Icebreaking emergency releaser

Abstract

The present disclosure relates to an actuation assembly for a vehicle configured to control movement of a cover assembly that selectively covers a compartment, such as a charging compartment, a fueling compartment, or a service compartment. The actuation assembly includes a drive assembly, a driveline, and a locking mechanism to secure the lid assembly in the closed position. In the event of an obstacle, such as ice accumulation, the mechanism features a manual override system that includes a handle and a cable that allow a user to disengage the locking mechanism and manually open the lid.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 539,893, filed on September 22, 2023, entitled “Ice Break Emergency Release,” which is hereby incorporated by reference in its entirety. Background Art

[0003] Hybrid and electric vehicles are typically characterized by a traction battery that can be charged via an external electrical connector accessible on the vehicle body. For plug-in hybrid vehicles (PHEVs) and battery electric vehicles (BEVs), the connector (commonly referred to as a charging port) enables connection to an external charging station or a standard electrical outlet. The charging port is housed in a charging / fueling compartment on the vehicle body that is covered by a charging flap or closure element. A mechanism associated with the charging flap allows the compartment to be selectively opened or closed, thereby permitting access to the charging port. In internal combustion engine vehicles, fuel is supplied to the fuel tank via a filler neck that is similarly accessible from the outside of the vehicle by connecting to a fuel pump or nozzle. The filler neck is typically enclosed in a housing that is covered by a fuel filling flap or closure element. As with the charging port, a mechanism allows the fuel filling compartment to be opened or closed, thereby permitting access to the filler neck.

[0004] Actuating assemblies and devices for opening and closing covers on vehicles are well known in the prior art (e.g., US8353553B2, US8585119 B2, US9631403 B2, US9616745 B2). However, there is still a need for a system that can coordinate multiple functions in a charging compartment, a fuel filling compartment, or a maintenance compartment. These functions include unlocking and locking the flap, moving the flap between an open position and a closed position, and controlling additional features in the compartment (such as lighting). Co-owned U.S. Patent Publication No. 2023 / 0151651 to Hegwein describes a locking device that is capable of locking a charging, fuel filling, or maintenance flap to a compartment. The flap is reversibly movable between a closed position and an open position.

[0005] The various functions should be coordinated and / or synchronized. For example, during charging, the flap must first be unlocked, and then the flap can be moved to the open position, thereby allowing access to the charging port. Only after the charging connector is properly engaged can the flap be locked again.

[0006] To achieve this coordination, multiple actuators are typically employed within the compartment system, where each actuator is responsible for a specific function (e.g., unlocking a flap or moving a flap). A control device is used to manage and synchronize the operation of these actuators. However, such systems are exposed to varying weather conditions, which can lead to sealing issues. For example, components like flaps can freeze, hampering their operation. However, despite the advances, a need for an actuation assembly with an override assembly still exists. Summary of the invention

[0007] The present disclosure is generally directed to an actuation assembly substantially as shown and described with reference to at least one of the accompanying drawings, as more fully set forth in the claims. For example, the present disclosure is generally directed to an actuation assembly having an override assembly to release a lid assembly when the lid assembly becomes stuck, such as due to ice formation. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing and other objects, features, and advantages of the devices, systems, and methods described herein will become apparent from the following description of specific examples as illustrated in the accompanying drawings, in which the same or similar reference numerals represent the same or similar structures. The accompanying drawings are not necessarily drawn to scale, with emphasis instead being placed upon illustrating the principles of the devices, systems, and methods described herein.

[0009] Figure 1a and Figure 1b Perspective views of an actuation assembly according to an aspect of the subject disclosure are shown in a closed position and an open position, respectively.

[0010] Figure 1c A side view of the actuation assembly is shown in a closed position.

[0011] Figure 1d A cross-sectional side view of the actuation assembly along section line AA is shown.

[0012] Figure 2a A detailed schematic of the drive train is shown with the gear assembly in the locked position.

[0013] Figure 2b A detailed schematic of the drive train is shown with the gear assembly in the unlocked position.

