Charging Port Cover Assembly and Covering Method

Abstract

An exemplary charging port cover assembly, among other aspects, includes a biasing device configured to move to a first position when a charger is decoupled from the charging port and to move to a second position when the charger is coupled to the charging port. When the biasing device is in the first position, the charging port door is movable to a closed position, and when the biasing device is in the second position, the charging port door remains in an open position. Among other aspects, an exemplary charging port covering method includes biasing the charging port door toward the open position using the biasing device in the first position and moving the biasing device from the first position to the second position to close the charging port door.

Description

Technical Field

[0001] The present disclosure generally relates to covering a charging port of an electric vehicle. In particular, the present disclosure relates to a charging port door that automatically closes when a charger is decoupled from the charging port. Background Art

[0002] Electric vehicles differ from conventional motor vehicles in that electric vehicles use one or more electric motors powered by a traction battery to selectively drive. The electric motor can drive the electric vehicle instead of or in conjunction with an internal combustion engine. Example electric vehicles include hybrid electric vehicles (HEVs), plug-in hybrid electric vehicles (PHEVs), fuel cell vehicles (FCVs), and battery electric vehicles (BEVs).

[0003] The traction battery is a relatively high-voltage battery that selectively powers the electric motors and other electrical loads of the electric vehicle. The traction battery can include a battery array, and each battery array includes a plurality of interconnected battery cells that store energy. Some electric vehicles (such as PHEVs) can charge the traction battery from an external power source (such as a grid power source).

[0004] When charging the traction battery from an external power source, a charger can be coupled to the charging port of the vehicle. Some electric vehicles include a charging port door to cover the charging port. The user opens the charging port door during charging to allow the charger to be coupled to the charging port. The user closes the charging port door after decoupling the charger from the charging port. Summary of the Invention

[0005] Among other aspects, a charging port covering assembly according to an exemplary aspect of the present disclosure includes a biasing device configured to move to a first position when a charger is decoupled from the charging port and move to a second position when the charger is coupled to the charging port. When the biasing device is in the first position, the charging port door is movable to a closed position, and when the biasing device is in the second position, the charging port door remains in an open position.

[0006] In another non-limiting embodiment of the foregoing assembly, the biasing device is a spring.

[0007] A further non-limiting embodiment of any of the foregoing assemblies includes a slidable member. The biasing device is coupled to the charging port door and the slidable member.

[0008] In another non-limiting embodiment of any of the foregoing assemblies, the biasing device in the second position holds the charging port door in the open position.

[0009] In a further non-limiting embodiment of any of the above assemblies, the slidable member is a pin.

[0010] In a further non-limiting embodiment of any of the foregoing components, the slidable member is configured to slide from a retracted position to an extended position to move the biasing device from a first position to a second position.

[0011] A further non-limiting embodiment of any of the foregoing components includes an actuator configured to move between an activated position and a deactivated position. The actuator in the activated position is configured to move the slidable member from the retracted position to the extended position. The actuator in the deactivated position is configured to allow the slidable member to move from the extended position to the retracted position.

[0012] In a further non-limiting embodiment of any of the foregoing components, the biasing device is a first biasing device, and the component further includes a second biasing device that biases the actuator toward the deactivated position.

[0013] Another non-limiting embodiment of any of the foregoing components includes a first actuator member of the actuator and a second actuator member of the actuator. When in the deactivated position, the second actuator member is moved to provide an open area for the first actuator member to fall downward and allow the slidable member to move to the retracted position.

[0014] Among other aspects, a charging port covering method according to another exemplary non-limiting embodiment of the foregoing disclosure includes: biasing a charging port door toward an open position using a biasing device in a first position, and moving the biasing device from the first position to a second position to close the charging port door.

[0015] Another non-limiting embodiment of the foregoing method includes coupling a charger to the charging port to move the biasing device from the first position to the second position, and decoupling the charger from the charging port to move the biasing device from the second position to the first position.

[0016] Another non-limiting embodiment of any of the foregoing methods includes moving a slidable member to move the biasing device.

[0017] In a further non-limiting embodiment of any of the foregoing methods, the biasing device is coupled to the slidable member and the charging port door.

[0018] In a further non-limiting embodiment of any of the foregoing methods, the slidable member is configured to slide from a retracted position to an extended position to move the biasing device from the first position to the second position.

[0019] Another non-limiting embodiment of the foregoing method includes applying a bias using a spring.

[0020] Another non - limiting embodiment of any of the foregoing methods includes coupling a charger to a charging port to move an actuator to a start position and decoupling the charger from the charging port to move the actuator to a deactivated position. Moving the actuator to the start position causes a sliding member to move from a retracted position to an extended position. Moving the actuator to the deactivated position allows the slidable member to move from the extended position to the retracted position.

