An arm mechanism

Abstract

Aspects of the present invention relate to an arm mechanism for moving a cover flap for an electric charging port. The arm mechanism has a plurality of leaves that are spaced apart along an axis of the arm to increase the strength of the arm and to allow the arm to extend thro0guh smaller apertures.

Description

[0001] AN ARM MECHANISM

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to an arm mechanism. Aspects of the invention relate to an arm mechanism, to a vehicle assembly, to a vehicle and to a method of assembling the arm assembly.

[0004] BACKGROUND

[0005] It is known to provide a cover panel for an accessible part of a vehicle, such as a charging port. The cover panel may prevent the ingress of debris and may restrict access to the part of the vehicle. There is a desire that a hinge or other connection for the cover, to allow the cover to be moved between an open and closed position. It is also desirable for the hinge or arm to have sufficient strength to hold the cover panel resiliently, including resisting deflection of the hinge or arm due to the weight of the cover panel.

[0006] Alongside the requirement for strength of a cover panel arm or hinge, there is also a need to maintain a small cross sectional area of the arm and to install the arm within a restricted volume of a vehicle. While conventional arms may be formed of a single piece, this may mean a large aperture must be formed in an adjacent vehicle panel through which the arm extends. This may lead to ingress of dirt into the vehicle via the aperture.

[0007] It is an aim of the present invention to address one or more of the disadvantages associated with the prior art.

[0008] SUMMARY OF THE INVENTION

[0009] Aspects and embodiments of the invention provide an arm mechanism, to a vehicle assembly, to a vehicle and to a method of assembling the arm assembly as claimed in the appended claims.

[0010] According to an aspect of the present invention there is provided an arm mechanism for moving a cover flap of a vehicle, the arm mechanism comprising: a connector module configured to be pivotally coupled to a vehicle body of the vehicle about a first axis; and a plurality of leaves spaced apart along the first axis, wherein each leaf comprises a first end coupled to the connector module, and a second end configured to be pivotally coupled to the cover flap at a second axis, wherein the leaves of the plurality of leaves are fixable together at their first end via the connector module to rotate together about the first axis at their first end, and wherein the leaves are coupleable to the charging port cover flap such that the leaves are fixed relative to one another at their respective second ends when coupled.

[0011] The cover flap may be a charging port cover flap.

[0012] The connector module may be configured to be rotatably coupled to an inside surface of the vehicle body. The plurality of leaves may be rigidly coupled to the connector module. In this case, the connector module and the plurality of leaves may both rotate about the first axis.

[0013] The leaves and the connector module may be assembled as a single assembly outside the vehicle and coupled to the vehicle body subsequently. The leaves may each pass through a separate orifice in a grey zone of the vehicle body, meaning that smaller orifices may be used and a grey zone panel may extend between the leaves to reduce the ingress of dirt to the vehicle body. The leaves may be coupled together rigidly at first and second ends such that shear forces may be transferred between the leaves. In this way, the leaves may act as a single arm, having an increased second moment of area, such that deflection of the arm due to a bending force (such as due to the weight of the charging port cover flap) is reduced.

[0014] Further, the leaves may be each be rotatable relative to the other when assembled on the connector module and when the connector module is coupled to the vehicle body. The leaves may subsequently be fixed together to rotate together. This may improve ease of assembly of the arm mechanism.

[0015] The connector module may comprise a shaft, the first end of each leaf being coupled to the shaft, and one or more spacers, each spacer being arranged between adjacent leaves of the plurality of leaves along the shaft. With such an arrangement, the spacers may rigidly couple the leaves together and may maintain a fixed distance between the leaves. The leaves may be rotatable with the shaft such that torque may be applied to the shaft to rotate the leaves, or the leaves may rotate relative to the shaft in which case the shaft may provide a consistent axis of rotation for the leaves.

[0016] The spacers may be arranged to frictionally or mechanically engage the leaves, such that the leaves are coupled together to rotate as one about the first axis. The spacers may engage the leaves by being axially compressed together with the leaves. A frictional or mechanical engagement may provide a simple way of engaging the leaves with the spacers while resiliently fixing the leaves together.

[0017] The connector module may be coupled to an actuator, the actuator being configured to rotate the connector module and the plurality of leaves about the first axis. The actuator may provide a torque to open the charging port cover flap, and the connector module may receive the torque and transfer torque to all leaves equally. This may allow a smoother movement of the charging port cover flap.

[0018] The connector module may further comprise a crank, and the crank may couple the connector module to the actuator. The use of a crank may allow the actuator, including any necessary gearing, to be spaced from the connector module and coupled to the crank via a linkage. This may allow the actuator to be spaced from the connector module. This may be desirable as the connector module is arranged within an enclosed space within the vehicle body.

[0019] At least one leaf of the plurality of leaves may be shaped such that a lamina cross-section of the at least one leaf, between the first end of the leaf and the second of the leaf, is substantially C-shaped. The leaves may be C-shaped when viewed along the first axis. While a linkage may often be considered on the basis of straight lines connecting ends of links, the leaves of may be C-shaped such that they deviate from a straight line between the first and second ends at an intermediate point between the first and second points. The leaves may be shaped to circumvent an edge of an adjacent vehicle panel without fouling. This may allow a greater range of movement for the charging port cover flap. According to another aspect of the present invention, there is provided a vehicle assembly for selectively covering a charging port, the vehicle assembly comprising: the arm mechanism of the first-mentioned aspect and a charging port cover flap moveable between a first position and a second position, wherein the second ends of the leaves are pivotally coupled to the charging port cover flap, and wherein the leaves are fixed relative to one another.

