A charging port cover structure matched with various front bumpers, an assembling method and a vehicle

Abstract

The application discloses a charging port cover structure matched with various front bumpers, an assembling method and a vehicle, and relates to the technical field of automobile charging ports. The charging port cover structure comprises a cover outer plate and a hinge port box assembly. The hinge port box assembly comprises a hinge body and a port box body. The cover outer plate is connected with the port box body through the hinge body. The hinge body comprises a hinge arm and a hinge matching module. The hinge matching module is matched with buckles on the structure surface of the cover outer plate. The hinge matching module is detachably fixedly connected with the hinge arm through positioning pins and interference pins. The cover outer plate is matched with the hinge matching module. The curvature profile of the hinge matching module is adjusted to adapt to cover outer plates with different shapes, so as to adapt to the shapes of front bumpers of different vehicle models. The application solves the problem of poor interchangeability and adaptability of the existing charging port cover assembly and the front bumpers of various vehicle models.

Description

Technical Field

[0001] This invention relates to the field of automotive charging port technology, and in particular to a charging port cover structure, assembly method, and vehicle compatible with various front bumpers. Background Technology

[0002] Currently, charging port covers for new energy vehicles are typically developed specifically for the front bumpers of particular vehicle models. The interfaces between the outer cover panel, hinge, and charging port body change with the shape of the front bumper. When the same platform needs to accommodate multiple front bumpers with different designs, the outer cover panel, hinge, and charging port body all need to be redesigned and molded separately, resulting in high mold development costs, long development cycles, and a lack of interchangeability between the parts.

[0003] However, the existing charging port cover assembly has an integral design for the hinge mating surface and the outer panel structure surface. The curvature contours of the hinge body mold and the mating area of ​​the outer panel correspond one-to-one, making it impossible to adapt to outer panels with different curvatures of the cover without replacing the entire set of hinge molds. At the same time, the mounting surface of the charging port cover body is fixed to the mounting interface of the front bumper or body bracket. The mounting point positions and bolt specifications of different front bumpers are different, which means that a matching charging port cover body mold needs to be redeveloped for each front bumper. This results in poor interchangeability and compatibility between the charging port cover assembly and the front bumpers of various car models. Summary of the Invention

[0004] To address the shortcomings of existing technologies, the purpose of this invention is to provide a charging port cover structure, assembly method, and vehicle that can be matched with various front bumpers, thus solving the problem of poor interchangeability between existing charging port cover assemblies and front bumpers of various vehicle models.

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: Firstly, this invention provides a charging port cover structure compatible with various front bumpers, including a cover outer panel and a hinge box assembly. The hinge box assembly includes a hinge body and a box body, with the cover outer panel connected to the box body via the hinge body. The hinge body includes a hinge arm and a hinge engagement module. The hinge engagement module engages with a snap-fit ​​mechanism on the structural surface of the cover outer panel. The hinge engagement module is detachably fixed to the hinge arm via a positioning pin and an interference pin. The cover outer panel engages with the hinge engagement module, and by adjusting the curvature profile of the hinge engagement module, it can adapt to different shapes of cover outer panels to accommodate the front bumper shapes of different vehicle models. By designing the area of ​​the hinge body that directly engages with the cover outer panel as an independent, replaceable hinge engagement module, when adapting to cover outer panels with different curvatures is required, only the hinge engagement module needs to be remanufactured, without replacing the entire hinge mold, thereby achieving standardized reuse of the hinge main structure.

[0006] As a further implementation, the outer panel of the bumper includes an appearance surface and a structural surface. The appearance surface is a shaping area, and the structural surface is a rigid constraint area. The structural surface is provided with buckles for engaging with the hinge body. The position, size, number, and demolding direction of the buckles are set according to actual conditions. By dividing the outer panel of the bumper into two functional areas, the appearance surface can freely change with the shape of the front bumper, while the buckle interfaces on the structural surface remain consistent, achieving a unity of diverse shapes and standardized functional interfaces.

[0007] As a further implementation, the housing body is hinged to the hinge body; the housing body has a rectangular structure, with an actuator located on the inner side of one end and a hinge base located on the outer side of the other end; a mounting base is provided on the housing body, and a screw mounting surface module is detachably connected to the mounting base. The screw mounting surface module has mounting holes that match the front bumper or body bracket. By introducing a replaceable screw mounting surface module to the housing body, the differences in mounting interfaces corresponding to different front bumpers are handled by the screw mounting surface module, and the main mold of the housing body does not need to be modified, thus achieving platform-based reuse of the housing body.