[0021] In another non - limiting embodiment of any of the foregoing methods, the biasing means is a first biasing means and the method further includes biasing the actuator towards the deactivated position using a second biasing means.

[0022] Another non - limiting embodiment of any of the foregoing methods includes coupling a charger to a charging port to overcome a biasing force exerted on the actuator by the second biasing means. The biasing force exerted by the second biasing means biases the actuator towards the deactivated position.

[0023] Another non - limiting embodiment of any of the foregoing methods includes moving a first actuator member of the actuator and a second actuator member of the actuator when moving the actuator between the deactivated position and the start position. When in the deactivated position, the second actuator member is moved to provide an open area for the first actuator member to fall downward and allow the slidable member to move to the retracted position. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In accordance with the detailed description, various features and advantages of the disclosed examples will become apparent to those skilled in the art. The accompanying drawings, which are incorporated in and constitute a part of this detailed description, may be briefly described as follows:

[0025] Figure 1 A side view of an exemplary electric vehicle is shown, where the charging port is covered by a charging port door in a closed position;

[0026] Figure 2 Shows Figure 1 A close - up view of the charging port of the electric vehicle, together with the charger and the charging port door in an open position;

[0027] Figure 3 Shows a cross - sectional view through Figure 1 The charging port and the charging port door;

[0028] Figure 4 Shows a cross - sectional view of Figure 3 When the charging port door is in the open position and the charger is coupled to the charging port;

[0029] Figure 5 Shows a flow of an exemplary method of covering the charging port with a charging port door Figure 1 ; DETAILED DESCRIPTION

[0030] The present disclosure generally relates to covering a charging port of an electric vehicle with a charging port door.

[0031] The charging port door can be opened by a user so that a charger can be coupled to the charging port to charge a traction battery of the electric vehicle. After the electric vehicle is charged, the user decouples the charger from the charging port. According to an exemplary embodiment, the charging port door automatically closes in response to decoupling the charger from the charging port. Thus, the charging port door will not inadvertently remain in the open position.

[0032] Referring Figure 1 and 2 , exemplary vehicle 10 is a plug-in hybrid electric vehicle (PHEV) that includes a traction battery. In another example, vehicle 10 is a battery electric vehicle (BEV). Other vehicles that include a charging port are included within the scope of the present disclosure.

[0033] The power-split powertrain of vehicle 10 employs a first drive system and a second drive system. The first and second drive systems generate torque to drive one or more sets of vehicle drive wheels 12. The first drive system can include a combination of an internal combustion engine and a generator. The second drive system can include at least one motor, a generator, and a traction battery.

[0034] There are times when it is desirable or necessary to charge the traction battery. When vehicle 10 is moving, power from regenerative braking can charge the traction battery. When vehicle 10 is stationary, an external power source such as grid power 14 can be used to charge the traction battery.

[0035] Vehicle 10 includes a charging port door that covers the charging port 20 of vehicle 10 when the charging port door is in the Figure 1 closed position shown. Charging port 20 is an interface of vehicle 10 that can be coupled to charger 24. Electric power from grid power 14 is transferred through charger 24 to charging port 20 to recharge the traction battery of vehicle 10. Charger 24 can draw power from grid power 14 at, for example, an operator's residence, a public charging station, etc.

[0036] Exemplary charging port 20 is an AC charging port that receives AC power from grid power 14. In another example, charging port 20 is a DC charging port that receives DC power from grid power 14. In yet another example, charging port 20 is a combined AC / DC charging port that can receive a combination of AC power or DC power.

[0037] The charging port 20 includes an electrical connector 28 that is electrically connected to a corresponding electrical connector 32 within the charger 24 when the charger 24 is coupled to the charging port 20. The charging port door 18 covers the electrical connector 28 when closed, which can prevent accidental contact with the electrical connector 28. The charging port door 18 can enhance the aesthetics of the vehicle 10 by hiding the charging port 20 when closed.

[0038] Continuing to refer Figure 2 while now referring Figure 3 , when the charger 24 is not coupled to the charging port 20, the charging port door 18 is in the closed position. The charging port door 18 is part of a charging port covering assembly. Due to the charging port covering assembly, when the charger 24 is decoupled from the charging port 20, the charging port door 18 automatically moves to Figure 3 the closed position. That is, due to the charging port covering assembly, when the charger 24 is decoupled from the charging port 20, the charging port door 18 does not remain in Figure 2 the position but will automatically move to Figure 1 the position. The movement to the closed position substantially does not require interaction from the user beyond decoupling the charger 24 from the charging port 20.