[0020] The charging port cover flap may be arranged to cover a charging port in the first position and to allow access to the charging port in the second position. In this way, the arm may move the charging port with a small deflection due to the high bending strength of the arm. The arm may also pass through small, separate apertures in order to reduce the ingress of particles into the vehicle body.

[0021] The vehicle assembly may further comprise a bushing, and the second end of each leaf may be fixed together via the bushing, the bushing being pivotally coupled to the charging port cover flap. The bushing may provide a low-friction means for allowing the charging port cover flap to rotate relative to the arm, reducing the torque required by the actuator. The bushing may also provide a convenient means for fixing the leaves together.

[0022] The bushing may comprise one or more spacers, each spacer being arranged between adjacent leaves of the plurality of leaves along the bushing. The spacers may provide a straightforward means for maintaining a distance between the leaves and for fixing them together.

[0023] A join pin may extend through the bushing to clamp the spacers onto the plurality of leaves, and thereby couple the plurality of leaves to the bushing. The join pin may be in tension in order to provide a compressive force between the spacers and leaves. The join pin may be a bolt which is tightened by a nut, allowing the compressive force to be applied and adjusted easily.

[0024] The vehicle assembly may further comprise a connecting bar, the connecting bar may comprise a first end configured to be pivotally coupled to the vehicle body about a third axis, and a second end pivotally coupled to the charging port cover flap about a fourth axis, and the third axis may be substantially parallel to and offset from the first axis, and the fourth axis is substantially parallel to and offset from the second axis.

[0025] All of the first to fourth axes may be substantially parallel and offset from each other. The third axis and the first axis may be fixed relative to each other as both may be fixed to the vehicle body. The second and fourth axes may be fixed relative to each other as both may be fixed to the charging port cover flap.

[0026] The connecting bar, together with the arm, the charging port cover flap and the vehicle body, may form a four- bar linkage that determines the orientation of the charging port cover flap. The charging port cover flap may be moved in a translation while remaining parallel to the vehicle body. The same surface of the charging port cover flap may face outwardly from the vehicle body at all times, reducing exposure of an internal surface to the environment. The connecting bar may be arranged below the arm and may be narrower than the arm. The connecting bar may therefore be obscured from the view of a user by the arm. In this way, the charging port cover flap may appear to be coupled to the vehicle body by a single arm.

[0027] Further, the connecting bar may be curved, with a smaller radius of curvature than the arm. The connecting bar may therefore be closer to the vehicle body when the charging port cover flap is in the second position. This may further obscure the connecting bar from the view of a user.

[0028] The vehicle assembly may further comprise a gear mechanism, the gear mechanism comprising a first gear fixed to the leaves, a second gear fixed to the connecting bar and an idler gear engaged with the first and second gears. The gear mechanism may transfer torque from an actuator to the arm and to the connecting bar. The idler gear may allow the torque on the first and second gears to be in the same direction. Generally, the gear mechanism may control relative rates of rotation of the arm and the connecting bar, further constraining the orientation of the charging port cover flap. This may constrain the orientation of the charging port cover flap in particular when a first straight line joining the first and second axes is close to a second line joining the third and fourth axes.

[0029] According to a further aspect of the invention, there is provided a vehicle comprising: a charging port, and the vehicle assembly of the another aspect, the charging port cover flap of the vehicle assembly being configured to selectively cover the charging port.

[0030] The vehicle may further comprise a panel having a plurality of apertures adjacent the charging port, the panel being coverable by the charging port cover flap and being disposed inboard of the charging port cover flap when the charging port cover flap is in the first position, wherein each leaf extends from the connector module, through a respective aperture of the panel and to the charging port cover flap.

[0031] The panel may be in a grey zone of the vehicle, meaning that it is not visible from the exterior of the vehicle when the charging port cover flap is in the first position but is visible when the charging port cover flap is in the second position. The panel may reduce the ingress of particles such as dust and dirt when the charging port cover flap is in the second position.

[0032] The number of apertures of the vehicle panel may be equal to the number of leaves or may be greater than the number of leaves. In particular, the number of apertures may be one greater than the number of leaves, with the connecting bar extending through one aperture.

[0033] According to a still further aspect of the invention, there is provided a method for assembling an arm mechanism for moving a charging port cover flap of a vehicle, the method comprising: providing a plurality of leaves, the plurality of leaves being arranged to form an arm, each leaf having a first end and a second end; coupling the plurality of leaves to a connector module at the first ends of the plurality of leaves such that the plurality of leaves are spaced along a first axis; with the leaves coupled to the connector module, positioning each leaf of the plurality of leaves in a respective aperture in a panel of a vehicle body of the vehicle, such that at least the second end of each leaf extends out of the vehicle body through a corresponding aperture; pivotally coupling the connector module to the vehicle body such that the connector module is pivotally coupled about the first axis; and fixing the leaves of the plurality of leaves together at their first end via the connector module such that the leaves rotate together about the first axis at their first end.

[0034] Such a method may allow the arm and connector module to be assembled externally to the vehicle body and arranged inside the vehicle body such that the leaves extend through apertures in a panel of the vehicle body. This may be preferable for a mechanic assembling the arm mechanism due to the volume constraints inside the vehicle body. The leaves may subsequently be fixed together to provide an arm having a high bending stiffness.

[0035] In will be understood that the arm mechanism described with reference to the method of assembly may have any features or properties of the previously described arm mechanism and that the method may extend to the assembly of a vehicle mechanism and to a vehicle as described above.

[0036] Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.