[0008] As a further implementation, the screw mounting surface module has a first positioning structure on the side facing the charging port body, and the mounting base has a second positioning structure that cooperates with the first positioning structure. The screw mounting surface module and the mounting base are detachably connected, allowing the charging port cover structure to be compatible with various bumpers. The cooperation between the first and second positioning structures ensures the precise positioning of the screw mounting surface module on the charging port body, and the detachable connection makes the replacement of the mounting surface module simple and efficient.

[0009] As a further implementation, the hinged arm includes a fixed part for mounting the hinge engagement module and a hinged part. The hinged part is fixedly connected to the fixed part, and the fixed part has reinforcing ribs on its side facing the hinge engagement module. The reinforcing ribs improve the structural rigidity of the fixed part, ensure the reliability of the connection between the hinge engagement module and the hinged arm, and prevent deformation due to stress during repeated opening and closing from affecting assembly accuracy.

[0010] As a further implementation, the hinge portion of the hinged arm is hinged to the hinge base of the lid body via a pin. An O-ring is fitted onto the pin, and the O-ring is interference-fitted with the hinge hole of the hinge portion. A spring, specifically a torsion spring, is also mounted on the pin to drive the hinged arm to rotate relative to the lid body. The interference fit between the O-ring and the hinge hole provides appropriate damping, ensuring smooth opening and closing of the lid. The torsion spring provides rotational driving force to the hinged arm, ensuring that the lid automatically springs open after the actuator unlocks.

[0011] As a further implementation, a fitting clearance is provided between the screw mounting surface module and the housing body. Both the screw mounting surface module and the housing body are provided with positioning holes, in which positioning pins are interference-fitted. The fitting clearance balances assembly convenience with connection stability, and the interference fit of the positioning pins eliminates assembly wobbling of the mounting surface module on the housing body, ensuring reliable connection.

[0012] As a further implementation, the articulated arm is equipped with a locking structure, which cooperates with the actuator to control the fixing and rotation of the articulated arm. Through the cooperation of the locking structure and the actuator, active control of the opening state of the charging port cover is achieved. When the charging port cover is closed, the locking structure locks the articulated arm; during charging, the actuator drives the locking structure to release, and the articulated arm, under the action of the torsion spring, causes the outer plate of the port cover to spring open.

[0013] Secondly, the present invention also provides an assembly method for a charging port cover structure that matches various front bumpers, comprising the following steps: The screw mounting surface module is positioned by engaging the first positioning structure with the second positioning structure on the mounting base of the mouth box body, and then the screw mounting surface module is fixed to the mounting base by screws. Based on the curvature of the outer panel structure of the target vehicle's cover, a corresponding hinge assembly module is manufactured. The hinge assembly module is then fixedly connected to the hinge arm via a locating pin and an interference pin to form the hinge body. The hinge engagement module is engaged with the snap-fit ​​mechanism on the structural surface of the outer cover plate to complete the assembly of the outer cover plate and the hinge box assembly. The assembled cover assembly is fixed to the front bumper or body bracket using the mounting holes on the screw mounting surface module.

[0014] Thirdly, the present invention also provides a vehicle, including a body, a front bumper, and a charging port cover structure that matches various front bumpers. The charging port cover structure is fixed to the front bumper or body bracket by the screw mounting surface module, and the outer panel of the cover is engaged with the hinge module by a snap fastener on the structural surface of the outer panel of the cover.

[0015] The beneficial effects of the present invention are as follows: This invention designs the area of ​​the hinge body that directly mates with the outer plate of the cover as an independent, replaceable hinge mating module, and achieves a detachable and fixed connection with the hinge arm through positioning pins and interference pins. This significantly improves the versatility of the hinge body structure. When it is necessary to adapt to the outer plate of the cover with different curvatures, only the hinge mating module needs to be remanufactured without replacing the entire hinge mold, which effectively reduces the mold development cost and shortens the development cycle.

[0016] This invention, by setting an installation base on the front bumper body and detachably connecting screw mounting surface modules, concentrates the differences in the installation interfaces of different front bumpers into the screw mounting surface modules. The main mold of the front bumper body can always be used without modification, realizing the multi-model platform reuse of the front bumper body. The cost of molds related to the front bumper body for a single model is significantly reduced, the development cycle of the mounting surface module mold is greatly shortened, and different models can be quickly switched on the same production line.

[0017] This invention divides the outer panel of the hatch into two functional areas: an appearance surface and a structural surface. The position, size, number, and demolding direction of the buckle interfaces on the structural surface remain consistent, while the appearance surface can freely change with the shape of the front bumper. This achieves effective unification of the diversity of hatch outer panel shapes and the hinge joints, ensuring compatibility and interchangeability for multiple vehicle models, and taking into account both design diversity and functional consistency.

