Charge Flap Hinge Arm Assembly for Force Absorption and Sealing
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Solution Overview
Problem
Existing tank or charging modules for vehicles face issues with complex designs that require high pressure to open the flap, risk damage to opening mechanisms, need multiple seals for environmental protection, and involve numerous components leading to assembly complexity and weak points.
Innovation Solution
A charge flap arrangement with an engaging feature that absorbs compressive forces, a simplified hinge arm assembly, and a sealing unit with multiple sealing zones to protect against environmental influences, reducing complexity and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If high pressure is applied to open the flap, then the locking mechanism can be actuated, but the opening mechanism (such as digital pressure sensors) can be damaged
Solution Approach 1:
The patent introduces an intermediary element (the engaging feature with force absorption capability) between the pressure source and the flap releasing button. This intermediary absorbs excess compressive forces (5-100 N) and transmits only the appropriate unlocking force to the button, protecting the pressure sensor from damage while ensuring reliable flap opening.
2Object-affected harmful factors
If multiple sealings are installed at different locations, then environmental protection is improved, but the overall design and preparation process becomes difficult
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealing unit. This sealing unit incorporates multiple sealing zones and sealing lips that simultaneously seal against the charging socket, body panel, and hinge plate, reducing the number of separate sealing components and simplifying the overall design and assembly process.
Solution Approach 2:
The sealing unit is designed as a multi-functional component that performs multiple sealing tasks simultaneously. It provides environmental protection at multiple locations (charging socket interface, body panel interface, hinge plate interface) with a single component, making it universal for protecting against various environmental influences.
3Reliability
If several different parts are used to link together drive components, then the motor driven flap can function, but the assembling process complexity increases and weak points increase
Solution Approach 1:
The patent merges multiple drive components (motor, drive shaft, hinge arm, sealing, and housing) into a more integrated assembly. The hinge arm assembly is designed as a unified structure where components are pre-assembled and interconnected, reducing the number of separate parts that need to be linked together during final assembly and reducing potential weak points.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a structurally simplified and robust charge flap mechanism that withstands compressive forces, ensures effective sealing, and simplifies assembly, while maintaining operational reliability and reducing component vulnerability.
Implementation Method 1
the engaging feature has a shape and is made from a material that is capable of absorbing forces in the range of 5 to 100 N in order to protect the flap releasing button from over pressurizing
Data Source
AI summary
A hinge arm assembly for a charge flap arrangement of a motor vehicle includes a housing cap having at least one flexible hinge arm support, a charge flap housing coupled partially with the flexible hinge arm support, a hinge arm with a built-in drive shaft clipped into the housing cap and hold in place with clamping force, an actuator coupled to the built-in drive shaft, and at least one sealing component arranged between the actuator and the housing cap.