[0039] The charging port door covering assembly includes the charging port door 18, a biasing device 40, a slidable member 44, and an actuator assembly 48. In this exemplary embodiment, the actuator assembly 48 of the charging port covering assembly includes a first actuator member 58, a second actuator member 62, and a biasing device 66.

[0040] The actuator assembly 48 is movable between Figure 3 a deactivated position and Figure 4 an activated position. In the deactivated position, the actuator assembly 48 allows the charging port covering assembly to move and holds the charging port door 18 in the closed position. In the activated position, the actuator assembly 48 allows the charging port covering assembly to hold the charging port door 18 in the open position. As will be described, coupling the charger 24 to the charging port 20 causes the actuator assembly 48 to move from the deactivated position to the activated position, and decoupling the charger 24 from the charging port 20 causes the actuator assembly 48 to move from the activated position to the deactivated position.

[0041] In Figure 3 , the actuator assembly 48 is shown in the deactivated position, in which the second actuator member 62 is biased outward in the direction O towards the charging port door 18. The lip 70 prevents the second actuator member from moving to a position where the second actuator member 62 can contact the charging port door 18 in the closed position.

[0042] Biasing the second actuator member 62 outwardly towards the charging port door 18 in the closed position provides a first opening area A1. The first actuator member 58 falls downwardly in the direction D into the first opening area A1 such that a portion of the first actuator member 58 is behind the second actuator member 62. For the purposes of the present disclosure, downward is with reference to the ground and the standard orientation of the vehicle 10 ( Figure 1 ) during charging from an external power source.

[0043] The tapered surface 74 of the first actuator member 58 contacts the corner area 78 of the second actuator member 62 to prevent further movement of the first actuator member 58 downward in the direction D.

[0044] As the first actuator member 58 moves downward, the slidable member 44 is able to slide inwardly in the slot 82 in the direction I to a retracted position. In the retracted position of this exemplary embodiment, the corner area 86 of the slidable member 44 abuts another tapered surface 90 of the first actuator member 58.

[0045] The biasing device 40 is a spring, such as a tension spring. One end of the biasing device is coupled to the charging port door 18 by a hinge member 94. The other opposite end of the biasing device 40 is directly coupled to the slidable member 44.

[0046] The slidable member 44 moving inwardly in the direction I provides a second opening area A2 which houses the biasing device 40. When housed within the second opening area A2, the biasing device 40 does not apply a biasing force on the charging port door 18 that would move the charging port door 18 to the open position. Instead, the biasing device 40 pulls on the charging port door 18 and holds the charging port door 18 in the closed position.

[0047] Moving the actuator assembly 48 to the activated position causes the slidable member 44 to transition from Figure 3 its retracted position to Figure 4 its extended position. In the extended position, the slidable member 44 slides into the second opening area A2 within the slot 82. The movement of the slidable member 44 causes the biasing device 40 to move, causing the biasing device 40 to bear against the hinge member 94 of the charging port door 18. The slidable member 44 in the extended position moves the biasing device 40 to a position that holds the charging port door 18 in Figure 4 the open position. Holding the slidable member 44 in the extended position causes the biasing device 40 to continue to bias the hinge member 94 to hold the charging port door 18 in the open position, in which the hinge member 94 pivots about the pivot member 98 to Figure 4 the open position.

[0048] To initially move the charging port door 18 from Figure 3 its closed position to Figure 4To the open position, the operator manually moves the charging port door 18 to the open position. The operator can hold the charging port door 18 in the open position and then couple the charger 24 to the charging port 20.

[0049] The coupling of the charger 24 to the charging port 20 causes the charger 24 to move against the second actuator member 62, causing the second actuator member 62 to slide inwardly along direction I. The force associated with coupling the charger 24 to the charging port 20 is sufficient to overcome the biasing force provided by the biasing device 66.

[0050] When the second actuator member 62 moves in direction I, the angular region 78 slides along the tapered surface 74 of the first actuator member 58, which causes the first actuator member 58 to move upward in direction U opposite to direction D. The movement of the first actuator member 58 in direction U causes the tapered surface 90 to slide along the angular region 86 of the slidable member 44, which forces the slidable member 44 from Figure 3 the retracted position to move to Figure 4 the extended position.

[0051] When the traction battery of the vehicle 10 is fully charged, the operator decouples the charger 24 from the charging port 20. The operator can choose to decouple the charger 24 from the charging port 20 at another time, for example when only a partial charge of the traction battery is desired.

[0052] Decoupling the charger 24 from the charging port 20 allows the biasing device 66 to force the second actuator member 62 of the actuator assembly 48 to return outwardly in direction O until the second actuator member 62 contacts the lip 70 as Figure 3 shown.