[0018] This invention achieves smoothness and reliability in opening the lid by using a pin hinge between the hinge arm and the hinge base of the lid body, combined with an O-ring interference connection and a torsion spring drive, as well as a locking structure and actuator coordination control. Attached Figure Description

[0019] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0020] Figure 1 This is a schematic diagram of the charging port cover structure installed on the front bumper of the present invention; Figure 2 This is a schematic diagram of the charging port cover structure of the present invention from the perspective of an inner side of the front bumper; Figure 3 This is a schematic diagram of the charging port cover structure installed on the front bumper 2 according to the present invention; Figure 4 This is a schematic diagram of the charging port cover structure of the present invention from the perspective of the inner side of the second front bumper; Figure 5 This is a schematic diagram of the hinge box assembly structure of the present invention; Figure 6 This is an exploded structural diagram of the hinge box assembly of the present invention; Figure 7 This is an exploded view of the hinge body structure of the present invention; Figure 8 This is an exploded view of the mouth box body structure of the present invention.

[0021] The components are: 1. Front bumper one; 2. Outer panel of the cover; 3. Front bumper two; 4. Hinge box assembly; 41. Hinge body; 411. Hinge arm; 412. Hinge mating module; 42. Box body; 421. Mounting base; 422. Screw mounting surface module; 43. Actuator; 44. Pin; 45. Spring; 46. O-ring. Detailed Implementation

[0022] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0023] Example 1 This embodiment provides a charging port cover structure that is compatible with various front bumpers, such as... Figures 1-8 As shown, the device includes an outer cover panel 2 and a hinged charging port assembly 4. The hinged charging port assembly 4 is mounted on either a front bumper 1 or a second front bumper 3. The outer cover panel 2 and the front bumper are connected by the hinged charging port assembly 4 to form an openable assembly relationship, thereby covering the charging port. This invention divides the charging port cover assembly into a fixed standard module and a variable adapter module. By modularizing the outer cover panel 2, the hinge body 41, and the charging port body 42, the hinge body 41 and the charging port body 42 can be adapted to various front bumper designs, thereby significantly reducing development costs, shortening the development cycle, and improving production line flexibility.

[0024] Specifically, the hinge mating module 412 in the hinge body 41 that directly mates with the outer plate 2 of the cover and the screw mounting surface module 422 on the box body 42 are designed as independent replaceable modules, while the main structure of the hinge arm 411 and the main structure of the box body 42 remain unchanged as standardized modules applicable to multiple vehicle models.

[0025] The hinge box assembly 4 includes a hinge body 41, a box body 42, an actuator 43, a pin 44, a spring 45, and an O-ring 46. The box body 42 has a rectangular structure. The actuator 43 is located on the inner side of one end of the box body 42, and a hinge base is located on the outer side of the other end. The hinge body 41 is hinged to the box body 42 via the hinge base, allowing the hinge body 41 to rotate relative to the box body 42 around a rotation axis at the hinge base. The outer cover plate 2 is fixedly connected to the hinge body 41 and opens or closes as the hinge body 41 rotates.

[0026] In this embodiment, the main structure of the housing body 42 remains standardized across different vehicle models. Differences in the mounting interfaces corresponding to different front bumpers are adapted by replaceable screw mounting surface modules 422, thus achieving multi-vehicle compatibility of the housing body 42. The kinematic parameters of the hinge body 41, such as the rotation center, opening angle, and driving torque, remain consistent across different vehicle models, ensuring consistent operating feel and durability. Differences in the curvature of the outer panels corresponding to different front bumpers are adapted by replaceable hinge mating modules 412.

[0027] The hinge body 41 includes a hinge arm 411 and a hinge mating module 412. The hinge arm 411 includes a fixed part and a hinge part, which are fixedly connected to the fixed part. The fixed part is used to install the hinge mating module 412. A reinforcing rib is provided on the side of the fixed part facing the hinge mating module 412. The reinforcing rib extends along the surface of the fixed part, which improves the structural rigidity of the fixed part and ensures the reliability of the connection between the hinge mating module 412 and the hinge arm 411 during repeated opening and closing, preventing deformation due to stress from affecting the assembly accuracy. The hinge part is located at one end of the hinge arm 411 and has a hinge hole. The hinge part is hinged to the hinge base of the housing body 42 through a pin 44, allowing the hinge arm 411 to rotate relative to the housing body 42.

[0028] In this embodiment, the hinge arm 411 is made of high-strength engineering plastic or metal. Its core parameters, such as main structural dimensions, rotating shaft hole positions, spring mounting points, and locking structure mating positions, remain completely consistent across all vehicle models, forming a standardized hinge main component. The reinforcing ribs on the fixing part adopt a grid-like or radial layout, which reduces the overall weight of the hinge arm 411 while ensuring the rigidity of the fixing part, thus facilitating the lightweight design of the charging port cover structure.