[0014] Figure 2c A detailed schematic diagram of an actuation assembly having a powered override actuator according to another aspect of the present disclosure is shown. DETAILED DESCRIPTION

[0015] Reference to singular items should be understood to include plural items, and vice versa, unless otherwise explicitly stated or clear from the context. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of connected clauses, sentences, words, etc., unless otherwise specified or clear from the context. Unless otherwise indicated herein, the description of the range of values ​​herein is not intended to be limited, but refers to any and all values ​​falling within and / or including the range individually, and each individual value within such a range is incorporated into the specification, just as it is separately narrated herein. In the following description, it should be understood that terms such as "first", "second", "top", "bottom", "side", "front", "back" are words for convenience and should not be interpreted as restrictive terms. For example, although in some examples, the first side is positioned adjacent to or close to the second side, the terms "first side" and "second side" do not mean any particular order in which these sides are sorted.

[0016] When accompanied by numerical values, the terms "about", "approximately", "substantially", etc. should be understood to indicate deviations, as understood by those of ordinary skill in the art, for satisfactory operation for the intended purpose. Values ​​and / or ranges of values ​​are provided herein only as examples and do not constitute limitations on the scope of the present disclosure. The use of any and all examples or exemplary language ("for example", "such as", etc.) provided herein is intended only to better illustrate the disclosed examples and does not constitute a limitation on the scope of the present disclosure. The terms "for example" and "such as" lead to a list with one or more non-limiting examples, instances, or illustrations. Any language in the specification should not be interpreted as indicating that any unclaimed element is essential to the practice of the disclosed examples.

[0017] The term "and / or" refers to any one or more of the multiple items in the list connected by "and / or". As an example, "x and / or y" refers to any element in the three-element set {(x), (y), (x, y)}. In other words, "x and / or y" means "one or both of x and y". As another example, "x, y and / or z" refers to any element in the seven-element set {(x), (y), (z), (x, y), (x, z), (y, z), (x, y, z)}. In other words, "x, y and / or z" means "one or more of x, y and z".

[0018] The present disclosure generally relates to a locking device for fixing a cover on or in a housing, in particular on a vehicle body. In particular, the present disclosure focuses on locking mechanisms that are configured to actuate a cover (such as a charging, fueling or maintenance flap) in a charging, fueling or maintenance compartment integrated into a vehicle body component. In addition, the present disclosure relates to a system comprising a cover (specifically in the form of a charging, fueling or maintenance flap) and a corresponding charging, fueling or maintenance compartment that is integrated or can be integrated into a vehicle body component. The cover is configured to reversibly move between a closed position and an open position relative to the compartment, and a locking device is provided to fix the cover in an appropriate position. Finally, the present disclosure also covers a vehicle equipped with such a system. The terms "fueling flap" and "fueling compartment" as used in the present disclosure extend beyond components specific to fuel tanks. These terms also cover components associated with tanks for other resources (such as AdBlue (urea), or additives such as water). Accordingly, the present disclosure includes actuation assemblies for service flaps associated with fill systems for various tanks, including those for fuel, AdBlue, or water.

[0019] In one example, a drive assembly for moving a lid assembly of a vehicle between an open position and a closed position relative to a housing, the drive assembly comprising: a drive pinion configured to receive a drive shaft; a cam pinion meshing with the drive pinion, wherein the drive pinion is configured to rotate the cam pinion; a rack cam having a first end and a second end, wherein the second end meshes with the cam pinion, and wherein the rack cam is configured to translate in response to rotation of the cam pinion; and a flip lock configured to pivot relative to the housing between a locked state and an unlocked state, wherein the flip lock is pivotally connected to the second end of the rack cam via a pivot connection; and an override assembly operably connected to the second end of the rack cam and configured to translate the rack cam to move the flip lock from the locked state to the unlocked state.

[0020] In another example, an actuation assembly for a cover assembly of a vehicle includes: a housing having a compartment; a drive assembly coupled to the housing, wherein the drive assembly includes a drive train configured to move the cover assembly between an open position and a closed position relative to the housing, and wherein the drive assembly is configured to secure the cover assembly in a locked state to cover the compartment; and an override assembly operably coupled to the drive train and configured to move the cover assembly from the locked state to an unlocked state.

