is incorporated by reference into the disclosure of the present application.

[0022] The assembly support according to the invention is intended for a door module of a vehicle door and is suitable and configured therefor. The assembly support comprises a support plate designed as a plastic injection-molded part. At least one vertically projecting bearing pin with an undercut for clip-on attachment of a clip element is integrally formed on the support plate.

[0023] In one conceivable embodiment, at least one guide rail for a cable window lifter is integrated into the support plate. The guide rail is preferably formed integrally, i.e., one-piece or monolithic, onto the support plate. The guide rail is provided and configured so that a driver or rail slider of the cable window lifter is guided displaceably thereon. At least one of the rail ends has a cable deflection area for deflecting a pull cable of the cable window lifter. The cable deflection area has the upstanding, molded-on bearing journal (bearing bolt) for the preferably rotatable mounting of the clip element. The clip element is preferably designed as a deflection element, in particular as a clip-on cable pulley (deflection pulley). The bearing journal thus forms the physical bearing axis (axis of rotation) of or for the cable pulley in the installed state.

[0024] The particularly cylindrical or hollow-cylindrical bearing journal preferably has a circumferential locking groove as an undercut, which is introduced as a radial recess extending tangentially into an outer circumference of the bearing journal. In such an embodiment, the undercut is thus introduced in particular as a radial annular groove into a lateral surface of the cylindrical or hollow-cylindrical bearing journal.

[0025] The clip element or the clip pulley can be joined as such to the undercut of the bearing journal in a snap connection (locking connection, clip connection). In other words, the clip element is directly clipped or latched onto the bearing journal during assembly or joining. To this end, locking tabs on the clip element side (cable pulley side) snap or latch into the undercut of the bearing journal, creating the snap connection.

[0026] "Axial" or an "axial direction" is understood here and below to mean, in particular, a direction parallel (coaxial) to the rotational axis of the clip element, i.e., along a longitudinal direction of the bearing journal. Accordingly, "radial" or a "radial direction" is understood here and below to mean, in particular, a direction oriented perpendicular (transverse) to the rotational axis of the clip element, along a radius of the cable pulley or bearing journal.

[0027] The axial direction is essentially oriented along a main demolding direction of the injection mold used to produce the carrier plate, with the radial direction being arranged, for example, along a secondary demolding direction. The (radial) undercut of the (axial) bearing journal is produced in particular by a demolding tool (molding tool), in particular by a slide (slide tongs) or a collapsible core, in the injection mold.

[0028] According to the invention, an axial recess is formed in the support plate or guide rail in the area of ​​the bearing journal. In other words, a local depression is provided in the area of ​​the bearing journal. The axial recess runs, for example, tangentially or radially to the bearing journal. In other words, the base surface is axially recessed tangentially or radially to the bearing journal.

[0029] The recess can be specifically used for water management, reducing grease leaching from the (lubricating) grease applied between the bearing journal and the clip element and containing contamination at the interface. The recess thus provides integrated water management for the clip connection between the clip element and the bearing journal. This provides a particularly suitable assembly support.

[0030] According to the invention, the recess is arranged such that a separating burr resulting from the injection molding of the bearing journal is arranged within the recess.

[0031] The recess is thus located in a mold parting area of ​​the injection mold, which is responsible for burr formation. As a result, the parting burr is essentially formed within the recess. The recess is at least 0.1 mm (millimeters) deep, so that burr formation has essentially no influence on the interface geometry of the bearing journal and the clip element. In particular, this ensures collision-free rotation of a clip-on pulley.

[0032] This eliminates the need for a complex testing concept to verify the installation of a cable pulley. Furthermore, the recess enables improved assembly robustness and greater design freedom for the deflection area. In particular, the injection molding tool for producing the unit carrier is simplified, as burr formation does not interfere with the function of the clip element.

[0033] Advantageously, the separating burr does not protrude axially from an edge of the recess. In other words, the (axial) depth of the recess is greater than or equal to the (axial) height of the separating burr. In an advantageous embodiment, the recess is dimensioned in particular between 0.1 mm and 5 mm. This ensures that the separating burr is essentially completely submerged in the recess and thus does not collide with a clip-mounted clip element.

[0034] In a suitable design, the recess is located in the area of ​​a contact surface of the clip element on the guide rail. As a result, the contact surface has essentially no axially protruding elevations that could complicate clip fastening of the clip element or interfere with the clip element during assembly.