[0037] BRIEF DESCRIPTION OF THE DRAWINGS

[0038] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0039] Figure 1 shows a side view of a vehicle according to an embodiment of the invention with a charge flap cover panel in a closed position;

[0040] Figure 2 shows a side view of the vehicle of Figure 1 with the charge flap cover panel in an open position;

[0041] Figure 3 shows a front view of the vehicle of Figure 1 with the charge flap cover panel in an open position; Figure 4 shows a side view of a further vehicle according to the invention;

[0042] Figures 5a and 5b show plan view of a vehicle assembly according to the invention in closed and open positions respectively;

[0043] Figure 6 shows a cross-sectional view of an arm according to the invention;

[0044] Figure 7 shows a cross-sectional view of a portion of a further arm mechanism according to the invention;

[0045] Figure 8 shows a cross-sectional view of a portion of a still further arm mechanism according to the invention; Figure 9 shows a schematic view of a gear arrangement for a vehicle assembly according to the invention;

[0046] Figure 10 shows a schematic view of an actuator arrangement for a vehicle assembly according to the invention; Figures 11 a, 11 b, 11c, 11d, 11e, 11f, 11g and 11 h show an arm mechanism according to the present invention at different stages of assembly; and

[0047] Figure 12 shows a flowchart illustrating a method of assembling an arm mechanism according to the invention.

[0048] DETAILED DESCRIPTION

[0049] A vehicle in accordance with embodiments of the present invention is described herein with reference to the accompanying Figures 1 to 4. An arm mechanism and a vehicle assembly in accordance with embodiments of the present invention is described herein with reference to the accompanying Figures 5a to 10. A method for assembling an arm mechanism according to an embodiment of the invention is described herein with reference to Figures 11 a to 12.

[0050] Figures 1 to 3 show a vehicle 10 from different views, and with vehicle panels in different positions.

[0051] The vehicle 10 has two front wheels 12, which are aligned along a front axle. It will be understood that the front axle may not necessarily be a through-axle and may generally refer to the two front wheels 12 in combination, regardless of the physical axle arrangement associated with the front wheels 12.

[0052] The vehicle 10 has two rear wheels 14, which are arranged on a rear axle. As with the front axle, the rear axle is generally a reference to the alignment of the rear wheels 14 and does not imply any specific power transfer or suspension arrangement.

[0053] The front and rear wheels 12, 14 may be arranged to align on a ground plane, which may be considered to define a horizontal plane for the purposes of this application.

[0054] The vehicle 10 also has two front doors 16 and two rear doors 18, which are movable panels moveable relative to a vehicle body of the vehicle. The front doors 16 and rear doors 18 are arranged to allow access to a passenger compartment of the vehicle. In some cases, the rear doors 18 of the vehicle 10 may be omitted and the vehicle 10 may have only one pair of doors.

[0055] The vehicle 10 has a vehicle body, which is a central, structural portion of the vehicle. Vehicle panels such as doors may move relative to the vehicle body and may be coupled to the vehicle body.

[0056] The vehicle 10 further includes a vehicle charging port arrangement 100. The vehicle charging port arrangement 100, includes an electrical charging port cover panel 102, which is shown in a first, closed position in Figure 1 and in a second, open position in Figures 2 and 3, and an electrical charging port 106, which is inaccessible to a user outside the vehicle when the electrical charging port cover panel 102 is in the closed position, and which is accessible to users of the vehicle when the electrical charging port cover panel 102 is in the open position. Vehicle 10 also includes a visual display 108, which may display a charging state of the vehicle 10. The visual display 108 may also be covered by the electrical charging port cover panel 102 when the electrical charging port cover panel 102 is in the closed position and may be accessible to a user and visible to a user when the electrical charging port cover panel 102 is in the open position. It will be understood that the visual display 108 may be omitted from any embodiments in which it is described and is purely optional. However, when present, the display unit may assist a user in knowing the charging state of a vehicle without needing to access the interior of the vehicle.

[0057] The electrical charging port 106 is arranged to be electrically coupled to an electrical charger, such as a mains electrical charger, so that the vehicle 10 may receive electrical power. The received electrical power may be used to charge a battery of the vehicle 10. The charging port arrangement 100 may include power electronics within the vehicle 10 arranged to transfer electrical energy from the mains charger to the battery. The power electronics may occupy a space within the vehicle, that may be adjacent to the electrical charging port 106.

[0058] The electrical charging port cover panel 102 may move horizontally between the open and closed positions. Optionally, as shown in Figure 2, the electrical charging port cover panel 102 may move forwardly relative to the vehicle body from the closed position to the open position and may overlap a front wheel 12 of the vehicle 10 when it is arranged in the open position. The charging port cover panel 102 may be moved using a vehicle panel opening mechanism 104.

[0059] The cover panels 102 may be arranged such that rear edge of the panel is adjacent a forward edge of the front door 16 when the panels are in the closed position. This may reduce the number vehicle panels required for the vehicle and may reduce the number of join lines required between vehicle panels.

[0060] In the open position, a rear edge of the cover panel 102 may align with a front edge of the electrical charging arrangement 100. Alternatively considered, the rear edge of the cover panel 102 in the open position may align with the position of the front edge of the cover panel 102 in the closed position. This may provide increased access to the electrical charging port 106 as there may be no overlap between the cover panel and the electrical charging port 106, while reducing the distance required for the hinge to provide a range of movement.

[0061] The vehicle 10 may also include, on a second side of the vehicle 10, which may be a right-hand side of the vehicle 10 or a left-hand side of the vehicle 10, a storage compartment 200 shown in Figure 3. The storage compartment 200 is arranged to be accessible via an opening in a side of the vehicle body. The storage compartment 200 is arranged forward of the front doors 16 and rearward of the front wheels 12, such that it can be accessed from a side of the vehicle 10. By providing a storage compartment 200 in such a location, a user of the vehicle may access stored luggage or other stored items from a pavement or curb next to a road. The storage capacity of the vehicle may also be increased.