[0021] In some examples, the override assembly includes a handle and a cable, wherein the cable is coupled to the handle and the second end of the rack cam.

[0022] In some examples, manipulation of the handle actuates the cable to move the flip lock from the closed position to the open position.

[0023] In some examples, the cable includes a wire and an outer sheath, the wire being slidable within the outer sheath to transmit force between the handle and the second end of the rack cam.

[0024] In some examples, the drive assembly further includes a power override actuator configured to pull the second end of the rack cam via a cable or a portion of a cable in response to a control signal to move the flip lock from the locked state to the unlocked state.

[0025] In some examples, the power override actuator includes an electric motor.

[0026] In some examples, the handle is a pull ring.

[0027] In some examples, the outer jacket includes: an inner liner; a longitudinal incompressible layer; and a protective outer cover.

[0028] In some examples, the drive train includes a cover linkage assembly configured to secure the cover assembly in the locked state and a gear assembly operably connected to the cover linkage assembly.

[0029] In some examples, the gear assembly includes a drive pinion configured to receive a drive shaft and a cam pinion meshing with the drive pinion.

[0030] In some examples, the lid linkage assembly includes a flip lock and a rack cam having a first end and a second end, wherein the flip lock is pivotally connected to the second end of the rack cam via a pivot connection and is configured to pivot about an axis relative to the housing.

[0031] In some examples, the rack cam is configured to mesh with the cam pinion, and the rack cam is configured to translate in response to rotation of the cam pinion.

[0032] In some examples, the flip lock is configured to pivot about an axis in response to translation of the rack cam, the flip lock moving between the locked state and the unlocked state.

[0033] In some examples, the compartment is: a charging compartment; a fueling compartment; or a maintenance compartment of the vehicle.

[0034] Figure 1a and Figure 1b Perspective views of an actuation assembly 100 in accordance with an aspect of the subject disclosure are shown in a closed position and an open position, respectively. Figure 1c A side view of the actuator assembly 100 in the closed position is provided, and Figure 1d A cross-sectional side view of the actuation assembly 100 along section line AA is depicted.

[0035] The actuation assembly 100 generally includes a cover assembly 102, a housing 104, and a drive assembly 108. The cover assembly 102 is shown here as a charging flap assembly (but the subject disclosure will also apply to fuel doors and other flaps / doors). In this example, the cover assembly 102 includes a cover 106 and a cover frame 110. The cover assembly 102 is configured to selectively cover a charging / fueling compartment 112. The cover frame 110 provides rigidity, structure, and operating features to the cover assembly 102, while the cover 106 provides a decorative element / cover that matches the surrounding vehicle aesthetics while covering the charging / fueling compartment 112. For example, the cover frame 110 can provide functional components (such as locking elements 148 or hinges), while the cover 106 can be designed to blend in with the exterior of the vehicle.

[0036] The actuation assembly 100 is configured to perform several functions. First, the actuation assembly moves the lid assembly 102 between the open position and the closed position. Second, the actuation assembly locks the lid assembly 102 in the closed position. The actuation assembly 100 also features an override and / or ice breaking function via, for example, an override assembly 114, which is configured to mitigate ice accumulation that may impede movement of the lid assembly 102.

[0037] The drive assembly 108 controls both the position (e.g., between the open position and the closed position) and the locking state (e.g., the locked state or the unlocked state) of the lid assembly 102. In some examples, the drive assembly 108 can be electric and can include an electric motor having a drive shaft 116, which is configured to generate and / or otherwise output a rotational force. The drive assembly 108 drives the lid assembly 102 through a transmission system 118, which includes a lid linkage assembly 120 and a gear assembly 122 operably connected to the lid linkage assembly 120. The rotational force from the drive assembly 108 is transmitted to the lid linkage assembly 120 through the drive shaft 116 and the gear assembly 122, thereby achieving the movement of the lid assembly 102.