[0029] The hinge engagement module 412 is detachably and fixedly connected to the fixing part of the hinge arm 411 via a locating pin and an interference pin.

[0030] Specifically, the hinge engagement module 412 has a positioning hole on the side facing the fixed part that cooperates with the positioning pin. After the positioning pin is inserted into the positioning hole, the hinge engagement module 412 is positioned relative to the fixed part in a planar manner. The interference pin is pressed into the corresponding hole in an interference manner to eliminate the assembly gap between the hinge engagement module 412 and the fixed part and ensure the stability of the connection.

[0031] In this embodiment, the hinge engagement module 412 achieves precise positioning in the XY plane through two locating pins and locking in the Z direction through three interference pins. The spatial layout of the six connection points is optimized to prevent the hinge engagement module 412 from loosening or shifting under periodic loads during the opening and closing of the outer cover plate 2. A clearance fit is used between the locating pins and the locating holes to facilitate the installation and disassembly of the hinge engagement module 412. The interference fit between the interference pins and the corresponding holes is designed according to material properties and load requirements, ensuring both connection reliability and the feasibility of replacement operations. The side of the hinge engagement module 412 facing the outer cover plate 2 has a curvature profile that matches the structural surface of the outer cover plate 2. This curvature profile engages with the snap-fit ​​mechanism on the structural surface of the outer cover plate 2, fixing the outer cover plate 2 to the hinge arm 411 via the hinge engagement module 412.

[0032] The curvature profile of the hinge mating module 412 is parametrically designed based on the structural surface shape of the outer cover plate 2 of the target vehicle model. The hinge mating module 412 of different models only differs in the spatial coordinates of the curvature profile and the claw features. It is completely consistent with the positioning pin hole position, interference pin hole position, and profile dimensions of the fixing part of the hinge arm 411, ensuring interchangeability. When it is necessary to adapt to the outer cover plate 2 with different curvatures, only the hinge mating module 412 with the corresponding curvature profile needs to be replaced, while the main structure of the hinge arm 411 remains unchanged. This achieves the universality of the hinge main structure, avoids the redevelopment of the entire hinge mold, effectively reduces mold development costs, and shortens the development cycle.

[0033] The outer panel 2 of the front bumper is divided into an appearance surface and a structural surface. The appearance surface is a purely styling area, and its curved shape varies with the style language of the front bumper. Complex geometries such as free-form surfaces, edges, and chamfered features can be introduced to adapt to the appearance requirements of front bumpers of different models. The structural surface is a rigidly constrained area, located on the side of the outer panel 2 facing the hinge body 41, and it undertakes the function of connecting with the hinge body 41. The structural surface is provided with buckles for engaging with the hinge mating module 412. The position, size, number, and demolding direction of the buckles are uniformly set according to the mating interface of the hinge mating module 412, and remain consistent across different models or front bumpers. Since the buckle interfaces on the structural surface are standardized, changes in the shape of the appearance surface will not affect the spatial coordinates and shape of any buckle features on the structural surface, thus ensuring compatibility and interchangeability across multiple models.

[0034] In this embodiment, the design of the outer cover plate 2 first involves solid modeling of the structural surface based on the mating interface of the hinge mating module 412. This ensures that the wall thickness and slider structure of the snap-fit ​​area meet the injection molding process requirements, including that the snap-fit ​​demolding angle is not less than the minimum value specified by the process, the wall thickness at the snap-fit ​​root meets the strength requirements, and there is no undercut interference in the snap-fit ​​area. After completing the structural surface modeling and verifying it through the injection molding process, the appearance surface is extended outward from the boundary of the structural surface to complete the curved surface design of the appearance surface. Any changes to the appearance surface must not intrude into the structural surface area or affect the spatial coordinates and shape of the snap-fit ​​features on the structural surface, in order to ensure compatibility and interchangeability across multiple vehicle models. Each new front bumper corresponds to the development of a mold for the outer cover plate 2. However, due to the standardization of the structural surface interface, the development of the mold for the outer cover plate 2 only requires designing the curvature of the appearance surface and the structural surface, without redesigning the snap-fit ​​interface, effectively shortening the development cycle of the mold for the outer cover plate 2.

[0035] The hinge portion of the hinge arm 411 is hinged to the hinge base of the lid body 42 via a pin 44. An O-ring 46 is fitted onto the pin 44. After the O-ring 46 is fitted into the hinge hole of the hinge portion, an interference fit is formed between the O-ring 46 and the hinge hole. Because the O-ring 46 is elastic, the interference fit provides appropriate damping between the hinge portion and the pin 44, making the opening and closing of the lid outer plate 2 smooth and preventing the lid from shaking or making abnormal noises during opening and closing.