[0062] As can be seen from Figure 3, the storage compartment 200 has a moveable storage compartment cover panel 202. The storage compartment cover panel 202 may be moved to a closed position, where the storage compartment cover panel 102 is arranged to prevent access to an interior volume 106 of the storage compartment 100. As best shown in Figure 3, the storage compartment cover panel 202 and the electrical charging port cover panel 102 may be spaced from the vehicle in the open position such that the storage compartment cover panel 102 and the electrical charging port cover panel 102 move away from a centreline C of the vehicle when moving from the closed position to the open position. This may avoid the cover panels 102, 202 fouling on the wheels 12 or wheel arches of the vehicle 10 when moving to the open position where it may overlap the wheel arch and / or a front wheel.

[0063] The electrical charging port cover panel 102 is coupled to the vehicle body via an arm mechanism 104, which may be formed of a four-bar linkage and may be configured to allow the electrical charging port cover panel 102 to translate from the closed position to the open position, and vice versa, such that exterior surface of the electrical charging port cover panel 102 may face away from the vehicle centreline C at all points between the open and closed positions.

[0064] Figure 3 shows a front view of the vehicle 10, and it can be seen that the electrical charging arrangement 100 and the storage compartment 200 may be arranged substantially symmetrically about a centreline C of the vehicle 10. This may be beneficial as the storage compartment 200 may be on a side of the vehicle that is selected based on a drive side of the vehicle 10. For example, the storage compartment 200 may be arranged on a nearside of the vehicle and the electrical charging port 106 may be arranged on an offside of the vehicle. This may allow a user of the vehicle to remove luggage from the vehicle 10 more easily. By arranging the storage compartment 200 and electrical charging arrangement 100 symmetrically, the sides of the vehicle on which the storage compartment 200 electrical charging arrangement 100 are arranged may be swapped more easily for different driving locations, without requiring a significant redesign of the vehicle. For example, a substantially similar vehicle design may be used for roads in the UK and France, while the storage compartment may be arranged on a left hand side of a vehicle intended for sale in the UK and on a right hand side of a vehicle intended for sale in France, both sides being offsides of the vehicle.

[0065] Further, in some cases storage compartments and / or electrical charging arrangements may be arranged on both sides of the vehicle. This may increase the storage capacity of the vehicle and / or accessibility for charging the vehicle.

[0066] Further, the electrical charging port cover panel 102 and the storage compartment cover panel 202 may have the same geometrical shape and size, such that the same panel may be used regardless of whether it is covering a storage compartment or an electrical charging port arrangement. This may simplify manufacture of the vehicle.

[0067] The electrical charging port cover panel 102 and / or the storage compartment cover panel 202 may each move outwardly from the vehicle in a horizontal direction, which is away from the centreline C of the vehicle as they move from the closed position to the open position as well as moving horizontally along a direction parallel to centreline C of the vehicle 10. The cover panels 102, 202 may be arranged further from the vehicle centreline C in the open positions than in the closed positions. This may allow the cover panels 102, 202 to avoid fouling on wheel arches or on edges of the front wheels 12 when the front wheels 12 are turned relative to the vehicle 10, such as due to a steering input.

[0068] Figure 4 shows a further vehicle 40. The vehicle 40 comprises a charging arrangement 300 that includes an electrical charging port 308 and a visual display 310 which may be covered by a charging port cover flap 302 when the charging port cover flap 302 is in the closed position, and which are accessible to a user when the charging port cover flap 302 is in the open position. The charging port cover flap 302 is moveable by an arm mechanism 304. It will be understood that similarly named parts may be substantially similar to equivalently parts described above with reference to Figures 1 to 3.

[0069] Figures 1 to 4 shows the different sizes that a charging arrangement 300 and a charging port cover flap 302 may have. In some cases, a storage compartment may be arranged on the same side of the vehicle as the charging arrangement, such as below the charging arrangement 300 of Figure 4.

[0070] Overall, any charging port cover flap, storage compartment cover flap or other moveable vehicle panel may be moveable by an arm mechanism as described below with reference to Figures 5 to 12. The vehicle panels may be located as shown in Figures 1 to 4 or may be located elsewhere on the vehicle.

[0071] Figures 5a and 5b show plan views of an arm mechanism 400 for moving a vehicle panel 402, which may be a charging port cover flap 402. The arm mechanism 400 is shown in a first, closed position in Figure 5a and in a second, open position in Figure 5b. The cover flap 402 has a flap coupling arrangement 404 that is arranged to pivotally couple to arms 406, 408 of the arm mechanism 400.

[0072] The arms include a first arm 406 and a second arm 408, which may be referred to as a connecting bar 408. The first arm 406 may be formed from a plurality of leaves and may carry a substantial portion of the weight of the vehicle panel 402. Put another way, the first arm 406 may have a greater stiffness than the connecting bar 408. The first arm 408 may derive strength from the plurality of leaves from which it is formed, as is explained in greater detail below with reference to Figure 6.

[0073] The second arm 408 may be thinner in plan view than the first arm 406 and may be arranged lower than the first arm 406. In this way, the second arm 408 may be substantially concealed from view by the first arm 406. In particular, when in the open position, at least 50% of the area of the second arm 408 may lie under the first arm 406. In some cases, the second arm 408 may be arranged so that, in the open position, at least 90% of the second arm 408 may be either underneath the first arm 406 or arranged between a portion of the first arm 406 and the vehicle body.