[0038] In the illustrated example, the actuation assembly 100 incorporates a manually operable override assembly 114. The override assembly 114 is configured to allow a user to manually actuate or disengage the drive assembly 108 or a component thereof (e.g., the drive train 118) in the event of an obstruction or failure. For example, if ice accumulation renders the actuation assembly 100 inoperable, the user can manually engage the override assembly 114 to break the ice and enable the lid 106 to move to the open position in the direction indicated by arrow 162. Similarly, in the event of a power failure, the user can manually engage the override assembly 114 to move the lid 106 to the open position.

[0039] In the illustrated example, the override assembly 114 includes a handle 124, which is depicted as a pull ring, which is connected to the drive assembly 108 via, for example, a cable 126. The illustrated cable 126 includes an inner wire 126a, which is configured to move within an outer sheath 126b. For example, the cable 126 can be a Bowden cable, which is configured to transmit mechanical force to push or pull components by allowing the inner wire 126a to slide relative to the outer sheath 126b. The handle 124 can be positioned adjacent to the actuating assembly 100 in a portion (such as a trunk or engine compartment) accessible during use of the vehicle. This configuration enables the operator to manually unlock the actuating assembly 100 and release the cover assembly 102 in the event of a power failure, mechanical failure, or adverse weather conditions (e.g., ice accumulation).

[0040] The outer jacket 126b of the cable can feature a composite construction including an inner liner, a longitudinal incompressible layer (e.g., a spiral winding or wire jacket), and a protective outer covering. This construction allows the cable 126 to effectively transmit manual force from the handle 124, thereby enabling the user to disengage the drive train 118 and overcome ice accumulation, thereby restoring the function of the actuation assembly 100 and allowing the lid 106 to open.

[0041] Figure 2a and Figure 2b Detailed schematic diagrams of an example transmission system 118 are shown, showing the gear assembly 122 in a locked state and an unlocked state, respectively. Various components are omitted in these views for clarity. The transmission system 118 shown includes the gear assembly 122 and the lid linkage assembly 120. The gear assembly 122 includes a drive pinion 128 and a cam pinion 130, while the lid linkage assembly 120 includes a flip cover lock 134 and a rack cam 136.

[0042] The drive pinion 128 is fixedly attached to the drive shaft 116 and is engaged with the cam pinion 130 through meshing gear teeth. In some configurations, the drive pinion 128 and the cam pinion 130 may include end stops to limit their rotation angles, which may limit the movement of the flip lock 134 or the cover assembly 102.

[0043] The cam pinion 130 meshes with the rack cam at the first end 136a of the rack cam 136. The teeth 138 on the first end 136a of the rack cam 136 engage with the teeth 140 on the drive pinion 128. A resilient abutment support may be provided to maintain constant contact between the teeth 138 of the rack cam 136 and the teeth 140 of the drive pinion 128. Such a resilient abutment (which may be a spring or similar mechanism) biases the first end 136a toward the cam pinion 130.

[0044] The flip lock 134 is pivotally connected to the second end 136b of the rack cam 136 via a pivot connection 142. The flip lock 134 pivots relative to the housing 104 about the axis 144. When the drive shaft 116 rotates the drive pinion 128, the cam pinion 130 also rotates, thereby engaging and translating the rack cam 136 (as indicated by arrow 146). This movement of the rack cam 136 causes the flip lock 134 to be in its locked state ( Figure 2a ) and unlocked state( Figure 2b ). In the locked state, the flip lock 134 engages with the locking element 148 on the lid frame 110, thereby fixing the lid assembly 102 in place. In the unlocked state, the flip lock 134 disengages from the locking element 148, thereby allowing the lid assembly 102 to move freely. Accordingly, the locking hook 134 has an undercut 156, which is operably engaged with a corresponding undercut 158 ​​of the locking element 148 when the lid assembly 102 is locked in its closed position.

[0045] A biasing element 150 (e.g., a spring, an elastic band, a linear actuator, etc.) can be connected between the housing 104 and the rack cam 136 via a hook 152 to bias the gear assembly 122 to a default locked position. Figure 2a ), the biasing element 150 holds the flip cover lock 134 in the locked position, thereby preventing the cover 106 from being opened without damaging the flip cover lock 134. Alternatively, the flip cover lock 134 can be configured to allow the cover to be opened without damage, even when locked.