[0036] Specifically, the interference fit between the cross-sectional diameter of the O-ring 46 and the diameter of the hinge hole is precisely designed to ensure that the hinge part experiences uniform elastic damping force during rotation. This damping force is sufficient to suppress random swaying of the outer cover 2 under vehicle driving vibration conditions, while not excessively hindering the automatic spring-driven opening action. The O-ring 46 is made of oil-resistant and heat-resistant rubber material, which can maintain its elastic performance for a long time under automotive use conditions, ensuring the durability and stability of the hinge damping. A spring 45 is also provided on the pin 44. The spring 45 is a torsion spring, with its two ends connected to the hinge arm 411 and the cover body 42, respectively, to drive the hinge arm 411 to rotate relative to the cover body 42 in the opening direction. The spring force of the torsion spring is calculated and designed so that the hinge arm 411 can overcome the damping force of the O-ring 46 after the actuator 43 unlocks, causing the outer cover 2 to automatically spring open to the predetermined opening angle, ensuring the automatic spring-opening function of the charging port cover.

[0037] Since the kinematic parameters such as the rotation center and opening angle of the hinge body 41 remain consistent across different vehicle models, the torsion spring specifications do not need to be changed with the vehicle model, further ensuring the consistency of operating feel and durability performance across different vehicle models.

[0038] The articulated arm 411 is provided with a locking structure, which cooperates with the actuator 43 to control the fixing and rotation of the articulated arm 411.

[0039] Specifically, when the charging port cover is closed, the actuator 43 drives the locking structure into the locked position. The locking structure abuts against the corresponding mating parts on the hinge arm 411, preventing the hinge arm 411 from rotating relative to the port box body 42, thus keeping the outer plate 2 of the cover closed. The locking force of the locking structure is designed to resist the aerodynamic load generated by the airflow on the outer plate 2 of the cover during vehicle operation and the inertial load caused by road vibration, ensuring that the charging port cover will not be accidentally opened during normal vehicle operation. When it is necessary to open the charging port cover, the actuator 43 receives the opening command and drives the locking structure out of the locked position. The constraint between the hinge arm 411 and the locking structure is released, and the hinge arm 411, under the rotational driving force of the torsion spring 45, causes the outer plate 2 of the cover to spring open.

[0040] In this embodiment, actuator 43 is an electric actuator that sends an opening command through the vehicle's charging control system to achieve linkage control between the opening action of the charging port cover and the charging process. In some embodiments, it can also be set as a manual actuator, which triggers the release of the locking structure through a mechanical linkage mechanism. The cooperation between the locking structure and actuator 43 achieves active control of the opening state of the charging port cover. When the charging port cover is closed, the locking structure locks the hinge arm 411. During charging, actuator 43 drives the locking structure to release, and the hinge arm 411, under the action of torsion spring 45, causes the outer plate 2 of the cover to spring open.

[0041] The housing body 42 is provided with a mounting base 421, on which a screw mounting surface module 422 is detachably connected. The screw mounting surface module 422 is an independent injection-molded part, with mounting holes that match the front bumper or body bracket. The position, number, and specifications of the mounting holes are designed according to the mounting interface requirements of the target front bumper. The screw mounting surface module 422 has a first positioning structure on the side facing the housing body 42, and the mounting base 421 has a second positioning structure that cooperates with the first positioning structure. During assembly, the screw mounting surface module 422 achieves precise positioning on the housing body 42 through the cooperation of the first and second positioning structures, and then the screw mounting surface module 422 is fixed to the mounting base 421 with screws to complete the locking process.

[0042] In this embodiment, the first positioning structure includes a main positioning pin and a secondary positioning pin. The main positioning pin is used to achieve precise positioning in both the X and Y directions, while the secondary positioning pin is used to restrict the rotational freedom around the main positioning pin. The combination of the two positioning pins achieves complete planar positioning of the screw mounting surface module 422 on the mounting base 421 of the housing body 42. The second positioning structure is a positioning hole corresponding to the positioning pin in the first positioning structure. The positional accuracy of the positioning hole is strictly controlled to ensure that the positional repeatability of the screw mounting surface module 422 after assembly meets the requirements of the installation interface. The screw mounting surface module 422 is fixed to the mounting base 421 from the bottom or side by 2 to 4 screws. The number of screws is selected according to the load on the mounting surface module and the installation space constraints, ensuring both connection reliability and ease of assembly operation.