[0074] The first and second arms 406, 408 may be coupled to the vehicle body via an arm coupling portion 412. The arm coupling portion 412 may include a gear mechanism and / or an actuator for moving the first and second arms 406, 408, as explained in greater detail below with reference to Figures 9 and 10. The first arm 406 is pivotally coupled to the vehicle body at a first pivot point 41 1 , which may be considered to have a first axis extending vertically through it. The first arm 406 is pivotally coupled to the vehicle panel 402 at a second pivot point 409, which may be considered to have a second axis extending vertically through it. The second arm 408 is pivotally coupled to the vehicle body at a third pivot point 413, which may be considered to have a third axis extending vertically through it. The second arm 408 is pivotally coupled to the vehicle panel 402 at a fourth pivot point 410, which may be considered to have a fourth axis extending vertically through it.

[0075] The first, second, third and fourth pivot points may be considered as joints of a four-bar mechanism formed of the vehicle both, first and second arms 406, 408 and the vehicle panel 402. In this way, the orientation of the vehicle panel 402 relative to the vehicle body may be constrained and may be determined by the first and second arms 406, 408.

[0076] A four-bar mechanism may attain a toggle point where two links are colinear. In such a position, the mechanism may become indeterminate, meaning that the position of the links is not properly constrained. In the case of a moveable vehicle panel, there is a risk of a toggle point occurring in or near the closed position as a line between the pivot points on the vehicle panel (the second and fourth pivot points 409, 410 here) may be colinear with a line joining pivot points of at least one of the arms (i.e. a line joining the first and second pivot points 411 , 409 or a line joining third and fourth pivot points 413, 410).

[0077] In the present case, the pivot points are arranged such that no toggle point exists between the open and closed positions. To this end, the flap coupling arrangement is provided such that the second and fourth pivot points 409, 410 are positioned different distances from the vehicle panel 402 and may be arranged at different distances from the vehicle centre line C in the closed position, and optionally in the open position. The first and third pivot points 411 , 413 are arranged different distances from the vehicle centreline C and arranged such that a line passing through the first and third pivot points 411 , 413 is not traversed by the second or fourth pivot points 409, 410 as the vehicle panel moves between the open and closed positions.

[0078] The first and second arms 406, 408 pass through an intermediate vehicle panel 414, which may simply be referred to as a panel 414 in some cases. The intermediate vehicle panel 414 may be referred to as a greyzone panel and may be visible to a user when the vehicle panel 402 is in the open position and may not be visible when the vehicle panel 402 is in the closed position. The intermediate vehicle panel 414 may be fixed relative to the vehicle body and may act to reduce an ingress of dirt into the vehicle body as well as preventing access to the actuator mechanism of the arm mechanism 400 to avoid a user inserting a body part into the actuator mechanism.

[0079] The intermediate vehicle panel 414 has a plurality of apertures for allowing the first and second arms 406, 408 to pass therethrough. There may be provided one aperture for each leaf of the first arm 406 to pass through and a further aperture for the second arm 408 to pass through. The apertures may be each be closed spaces and the intermediate vehicle panel 414 may include continuous members extending between the apertures. The first arm 406 has a C-shape when viewed from above and each leaf of the first arm 406 may have a C- shape, optionally each leaf may have the same geometrical shape and size: the leaves may be congruent. The C-shape may be characterised by the shape of the arm not extending along a straight line between the first and second pivot points 409, 411 . In particular, a central portion of the arm may be arranged on an opposite side of a straight line between the first and second pivot points 409, 411 from the vehicle panel 402 when the vehicle panel 402 is in the closed position. The C-shape of the first arm 406 may allow the first arm 406 to extend around an adjacent vehicle panel P when the vehicle panel 402 is in the open position, allowing a greater range of movement for the vehicle panel P. The second arm 408 may also be C-shaped for the same reason.

[0080] The first arm 406 may have an elbow portion 406a. The elbow portion 406a may have a width, as viewed from above, which is greater than a width of the remainder of the first arm 406. The elbow portion 406a may be positioned in the aperture of the intermediate vehicle panel 414 when the vehicle panel 402 is in the open position. The elbow portions 406a of each leaf of the first arm 406 may substantially fill a respective aperture when the vehicle panel 402 is in the open position. In this way, the ingress of dirt into the vehicle body may be reduced when the vehicle panel 402 is in the open position.

[0081] Figure 6 shows an arm mechanism 500 including a first arm 504, which may be the first arm 406 of Figures 5a and 5b. The arm mechanism includes a connector module 502 at a first end, which is arranged to pivotally couple the first arm 504 to a vehicle body 510. The space within the vehicle body 510 adjacent the connector module 502 may be limited and so the connector module 502 and the first arm 504 may be assembled together before insertion into the vehicle body.

[0082] The connector module 502 may comprise a shaft 503, which may extend along a first axis A1 about which the first arm 504 is pivotally coupled to the vehicle body 510. The shaft 503 may be keyed, have a flattened portion or may otherwise be non-circular in order to transfer a torque to the first arm 504 and in particular to transfer a torque evenly to the different leaves 504a-e of the first arm 504. Alternatively, the shaft 503 may be cylindrical and a frictional engagement between the leaves 504a-e and spacers 505 may allow torque to be transferred between the shaft 505 and the leaves 504a-e.

[0083] The connector module 502 includes spacers 505, which are arranged along the shaft 503 between the leaves 504a-e. The spacers 505 are arranged to maintain a distance between the adjacent leaves 504a-e. The spacers 505 may frictionally engage the leaves in order to rigidly couple the leaves 504a-e together or may mechanically engage the leaves 504a-e, such as by an interlocking arrangement between the spacers 505 and the leaves 504a-e.