[0035] In a suitable embodiment, the recess is designed as an elongated trench or a groove. The recess runs or extends tangentially or radially to the bearing journal. The recess is created, in particular, by contours on the demolding tools of the injection molding tool, so that the recess extends along a demolding or movement direction of the demolding tools, for example, along the secondary demolding direction in the case of a slider.

[0036] The recess or trench can, for example, have a rectangular cross-sectional shape. Alternatively, other cross-sectional shapes, such as a semicircle, are also conceivable, so that the recess is essentially designed as a groove. In particular, essentially any cross-sectional geometries are conceivable for the recess or trench, whereby the tool direction and the demolding direction, i.e., the main and secondary demolding directions, must be taken into account accordingly.

[0037] In one conceivable embodiment, the bearing journal is formed by two slides oriented along a secondary demolding direction, whereby the parting burr is formed along a radially oriented parting plane between the slide end faces.

[0038] In particular, two recesses are provided that extend parallel to each other. In particular, the recesses are arranged on both sides of the bearing journal. This is particularly advantageous because the separating burr forms between the end faces of the slides—and thus on both sides of the bearing journal. This ensures that the separating burr is located completely outside the mounting area of ​​the clip element.

[0039] In an equally conceivable alternative embodiment, the bearing journal is demolded by a folding core with a number of core segments, with a separating ridge being formed along a radial parting plane between two adjacent core segments. The folding core has, for example, eight core segments, so that eight separating ridges are formed extending radially in a star shape from the bearing journal. Preferably, eight corresponding radially star-shaped recesses are formed in the material of the carrier plate, into which the separating ridges are countersunk.

[0040] The door module according to the invention is intended for installation in a vehicle door, and is suitable and configured for this purpose. The door module comprises a previously described unit or (door) module carrier as a carrier plate, on which functional components of the vehicle door, such as a window lifter, are pre-assembled or can be pre-assembled. The unit carrier is made at least in sections from a plastic material, wherein, for example, a guide rail for a cable window lifter is integrated or molded in the region of the plastic material, which guide rail has an upstanding bearing pin for a clip element, for example for a (clip) cable pulley, and at least one recess at one end of the rail. This provides a particularly suitable door module for a cable window lifter with a clip-on cable pulley, in which reliable and reproducible (pre-)assembly of the clip-on cable pulley is guaranteed.

[0041] "Made in sections from a plastic material" is understood in particular to mean that at least one part of the carrier plate or several parts of the carrier plate are made of a plastic material. Preferably, a large part of the carrier plate, i.e., more than 40% or 50% of the carrier plate, and in particular a support or mounting surface defined by the carrier plate for the arrangement of functional components, is formed from the plastic material.

[0042] The injection molding tool according to the invention is intended for the production of an aggregate carrier as described above, and is suitable and configured for this purpose.

[0043] The injection molding tool has two mold halves movable along a main demolding direction for forming the carrier plate, wherein the main demolding direction is oriented, for example, substantially perpendicular to the carrier plate's upper side. A guide rail for a cable window lifter is preferably produced or demolded integrally with the carrier plate by the mold halves.

[0044] The injection molding tool according to the invention further comprises a demolding tool for demolding or removing the bearing journal. In a first embodiment, the demolding tool is designed as two slides (slide tongs) movable perpendicular to the main demolding direction along a secondary demolding direction. In a second, alternative embodiment, the demolding tool is designed as a collapsible core oriented perpendicular to the main demolding direction with a number of movable core segments for demolding the bearing journal.

[0045] The demoulding tool, i.e. the slides or the core segments, has a (first) mould contour for the bearing journal and the undercut, whereby the slides or the core segments are moved towards each other for demoulding and come into contact with each other at the front or tangentially.

[0046] According to the invention, the slides or the core segments have (second) shape contours oriented in the main demolding direction. The shape contours are arranged on an underside of the demolding tool facing the carrier plate. During the molding of the bearing journal, the shape contours are guided in a furrow-like manner through the not yet completely cooled material of the carrier plate, so that recesses running along the direction of movement of the demolding tool are introduced into the unit carrier by means of the shape contours. The shape contours are arranged such that a separating burr forming on the end faces of the slides or at the contact points of the core segments is arranged within the created recesses. The shape contours are dimensioned such that the resulting recess is at least 0.1 mm deep, so that the separating burr preferably does not protrude axially from an edge of the recess.This results in a particularly suitable injection molding tool.