[0043] Because the mounting interfaces for different front bumpers differ, adaptation is achieved by adjusting the screw mounting surface molds, while the main structure of the mounting box body 42 remains unchanged. When adapting to different front bumpers, only the corresponding screw mounting surface module 422 needs to be replaced, without the need to redevelop the mounting box body 42 mold, thus achieving multi-vehicle universality for the mounting box body 42. All screw mounting surface modules 422 and the mounting box body 42 maintain complete consistency in the locating pin positions, locking hole positions, and outline dimensions, ensuring interchangeability and allowing for rapid switching between assembly tasks of different vehicle models on the same production line.

[0044] A fitting clearance is provided between the screw mounting surface module 422 and the housing body 42, ranging from 0.1mm to 0.2mm. This fitting clearance balances the ease of assembly and connection stability between the screw mounting surface module 422 and the housing body 42: too small a clearance would make it difficult to smoothly install the mounting surface module into the mounting base 421, affecting assembly efficiency; too large a clearance would cause significant wobbling before the screws are tightened, affecting positioning accuracy. Both the screw mounting surface module 422 and the housing body 42 are provided with positioning holes, in which positioning pins are interference-fitted, with an interference amount ranging from 0.02mm to 0.05mm. The interference fit of the locating pin eliminates the assembly wobbling of the screw mounting surface module 422 on the charging port body 42, so that the screw mounting surface module 422 forms a stable rigid connection with the charging port body 42 after the screw is tightened. This ensures the reliability of the connection between the screw mounting surface module 422 and the charging port body 42, ensures the connection stability of the charging port cover structure under vehicle driving vibration conditions, and ensures the removability of the locating pin when the mounting surface module needs to be replaced.

[0045] Example 2 This embodiment provides an assembly method for charging port cover structures that are compatible with various front bumpers, including the following steps: Assembly of the screw mounting surface module 422 with the housing body 42. Based on the mounting interface requirements of the front cover 1, select the corresponding screw mounting surface module 422. Align the first positioning structure on the side of the screw mounting surface module 422 facing the housing body 42 with the second positioning structure on the mounting base 421 of the housing body 42. Press the screw mounting surface module 422 into the mounting base 421 along the assembly direction. The first positioning structure is inserted into the corresponding second positioning structure, achieving precise positioning of the screw mounting surface module 422 on the housing body 42. Because there is a 0.1mm to 0.2mm clearance between the screw mounting surface module 422 and the mounting base 421, the assembly process is smooth and unobstructed. After positioning, lock the screw mounting surface module 422 from the bottom or side of the mounting base 421 with 2 to 4 screws, completing the assembly of the screw mounting surface module 422 and the housing body 42. After locking, the interference fit of the positioning pin eliminates the residual clearance between the screw mounting surface module 422 and the housing body 42, ensuring the rigidity and stability of the connection.

[0046] Assembly of the hinge engagement module 412 and the hinge arm 411. Based on the curvature of the outer cover plate 2 corresponding to the front bumper 1, a hinge engagement module 412 with a corresponding curvature profile is selected. The side of the hinge engagement module 412 facing the fixing part of the hinge arm 411 is aligned with the fixing part, and two positioning pins are inserted into the corresponding positioning holes on the hinge engagement module 412 to achieve planar positioning of the hinge engagement module 412 relative to the fixing part. Subsequently, three interference pins are pressed into the corresponding holes. The interference fit of the interference pins eliminates the assembly gap between the hinge engagement module 412 and the fixing part, completing the fixed connection between the hinge engagement module 412 and the hinge arm 411, forming a complete hinge body 41. The curvature profile of the side of the hinge engagement module 412 facing the outer cover plate 2 matches the structural surface of the outer cover plate 2 corresponding to the front bumper 1, ensuring the subsequent snap-fit ​​accuracy with the outer cover plate 2.

[0047] Assembly of the outer cover plate 2 and the hinge box assembly 4. Align the structural surfaces of the hinge mating module 412 and the outer cover plate 2. After aligning the claw features of the hinge mating module 412 with the buckles on the structural surface of the outer cover plate 2, apply assembly force to make the buckles engage with the corresponding snap-fit ​​structures on the hinge mating module 412. The buckles and snap-fit ​​structures form a stable snap-fit ​​engagement, and the outer cover plate 2 and the hinge body 41 form a stable fixed connection, thus completing the assembly of the outer cover plate 2 and the hinge box assembly 4.