[0084] The shaft 514 may have a D-shape or other non-circular shaped cross-section and the leaves 504a-e and, optionally the spacers 512 may have a corresponding non-circular shaped hole. This may cause the leaves 504a, e to be in a fixed relative orientation. The connector module 502 may comprise a locking screw 511 that is arranged to engage the shaft 503. The locking screw 511 may be tightened such that the shaft 503 is in tension and a compressive force is exerted between the spacers 505 and the leaves 504a-e. The shaft 503 may have a radially-extending flange at an end opposite the locking screw 511 , the radially-extending flange being arranged to engage a first one of the leaves 504a or a spacer 503. In this way, the leaves 504a-e may be free to rotate relative to each other when the connector module 502 and arm 504 are first arranged within the vehicle body 510 and subsequently the leaves 504a-e may be rigidly coupled together by a compressive force exerted on the leaves 504a-e and spacers 505 by the locking screw 511 and shaft 503. This may allow the arm 504 and connector module 502 to be more easily arranged within the vehicle body while maintaining the advantages of the leaves 504a-e being rigidly coupled together.

[0085] The vehicle body 510 may couple to the connector module 502 via two vehicle body portions 510a, 510b. A first vehicle body portion 510a may be a coupling portion of a vehicle body and may include a bearing or bushing arrangement for receiving a top of the shaft 503. A second vehicle body portion 510b may be a coupling plate, gear mounting plate, or similar that may receive the shaft 503 and / or the locking screw 511 . The second vehicle body portion 510b may be a portion of an actuator assembly that is inserted into the vehicle body with the connector module 503 and subsequently rigidly coupled to the vehicle body.

[0086] The arm 504 extends through an intermediate vehicle panel 507, which may be the panel 414 of Figures 5a and 5b. The intermediate vehicle panel 507 have a plurality of apertures 509a-e for receiving the leaves 504a- e of the arm 504. It can be seen that each leaf 504a-e extends through a respective aperture 509a-e. For example, a first leaf 504a extends through a first aperture 509a and a second leaf 504b extends through a second aperture 509b. The intermediate vehicle panel 507 may be substantially continuous between the apertures 509a-e such that each aperture is separated by a portion of the intermediate vehicle panel 507.

[0087] During assembly, each leaf 504a-e may be inserted into and through a respective aperture 509a-e. This may occur while the leaves 504a-e are rotatable relative to each other, before the leaves 504a-e are rigidly coupled together. This may improve the ease of insertion of the leaves 504a-e through the apertures 509a-e.

[0088] Afterthe leaves 504a-e are inserted through the apertures 509a-e, the leaves 504a-e may be coupled together at a second end via a vehicle panel connector module 506. The vehicle panel connector module 506 may include a shaft 514 extending along an axis A2 and a plurality of spacers 512 arranged between the leaves 504a-e. The leaves 504a-e may be pivotally coupled to the vehicle panel 508, which may be a charging port cover flap, via the vehicle panel connector module 506 such that the vehicle panel 508 is pivotable relative to the arm 504 about a second axis A2.

[0089] Similarly to the connector module 502, the vehicle panel connector module 506 comprises a locking screw 516. The locking screw may be engaged with the shaft 514 to exert a compressive force on the spacers 512 and the leaves 504a-e such that the leaves 504a-e are rigidly coupled together. The spacers 512 and the leaves 504a-e may engage by frictionally or by mechanical interlocking in order to be rigidly coupled together. By coupling the leaves 504a-e together rigidly at both ends, a high bending stiffness of the arm 504 may be achieved, while the arm 504 may have a low weight due to the leaves 504a-e being spaced apart. The apertures 509a-e may also be formed as small, separate apertures. This may reduce the ingress of dust or dirt into the vehicle body.

[0090] It will be understood that the high bending stiffness of the arm 504 may be a high bending stiffness about a horizontal axis perpendicular to the direction of extension of the arm 504, i.e. a resistance to deflection due to the weight of the vehicle panel 508. The high bending stiffness of the arm 504 may be achieved in particular via the rigid coupling together of the top and bottom leaves 504a, 504e. Since the top and bottom leaves 504a, 504e are spaced apart far from a neutral axis of the arm (i.e. a point at which the arm does not extend or contract under bending, approximately in line with the central leaf 504c), the top and bottom leaves 504a, 504e contribute significantly to the second moment of area of the arm 504. It will be understood that the arm mechanism 500 may comprise any number of spaced apart leaves, such as two leaves or more.

[0091] The vehicle panel 508 may be coupled to the leaves 504a-e via a low-friction surface or via one or more bearings in order to allow the vehicle panel 508 to pivot relative to the arm 504.

[0092] Figure 7 shows a further vehicle panel connector module 600. The vehicle panel connector module 600 is arranged to pivotally couple the leaves 604 of a first arm to a vehicle panel 608. The leaves 604 are rigidly fixed together via spacers 612 similarly to the above-described connector modules, with a compressive force being exerted on the spacers 612 and leaves 604 by a locking screw 616 and a shaft 614, the shaft 614 extending through the leaves 604 and spacers 612.

[0093] The vehicle panel connector module 600 further comprises a bushing 606. The bushing 606 is arranged to transmit a compressive force from the shaft 614, which may be referred to as a join pin 614, and locking screw 616 to the spacers 612 and leaves 604 while allowing the shaft 614 and vehicle panel 608 to rotate relative to the leaves 604 and spacers 612. The bushing 606 has an inner sleeve that engages the shaft 614 and an outer sleeve arranged to engage the leaves 604 and spacers 612. The bushing 606 may also have radial flanges arranged to abut top and bottom surfaces of the leaves 504 and / or spacers 612. The outer sleeve of the bushing 606 may include axial extensions arranged to transfer compressive forces between the locking screw 616 and shaft 614 and the stack of leaves 604 and spacers 612, which the axial extensions may have low-friction surfaces contacting the vehicle panel 608.