[0053] The outward movement of the second actuator member 62 reopens the first open area A1 to allow the first actuator member 58 to fall downward in direction D back to Figure 3 its position. Since the first actuator member 58 no longer holds the slidable member 44 in the extended position after falling downward, the slidable member 44 slides back to Figure 3 the retracted position. Typically, the weight of the charging port door 18 forces the slidable member 44 to slide back to the retracted position. Since the movement is no longer blocked by the first actuator member 58, the weight of the charging port door 18 moves the slidable member 44.

[0054] Referring to Figure 5 , an exemplary method 100 of covering a charging port includes opening a charging port door in step 104. Next, in step 108, a charger is coupled to the charging port to move the biasing device from a first position to a second position. At step 112, the biasing device in the second position holds the charging port door open.

[0055] Next, at step 116, the charger is decoupled from the charging port, which causes the biasing device to move back from the second position to the first position. At step 120, the biasing device moves to the first position to close the charging port door.

[0056] Features of the disclosed examples include a charging port door that automatically closes when the charger is decoupled from the charging port. This can prevent the charging port door from being accidentally opened. Compared to a typical fuel door of a conventional vehicle, the charging port door may be opened and closed more frequently. Thus, the chance of accidentally leaving the charging port door open may be greater than that of leaving such a typical fuel door open. Additionally, electric vehicles can generally have their chargers engaged to the charging port by an operator other than the vehicle driver (e.g., a worker at a public charging distribution center).

[0057] The foregoing specification is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art without necessarily departing from the essence of the disclosure. Therefore, the scope of legal protection given to this disclosure can only be determined by studying the following claims.

Claims

1. A charging port covering assembly, comprising: A biasing device configured to move to a first position when the charger is decoupled from the charging port and move to a second position when the charger is coupled to the charging port; and A charging port door movable to a closed position when the biasing device is in the first position and remaining in an open position when the biasing device is in the second position; Further comprising a slidable member, wherein the biasing device is coupled to the charging port door and the slidable member; Wherein the slidable member is configured to slide from a retracted position to an extended position to move the biasing device from the first position to the second position, and the charging port covering assembly further comprises an actuator configured to move between an activated position and a deactivated position, the actuator in the activated position being configured to move the slidable member from the retracted position to the extended position, and the actuator in the deactivated position being configured to allow the slidable member to move from the extended position to the retracted position; Wherein the biasing device is a first biasing device and the charging port covering assembly further comprises a second biasing device biasing the actuator towards the deactivated position; Further comprising a first actuator member of the actuator and a second actuator member of the actuator, wherein the second actuator member is moved when in the deactivated position to provide an open area for the first actuator member to fall downwards and allow the slidable member to move to the retracted position.

2. The charging port covering assembly according to claim 1, wherein the biasing means is a spring.

3. The charging port covering assembly according to claim 1, wherein the slidable member is a pin.

4. The charging port covering assembly according to claim 1, wherein the biasing means in the second position holds the charging port door in the open position.

5. A method of covering a charging port, comprising: Biasing the charging port door towards the open position using the biasing device in the first position; and Moving the biasing device from the first position to the second position to close the charging port door; Including coupling the charger to the charging port to move the biasing device from the first position to the second position, and decoupling the charger from the charging port to move the biasing device from the second position to the first position; Further comprising moving the slidable member to move the biasing device, wherein the slidable member is configured to slide from a retracted position to an extended position to move the biasing device from the first position to the second position; Further comprising coupling the charger to the charging port to move the actuator to the activated position, and decoupling the charger from the charging port to move the actuator to the deactivated position, wherein moving the actuator to the activated position causes the slidable member to move from the retracted position to the extended position, and moving the actuator to the deactivated position allows the slidable member to move from the extended position to the retracted position; Wherein the biasing device is a first biasing device, and the charging port covering method further comprises using a second biasing device to bias the actuator towards the deactivated position; Wherein coupling the charger to the charging port overcomes the biasing force exerted by the second biasing device, and the biasing force exerted by the second biasing device biases the actuator towards the deactivated position.

6. The method of covering a charging port according to claim 5, wherein the biasing means is coupled to the slidable member and the charging port door.

7. The method of covering a charging port according to claim 6, wherein the method of covering a charging port uses a spring to apply the bias.

8. The method of covering a charging port according to claim 5, further comprising: When the actuator moves between the deactivated position and the activated position, a first actuator member of the actuator and a second actuator member of the actuator are moved, wherein the second actuator member is moved when in the deactivated position to provide an open area for the first actuator member to fall downward and to allow the slidable member to move to the retracted position.

Images