[0048] Vehicle installation of the charging port cover assembly. Move the assembled charging port cover assembly (including the outer cover plate 2 and the hinge box assembly 4) to the charging port position of the front bumper 1. Align the mounting holes on the screw mounting surface module 422 with the corresponding mounting points on the front bumper 1 or the body bracket. Secure the charging port cover assembly to the front bumper 1 or the body bracket using screws, completing the installation of the entire charging port cover structure. After installation, verify whether the opening and closing action of the outer cover plate 2 is smooth, whether the locking and unlocking functions of the actuator 43 are normal, and whether the gap and surface difference between the outer cover plate 2 and the outer surface of the front bumper 1 meet the appearance quality requirements.

[0049] Replacement of screw mounting surface module 422. Remove the screw mounting surface module 422 corresponding to front guard 1 that is already installed on the housing body 42: Unscrew the locking screws and remove the screw mounting surface module 422 from the mounting base 421 in the disassembly direction. The locating pin will exit the locating hole along with the mounting surface module. After removing the screw mounting surface module 422 corresponding to front guard 1, select the screw mounting surface module 422 corresponding to front guard 3 and assemble it onto the mounting base 421 of the housing body 42 using the aforementioned method. Since the connection interfaces of all screw mounting surface modules 422 and the housing body 42 are completely identical, the replacement operation requires no modification to the housing body 42.

[0050] Replacement of hinge engagement module 412. Disassemble the hinge engagement module 412 corresponding to the front bumper 1, which is already installed on the fixing part of the hinge arm 411: remove the interference pin from the corresponding hole, pull out the locating pin, and remove the hinge engagement module 412 corresponding to the front bumper 1. Based on the curvature of the outer cover plate 2 structure surface corresponding to the front bumper 3, select a hinge engagement module 412 with the corresponding curvature profile, and assemble it onto the fixing part of the hinge arm 411 using the aforementioned method to form a hinge body 41 adapted to the front bumper 3. The main structure of the hinge arm 411 does not need to be modified; only the hinge engagement module 412 is replaced.

[0051] After assembling the outer cover plate 2 corresponding to the front bumper 3 with the hinge box assembly 4, fix it to the front bumper 3 or the vehicle body bracket through the mounting holes on the screw mounting surface module 422, thus completing the installation of the entire charging port cover structure on the front bumper 3. After installation, verify the opening and closing actions of the outer cover plate 2, the locking and unlocking functions of the actuator 43, and whether the gap and surface difference between the outer cover plate 2 and the outer surface of the front bumper 3 meet the appearance quality requirements.

[0052] Example 3 This embodiment provides a vehicle, including a body, a front bumper, and the aforementioned charging port cover structure. The charging port cover structure is fixed to the front bumper or body bracket via mounting holes on the screw mounting surface module 422. The screw mounting surface module 422 and the charging port body 42 are positioned by a first positioning structure and a second positioning structure and locked by screws. The fit clearance between the screw mounting surface module 422 and the charging port body 42 is 0.1mm to 0.2mm, and the interference fit of the positioning pin is 0.02mm to 0.05mm, ensuring the stability and reliability of the connection. The outer panel 2 of the charging port is engaged with the hinge module 412 via a snap fastener on its structural surface. The hinge body 41 is hinged to the hinge base of the charging port body 42 via a pin 44. An O-ring 46 is fitted on the pin 44 and is interference-fitted with the hinge hole of the hinge part to provide appropriate damping for the rotation of the hinge part. A torsion spring 45 is fitted on the pin 44 and drives the hinge arm 411 to rotate relative to the charging port body 42 in the opening direction. An actuator 43 is located on the inner side of one end of the charging port body 42 and controls the locking and releasing of the hinge arm 411 through a locking structure to realize the automatic opening and closing locking function of the charging port cover.

[0053] In this embodiment, the vehicle can be a pure electric vehicle or a plug-in hybrid electric vehicle, and the front bumper can be of various styles. When different styles of front bumpers are installed on the same vehicle platform, only the corresponding hinge mating module 412 and screw mounting surface module 422 need to be replaced respectively. The main structure of the charging port cover 42 and the hinge arm 411 does not need to be modified, thereby realizing the universal adaptation of the charging port cover structure among various front bumpers, which fully demonstrates the platform design advantages of the charging port cover structure of the present invention.

[0054] It is understandable that, without changing the core structural mechanism described above, the hinge engagement module 412 is not limited to the specific form described above. Its curvature profile can be adjusted accordingly based on the structural surface shape of the outer cover plate 2 of different vehicle models, as long as it can form a detachable fixed connection with the hinge arm 411 through the positioning pin and interference pin, and form a snap-fit ​​relationship with the buckle on the structural surface of the outer cover plate 2. The screw mounting surface module 422 is not limited to the specific form described above. The position, number, and specifications of its mounting holes can be designed according to the specific front bumper or body bracket mounting interface requirements, as long as it can achieve precise positioning on the mounting base 421 through the first positioning structure and the second positioning structure and be fixed by screws.