[0094] The bushing 606 may be replaced by two spaced apart bushings separated by a hollow shaft, the bushings and hollow shaft being arranged to receive the shaft 614. The two spaced apart bushings may be arranged within top and bottom leaves of the arm and the two spaced apart bushings may be coupled together via the hollow shaft.

[0095] Figure 8 shows a still further vehicle panel connector module 700. The vehicle panel connector module 700 includes a stack of leaves 704 and spacers 712, which are compressed together to be rigidly coupled by a compressive force exerted by a locking screw 716 engaged with a shaft 714, the leaves 704 and spacers 712 being stacked around the shaft 714.

[0096] Compressive forces are transferred between the shaft 714 and locking screw 716 and the stack of leaves 704 and spacers 712 via inner sleeves of bushings 706a, b. The bushings 706a, b are arranged within coupling portions of a moveable vehicle panel 708 such that outer sleeves of the bushings 706a, b engage the vehicle panel 708 and inner sleeves of the bushings 706a, b engage the shaft 714 and locking screw 716. Axial ends of the inner sleeves of the bushings 706, b also abut the stack of leaves 704 and spacers 712 in order to compress the leaves 704 and spacers 712 together.

[0097] Figures 9 and 10 show a gear arrangement 800 for an actuator assembly and an actuator assembly 900 respectively.

[0098] Figure 9 is a view of an underside of a gear arrangement 800 for transferring torque to a vehicle assembly or an arm mechanism, such as the vehicle assembly of Figures 5a and 5b or the arm mechanism of Figures 6, 7 or 8. The gear arrangement 800 comprises a gear mounting plate 814, which may provide a resilient surface for supporting the gears of the gear arrangement. The gear mounting plate 814 may be a portion of or may be fixed to the vehicle body.

[0099] The gear arrangement 800 comprises a first gear 806, which is fixed to a first shaft 802, which in turn is fixed to a first arm 902, which may be the first arm of Figures 5a to 8. The first shaft 802 is therefore arranged to transfer torque from the first gear 806 to the first arm 902. A second gear 808 is fixed to a second shaft 804, which is fixed to a second arm 904, which may be the second arm of Figures 5a and 5b. The second shaft 804 is therefore arranged to transfer torque from the second gear 808 to the second arm 904.

[0100] An idler gear 810 is arranged to engage with the first and second gears 806, 808. The idler gear 810 may be provided such that the first and second gears 806, 808 rotate in the same direction and may be omitted if a pulley and belt system is used in place of the first and second gears 806, 808. The idler gear 810 may be arranged to rotate about a pivot point on the gear mounting plate 814.

[0101] A crank 812 is provided on the second shaft 804, although the crank 812 may be fixed to any of the gears or shafts of the gear arrangement 800. The crank 812 may receive torque from an actuator 906. The actuator 906 may comprise an electric motor and optionally a gearbox and may be arranged to generate torque in order to move a vehicle panel, by supplying torque to the gearing arrangement 800 to move the first and second arms 902, 904.

[0102] Figures 11 a to 11 h illustrate steps of a method of assembly of an arm mechanism. The flowchart of Figure 12 also illustrates the assembly method 1100.

[0103] At step 1102, a plurality of leaves are provided, the leaves 1002 may be those described with reference to Figures 5a to 8 and may be suitable for forming an arm. At step 1104, the leaves 1002 may be coupled to a connector module 1004 to form the partial arm mechanism 1000. The connector module may comprise spacers 1008 and a shaft 1006 extending through the leaves 1002 and the spacers 1002.

[0104] At step 1106, the leaves 1002 may be inserted into apertures 1012 within an intermediate vehicle panel 1014 to form a further partially assembled vehicle assembly 1010. The leaves 1002 may be inserted into the apertures 1012 before the connector module is coupled to the vehicle body in order to allow easier insertion into the apertures 1012.

[0105] At step 1 108, the connector module 1004 may be pivotally coupled to the vehicle body 1040. The pivotal coupling of the connector module 1004 to the vehicle body may comprise coupling of a gear mounting plate to the vehicle body 1024 and / or the shaft 1006 being received in a portion of the vehicle body or any other coupling method. This may result in a still further partial arm assembly 1020 being formed.

[0106] At step 1110, the leaves may be fixed together at the connector module such that the leaves are constrained to rotate together. This may be performed by engaging a locking screw 1032 with the shaft 1006 to fix the leaves 1002 and spacers 1008 together. This may result in an even still further partial arm assembly 1030 being formed.

[0107] Steps 1106, 1108 and 1 100 may be performed in any order. For example, the leaves may be rigidly fixed together and / or pivotally coupled to the vehicle body before being inserted through the apertures in the intermediate vehicle panel. The steps may be ordered based on the relative difficulty of each step taking into account the space available within the vehicle body for performing each task.

[0108] At step 1112, a vehicle panel connector module may be coupled to a second end of the arm to form an arm mechanism 1070.

[0109] The coupling of the vehicle panel connector module to the leaves 1002 may comprise a number of sub-steps. A first sub-step is illustrated in Figure 11 e, where a yet still further partial arm assembly 1040 is shown. The yet still further partial arm assembly 1040 comprises a plurality of spacers 1042 arranged between the leaves 1002 in order to maintain a spacing of the leaves 1002.