[0046] In the locked state, the flip lock 134 secures the lid 106 by engaging a locking element 148 formed in or on the lid frame 110. To unlock the lid assembly 102, the drive pinion 128 is rotated clockwise, thereby driving the cam pinion 130 counterclockwise. This movement pulls the rack cam 136, thereby rotating the flip lock 134 and disengaging the locking element 148, thereby releasing the lid assembly 102 for movement. The override assembly 114 is operated by pulling the wire 126a, which is fixedly coupled to the first end 136a of the rack cam 136 via its distal end 160. This action opposes the force applied by the biasing element 150, thereby manually pivoting the flip lock 134 about the axis 144 to the unlocked state.

[0047] Although the override assembly 114 is described as a manual mechanism (eg, using the handle 124 ), a powered override actuator 154 may also be employed. Figure 2c A detailed view of an actuation assembly having a power override actuator according to another aspect of the present disclosure is provided.

[0048] As an addition or replacement to the handle 124, the power override actuator 154 can be electric, pneumatic, or hydraulically controlled, which can be used to pull the wire 126a. In the case where ice accumulation hinders the drive shaft 116 or the electric motor, the power override actuator 154 can provide the necessary force to break the obstacle or ice accumulation. The power override actuator 154 can be located in a protected area of ​​the vehicle (e.g., protected from the influence of the elements), such as a trunk, to ensure reliability. In addition, the actuating assembly 100 can include a push element that helps release the cover assembly when the cover assembly 102 is stuck, for example, due to ice. For example, the power override actuator 154 can be configured to pull the second end 136b of the rack cam 136 via the cable 126 or a portion of the cable (e.g., the wire 166a) in response to a control signal, so that the flip cover lock 134 moves from a locked state to an unlocked state.

[0049] In one example, the transmission system 118 is operated by an electric motor to rotate the drive pinion 128, which transmits motion to the rack cam 136 through the cam pinion 130. The cam pinion 130 can be composed of two parts: a cam gear part and a motor drive gear part. The cam gear part and the motor drive gear part can be integrated into a single integral structure or assembled as two separate parts sharing a common rotation axis. When the drive pinion 128 engages the cam gear part of the cam pinion 130, the motor drive gear part can rotate at a transmission ratio of 1:1.5. Specifically, the motor drive gear rotates the drive pinion 128 137 degrees after the initial 21.5 degree rotation to move the latch system. Then, the cam pinion 130 rotates 78 degrees along the rack cam 136, and is kept engaged by the spring force until a total rotation of 226.5 degrees is reached. This movement pulls the flip lock 134 downward 21.5 degrees to disengage the cover assembly 102, and then rotates the flip lock and the rack cam another 78 degrees.

[0050] The override assembly 114 is activated by pulling a cable cord, which transmits force to a rack cam 136 near the motor. This action pulls the rack cam 136 downward, causing the cam pinion 130 to rotate and initiate the movement of the motor to begin opening the lid assembly 102. As the rack cam 136 moves downward, it also pulls the flip lock 134, disengaging the lid assembly 102. Once disengaged, the user can manually push the lid assembly 102 downward to fully open the lid assembly. The rack cam 136 only needs to move enough to initiate the motor movement, allowing the top of the lid assembly 102 to be exposed for manual operation. The override assembly 114, which acts as an electronic release (e-release), is directly connected to the rack cam 136 because it controls the latch system and coordinates the movement of both the motor and the flip lock 134 to release the lid assembly 102.

[0051] The patents and patent publications cited above are hereby incorporated herein by reference in their entirety. Although the present method and / or system have been described with reference to certain embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present method and / or system. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the present disclosure without departing from the scope of the present disclosure. For example, the frames and / or components of the disclosed examples may be combined, divided, rearranged and / or otherwise modified. Therefore, the present method and / or system are not limited to the disclosed specific embodiments. Alternatively, the present method and / or system will include all embodiments that fall within the scope of the appended claims, whether literally or according to the doctrine of equivalents.