[0055] The hinge module 412 can be made of engineering plastic or die-cast aluminum alloy, selected according to the mass and opening / closing frequency requirements of the outer cover 2. The screw mounting surface module 422 can be made of engineering plastic or metal, selected according to the installation load and installation environment requirements. The cross-sectional diameter and material of the O-ring 46 can be selected according to the hinge hole size and the operating temperature range to ensure damping effect and durability. The spring force of the torsion spring 45 can be adjusted according to the mass, opening angle, and opening speed requirements of the outer cover 2 to ensure the automatic pop-opening function of the charging port cover.

[0056] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A charging port cover structure compatible with various front bumpers, characterized in that, include: The outer cover panel and hinge box assembly include a hinge body and a box body. The outer cover panel is connected to the box body via the hinge body. The hinge body includes a hinge arm and a hinge engagement module. The hinge engagement module engages with a snap-fit ​​mechanism on the structural surface of the outer cover panel. The hinge engagement module is detachably and fixedly connected to the hinge arm via a positioning pin and an interference pin. The outer cover panel engages with the hinge engagement module. By adjusting the curvature profile of the hinge engagement module, it can adapt to different shapes of outer cover panels to accommodate the front bumper shapes of different vehicle models.

2. The charging port cover structure for matching various front bumpers according to claim 1, characterized in that, The outer panel of the cover includes an appearance surface and a structural surface. The appearance surface is a shaping area, and the structural surface is a rigid constraint area. The structural surface is provided with buckles for engaging with the hinge body.

3. The charging port cover structure for matching various front bumpers according to claim 2, characterized in that, The mouth box body is hinged to the hinge body; the mouth box body has a rectangular structure, an actuator is provided on the inner side of one end of the mouth box body, and a hinge base is provided on the outer side of the other end; a mounting base is provided on the mouth box body, and a screw mounting surface module is detachably connected to the mounting base, and the screw mounting surface module has mounting holes that match the front bumper or body bracket.

4. The charging port cover structure for matching various front bumpers according to claim 1, characterized in that, The screw mounting surface module has a first positioning structure on the side facing the charging port body, and the mounting base has a second positioning structure that cooperates with the first positioning structure. The screw mounting surface module and the mounting base are detachably connected, so that the charging port cover structure can be adapted to various bumpers.

5. The charging port cover structure for matching various front bumpers according to claim 1, characterized in that, The hinge arm includes a fixed part for mounting the hinge engagement module and a hinge part. The hinge part is fixedly connected to the fixed part, and the fixed part has a reinforcing rib on its side facing the hinge engagement module.

6. The charging port cover structure for matching various front bumpers according to claim 5, characterized in that, The hinge portion of the hinge arm is connected to the hinge base of the mouth box body via a pin. An O-ring is fitted on the pin, and the O-ring is interference-fitted with the hinge hole of the hinge portion. A spring, which is a torsion spring, is also provided on the pin to drive the hinge arm to rotate relative to the mouth box body.

7. The charging port cover structure for matching various front bumpers according to claim 1, characterized in that, There is a fitting gap between the screw mounting surface module and the mouth box body. Both the screw mounting surface module and the mouth box body are provided with positioning holes, and a positioning pin is interference-fitted in the positioning hole.

8. The charging port cover structure for matching various front bumpers according to claim 1, characterized in that, The hinge arm is equipped with a locking structure, which cooperates with the actuator to control the fixing and rotation of the hinge arm.

9. The assembly method of a charging port cover structure for matching multiple front bumpers as described in any one of claims 1-8, characterized in that, Includes the following steps: The screw mounting surface module is positioned by engaging the first positioning structure with the second positioning structure on the mounting base of the mouth box body, and then the screw mounting surface module is fixed to the mounting base by screws. Based on the curvature of the outer panel structure of the target vehicle's cover, a corresponding hinge assembly module is manufactured. The hinge assembly module is then fixedly connected to the hinge arm via a locating pin and an interference pin to form the hinge body. The hinge engagement module is engaged with the snap-fit ​​mechanism on the structural surface of the outer cover plate to complete the assembly of the outer cover plate and the hinge box assembly. The assembled cover assembly is fixed to the front bumper or body bracket using the mounting holes on the screw mounting surface module.

10. A vehicle, characterized in that, The invention includes a vehicle body, a front bumper, and a charging port cover structure as described in any one of claims 1-8 that is compatible with various front bumpers. The charging port cover structure is fixed to the front bumper or vehicle body bracket by the screw mounting surface module, and the outer panel of the cover is engaged with the hinge module by a snap fastener on the structural surface of the outer panel.

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