[0110] A sleeve 1052 is inserted through the leaves 1002 and spacers 1042 to form an even yet still further partial arm assembly 1050. The sleeve 1052 has a bushing 1054, 1056 at either end, the bushings 1054, 1056 are arranged to receive a shaft and to provide a low friction wear surface for the shaft. The bushing 1054, 1056 may extend radially outwardly at axial ends of the sleeve 1052 to provide low friction surfaces to engage with mounting portions of a vehicle panel, such as a charging port cover flap. The sleeve 1052 has a hollow central portion 1053 arranged to receive the shaft and to couple the bushings 1054, 1056 together. The sleeve 1052 may have a non-circular external cross section and the leaves 1002 and, optionally the spacers 1042, may have corresponding non-circular holes for receiving the sleeve 1052. In this way, the sleeve 1052 may prevent relative rotation of the leaves 1002.

[0111] The even yet still further partial arm assembly 1050 may be inserted into a mounting portion 1062 of a moveable vehicle panel, such as charging port cover flap. The mounting portion 1062 may include holes 1064, 1066 for receiving a shaft, which may align with a corresponding hole through the sleeve 1052. The mounting portion 1062 may abut the radially extending surfaces of the bushings 1054, 1056. In this way, a partial vehicle assembly 1060 may be formed.

[0112] Subsequently, a shaft 1074 may be inserted through the leaves 1002 and spacers 1082 by being inserted through the sleeve 1052. The shaft 1074 may also be inserted through the mounting portion 1062 of the vehicle panel. The shaft may be coupled to a locking screw 1076 such that a compressive force is exerted on the leaves 1002 and spacers 1042 to fix the leaves 1002 and spacers 1042 together. The arm may also be pivotally coupled to a vehicle panel 1062.

[0113] It will be understood that the method 1100 or any steps thereof may be used to construct any vehicle assembly or arm mechanism described with reference to Figures 5a to 10.

[0114] It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.

Claims

CLAIMS1. An arm mechanism for moving a charging port cover flap of a vehicle, the arm mechanism comprising: a connector module configured to be pivotally coupled to a vehicle body of the vehicle about a first axis; and a plurality of leaves spaced apart along the first axis, wherein each leaf comprises a first end coupled to the connector module, and a second end configured to be pivotally coupled to the charging port cover flap at a second axis, wherein the leaves of the plurality of leaves are fixable together at their first end via the connector module to rotate together about the first axis at their first end, and wherein the leaves are coupleable to the charging port cover flap such that the leaves are fixed relative to one another at their respective second ends when coupled.

2. The arm mechanism of claim 1 , wherein the connector module comprises a shaft, the first end of each leaf being coupled to the shaft, and one or more spacers, each spacer being arranged between adjacent leaves of the plurality of leaves along the shaft.

3. The arm mechanism of claim 2, wherein the spacers are arranged to frictionally or mechanically engage the leaves, such that the leaves are coupled together to rotate as one about the first axis.

4. The arm mechanism of any preceding claim, wherein the connector module is coupled to an actuator, the actuator being configured to rotate the connector module and the plurality of leaves about the first axis.

5. The arm mechanism of claim 4, wherein the connector module further comprises a crank, and wherein the crank couples the connector module to the actuator.

6. The arm mechanism of any preceding claim, wherein at least one leaf of the plurality of leaves is shaped such that a lamina cross-section of the at least one leaf, between the first end of the leaf and the second of the leaf, is substantially C-shaped.

7. A vehicle assembly for selectively covering a charging port, the vehicle assembly comprising: the arm mechanism of any preceding claim and a charging port cover flap moveable between a first position and a second position, wherein the second ends of the leaves are pivotally coupled to the charging port cover flap, and wherein the leaves are fixed relative to one another.

8. The vehicle assembly of claim 7, further comprising a sleeve, wherein the second end of each leaf is fixed together via the sleeve, the sleeve being pivotally coupled to the charging port cover flap.

9. The vehicle assembly of claim 8, further comprising one or more spacers, each spacer being arranged between adjacent leaves of the plurality of leaves along the bushing.

10. The vehicle assembly of claim 9, wherein a join pin extends through the sleeve to clamp the spacers onto the plurality of leaves.11 . The vehicle assembly of any one of claims 7 to 10, further comprising a connecting bar, wherein the connecting bar comprises a first end configured to be pivotally coupled to the vehicle body about a third axis, and a second end pivotally coupled to the charging port cover flap about a fourth axis, wherein the third axis is substantially parallel to and offset from the first axis, and the fourth axis is substantially parallel to and offset from the second axis.

12. The vehicle assembly of claim 11 , further comprising a gear mechanism, the gear mechanism comprising a first gear fixed to the leaves, a second gear fixed to the connecting bar and an idler gear engaged with the first and second gears.

13. A vehicle comprising: a charging port, and the vehicle assembly of any one of claims 7 to 12, the charging port cover flap of the vehicle assembly being configured to selectively cover the charging port.

14. The vehicle of claim 13, further comprising a panel, having a plurality of apertures, adjacent the charging port, the panel being coverable by the charging port cover flap and being disposed inboard of the charging port cover flap when the charging port cover flap is in the first position, wherein each leaf extends from the connector module, through a respective aperture of the panel and to the charging port cover flap.

15. A method for assembling an arm mechanism for moving a charging port cover flap of a vehicle, the method comprising: providing a plurality of leaves, the plurality of leaves being arranged to form an arm, each leaf having a first end and a second end; coupling the plurality of leaves to a connector module at the first ends of the plurality of leaves such that the plurality of leaves are spaced along a first axis; with the leaves coupled to the connector module, positioning each leaf of the plurality of leaves in a respective aperture in a panel of a vehicle body of the vehicle, such that at least the second end of each leaf extends out of the vehicle body through a corresponding aperture; pivotally coupling the connector module to the vehicle body such that the connector module is pivotally coupled about the first axis; and fixing the leaves of the plurality of leaves together at their first end via the connector module such that the leaves rotate together about the first axis at their first end.

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