Claims

1. A drive assembly for moving a hood assembly of a vehicle between an open position and a closed position relative to a housing, the drive assembly comprising: a drive pinion configured to receive a drive shaft; a cam pinion meshing with the drive pinion, wherein the drive pinion is configured to rotate the cam pinion; a rack cam having a first end and a second end, wherein the second end is meshed with the cam pinion, and wherein the rack cam is configured to translate in response to rotation of the cam pinion; and a flip lock configured to pivot relative to the housing between a locked state and an unlocked state, wherein the flip lock is pivotally connected to the second end of the rack cam via a pivot connection; and An override assembly is operably coupled to the second end of the rack cam and is configured to translate the rack cam to move the flip lock from the locked state to the unlocked state.

2. The drive assembly according to claim 1, wherein: The override assembly includes a handle and a cable, wherein the cable is coupled to the handle and a second end of the rack cam.

3. The drive assembly of claim 2, wherein: Manipulation of the handle actuates the cable to move the flip lock from the closed position to the open position.

4. The drive assembly of claim 2, wherein: The cable includes a wire and an outer sheath, the wire being slidable within the outer sheath to transmit force between the handle and the second end of the rack cam.

5. The drive assembly of claim 1 , further comprising a power override actuator configured to pull the second end of the rack cam via a cable or a portion of a cable in response to a control signal, thereby moving the flip lock from the locked state to the unlocked state.

6. The drive assembly of claim 5, wherein: The power override actuator includes an electric motor.

7. An actuation assembly for a hood assembly of a vehicle, the actuation assembly comprising: a housing having a compartment; a drive assembly coupled to the housing, wherein the drive assembly comprises a transmission system configured to move the lid assembly relative to the housing between an open position and a closed position, and wherein the drive assembly is configured to secure the cover assembly in a locked state to cover the compartment; and An override assembly is operably coupled to the drive train and is configured to move the lid assembly from the locked state to an unlocked state.

8. The actuating assembly of claim 7, wherein: The override assembly includes a handle and a cable, wherein the cable is coupled between the handle and the drive train.

9. The actuation assembly of claim 8, wherein: The handle is a pull ring.

10. The actuation assembly of claim 8, wherein: Manipulation of the handle actuates the cable to allow the lid assembly to move from the closed position to the open position.

11. The actuation assembly of claim 8, wherein: The cable includes a wire and an outer sheath, the wire being slidable within the outer sheath to transmit force between the handle and the drive train.

12. The actuation assembly of claim 11, wherein: The outer jacket comprises: an inner liner; a longitudinal incompressible layer; and a protective outer cover.

13. The actuation assembly of claim 7, wherein: The drive train includes a cover linkage assembly configured to secure the cover assembly in the locked state and a gear assembly operably connected to the cover linkage assembly.

14. The actuation assembly of claim 13, wherein: The gear assembly includes a drive pinion configured to receive a drive shaft and a cam pinion meshing with the drive pinion.

15. The actuation assembly of claim 14, wherein: The lid linkage assembly includes a flip lock and a rack cam having a first end and a second end, wherein the flip lock is pivotally connected to the second end of the rack cam via a pivot connection and is configured to pivot about an axis relative to the housing.

16. The actuation assembly of claim 15, wherein: The rack cam is configured to mesh with the cam pinion, and the rack cam is configured to translate in response to rotation of the cam pinion.

17. The actuation assembly of claim 16, wherein: The flip lock is configured to pivot about an axis in response to translation of the rack cam, the flip lock moving between the locked state and the unlocked state.

18. The actuation assembly of claim 7, further comprising a powered override actuator configured to pull the cable or portion of the cable in response to a control signal to disengage the locking mechanism and allow the lid assembly to move to the open position.

19. The actuation assembly of claim 18, wherein: The power override actuator includes an electric motor.

20. The actuation assembly of claim 12, wherein: The compartment is: a charging compartment; a fuel filling compartment; or a maintenance compartment of the vehicle.

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