[0047] An embodiment of the invention is explained in more detail below with reference to a drawing. In the drawings: Fig. 1 in plan view a door module with an aggregate carrier according to the prior art, Fig. 2, Fig. 3 in plan view a forming of a bearing journal on the unit carrier according to the prior art, Fig. 4 in perspective view, a detail of a deflection point of the aggregate carrier according to the prior art without a cable pulley, Fig. 5 in perspective view, a detail of a deflection point of the aggregate carrier according to the prior art with a cable pulley, Fig. 6 in sectional view of the bearing journal according to the state of the art, Fig. 7 shows a section view of the bearing journal with a fixed pulley according to the prior art, Fig. 8, Fig. 9 in plan view an inventive forming of a bearing journal on an aggregate carrier according to the invention, Fig. 10 in plan view a deflection area of ​​the aggregate carrier according to the invention, Fig. 11 in plan view the deflection area with a pulley and a pulley, Fig. 12 in sectional view of the bearing journal, Fig. 13 in sectional view, a section of the bearing journal with a fixed pulley, Fig. 14 in perspective view, a section of an injection moulding tool, Fig. 15 in perspective view two slides of the injection molding tool with a view of an upper side, Fig. 16 in perspective view two slides of the injection molding tool with a view of an underside, Fig. 17 in perspective view the deflection area with a rope pulley, Fig. 18 in perspective sectional view the deflection area with a rope pulley, Fig. 19 in perspective view the deflection area, and Fig. 20 shows a perspective view of the deflection area in which the bearing journal is demolded by means of a folding core.

[0048] Corresponding parts and sizes are always provided with the same reference symbols in all figures.

[0049] The door module 2 according to the invention essentially corresponds to the Fig. 1, wherein the unit carrier 4 designed as an injection-molded part, in particular the deflection area or the deflection devices 14, is / are designed differently.

[0050] As in the representations of the Fig. 8 to 16, during the molding or demolding of the bearing pin 20, two additional elongated axial recesses 28 are introduced into the plastic material of the carrier plate 6 or the guide rail 10, which recesses run approximately tangentially to the bearing pin 20.

[0051] For this purpose, the slides 24 of the injection molding tool have additional mold contours 30 on a bottom side facing the guide rail 10, which, when the slides 24 are closed and opened, form the groove- or pit-like depressions 28 in the guide rail 10 ( Fig. 16).

[0052] The recesses 28 or shaped contours 30 have, for example, an approximately rectangular cross-sectional shape. The shaped contours 30 are arranged tangentially to the contour region forming the bearing journal 20, so that the recesses 28 extend tangentially to the bearing journal 20.

[0053] The parallel recesses 28 are thus introduced into the guide rail 10 along the movement or sliding direction of the slides 24, i.e., along the secondary demolding direction N. In other words, the recesses 28 extend along the secondary demolding direction.

[0054] The recesses 28 are arranged and positioned in such a way that the separating ridge 26 forming on the front side between the slides 24 is arranged within the recesses 28 ( Fig. 9, Fig. 10). The (axial) depth of the recess 28 is greater than or equal to the (axial) height of the separating ridge 26. In other words, the separating ridge 26 does not protrude beyond the edge of the recess 28. The recesses 28 have a depth of at least 0.1 mm, in particular between 0.1 mm and 5 mm.

[0055] As shown by the Fig. 11 to 13 and 17 to 19, the separating burr 26 is thus arranged below a support surface of the clip element 18 designed as a clip pulley, so that the burr formation has no influence on the interface geometry of the bearing pin 20 and the clip pulley 18. In particular, a collision-free rotation of the clip pulley 18 in the assembled state ( Fig. 11, Fig. 17) is ensured so that a pull cable 32 of the cable-operated window lifter 8 is reliably deflected. In the illustrations of the Fig. 18 and Fig. 19, the separating ridge 26 is not shown here.

[0056] This eliminates the need for a complex testing concept to verify the installation of the cable pulley. Furthermore, the recesses 28 enable improved assembly robustness and greater design freedom for the deflection area. In particular, the injection molding tool for producing the assembly support 4 is simplified, since burr formation does not interfere with the function of the clip-on cable pulley 18.

[0057] In the Fig. 20 shows an embodiment of the unit carrier 4, in which the bearing pin 20 is demolded by a folding core not shown in detail.

[0058] The folding core used in the embodiment shown has, for example, eight core segments which are movable radially to the bearing journal 20 along a demoulding direction E. The mould contours 30 are arranged on the core segments so that eight recesses 28 extending radially in a star shape from the bearing journal 20 are formed, in each of which a radial separating ridge 26 is formed. Fig. 20 only one separating ridge 20 is shown, wherein the recesses 28 are provided with reference numerals merely as an example.

[0059] The claimed invention is not limited to the exemplary embodiments described above. Rather, other variants of the invention can also be derived therefrom by those skilled in the art within the scope of the disclosed claims without departing from the subject matter of the claimed invention. In particular, all individual features described in connection with the various exemplary embodiments can also be combined in other ways within the scope of the disclosed claims without departing from the subject matter of the claimed invention. List of reference symbols 2 door module 4 aggregate carriers 6 Carrier plate 8 cable window lifters 10 Guide rail 12 Actuator 14 Deflection device 16 Deflection device 18 deflection element, clip element, (clip) rope pulley 20 bearing journals 22 undercut 24 sliders 26 Separation ridge 28 Deepening 30 Shape contour 32 traction rope N Secondary demolding direction E Demolding direction 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 2020 204 027 A1

[0009] DE 20 2023 104 437 U1

[0021]

Claims

[1] Aggregate carrier (4) for a door module (2), comprising a carrier plate (6) designed as a plastic injection molded part, on which at least one vertically rising bearing pin (20) with an undercut (22) for a clip element (18), in particular for a clip pulley, is integrally formed, - wherein at least one axial recess (28) is formed in the carrier plate (6) in the area of ​​the bearing pin (20) such that a parting line (26) created when the bearing pin (20) is demolded is arranged within the recess (28), and - where the depression (28) is deeper than 0.1 mm. [2] Aggregate carrier (4) according to claim 1, characterized by , that the depression (28) is between 0.1 mm and 5 mm deep. [3] Aggregate carrier (4) according to claim 1 or 2, characterized by , that the depression (28) is designed as an elongated trench which extends tangentially or radially to the bearing journal (20). [4] Aggregate carrier (4) according to one of claims 1 to 3, characterized by , that the recess (28) is arranged in the area of ​​a contact surface of the clip element (18) on the carrier plate (6). [5] Aggregate carrier (4) according to any one of claims 1 to 4, characterized by , that the bearing journal (20) is demolded by two slides (24) movable along a secondary demolding direction (N), the parting line (26) being formed along a parting plane between the slide end faces. [6] Aggregate carrier (4) according to any one of claims 1 to 4, characterized by , that the bearing journal (20) is demolded by a folded core with a number of core segments, whereby a parting line (26) is formed along a parting plane between two adjacent core segments. [7] Door module (2) for a vehicle door comprising an aggregate carrier (4) according to one of claims 1 to 6. [8] Injection mold for producing an aggregate carrier (4) according to any one of claims 1 to 6, comprising - two mold halves movable along a main demolding direction for the carrier plate (6), and - two secondary demolding direction (N) movable along a secondary demolding direction (N) oriented perpendicular to the main demolding direction for forming a bearing pin (20) with an undercut (22), - wherein the slides (24) have form contours (30) oriented in the main demolding direction in order to introduce recesses (28) extending along the secondary demolding direction (N) into the aggregate carrier (4) in such a way that a parting line (26) resulting from the demolding of the bearing pin (20) is arranged within the recesses (28). [9] Injection mold for producing an aggregate carrier (4) according to any one of claims 1 to 6, comprising - two mold halves movable along a main demolding direction for the carrier plate (6), and - a folding core oriented perpendicular to the main demolding direction with a number of movable core segments for demolding a bearing pin (20) with an undercut (22), - wherein the core segments have shape contours (30) oriented in the main demolding direction in order to introduce recesses (28) extending along a demolding direction (E) and at least 0.1 mm deep into the aggregate carrier (4) such that a parting line (26) resulting from the demolding of the bearing pin (20) is arranged within the recesses (28).

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