Two-Step Charge-Port Door Hinge for EV Parking Clearance
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Solution Overview
Problem
Existing charge port doors in electric vehicles face limitations in rotation range, leading to potential clearance issues when parked adjacent to other vehicles, and larger hinges compromise vehicle aesthetics.
Innovation Solution
A two-step hinge assembly with a hinge inlet and neck that rotates independently, featuring a retaining member and biasing mechanism to increase the angle between the door cover and body panel, allowing for a wider range of motion without enlarging the door.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a larger hinge is provided to allow further rotation of the charge port door, then the range of rotation is improved, but the overall aesthetics of the electric vehicle deteriorates due to a larger charge port door
Solution Approach 1:
The hinge assembly is divided into two functional segments: a first hinge assembly that rotates with the door cover, and a second hinge assembly that rotates independently. This segmentation allows the door cover to achieve a greater angle relative to the body panel (positioned parallel thereto) without requiring an overall larger hinge structure, thus maintaining aesthetics while improving rotation range
Solution Approach 2:
The hinge system transitions from a static single-rotation model to a dynamic two-step rotation model. The retaining member enables the system to switch between a closed position (both hinges engaged), a first opened position (first hinge disengaged), and a second opened position (second hinge disengaged, door cover parallel to body panel). This dynamic behavior allows adaptive rotation ranges based on operational needs without permanently increasing the hinge footprint
2Ease of operation
If the charge port door is positioned perpendicular to the vehicle when opened, then access to the charge port is improved, but clearance issues arise when parked adjacent to other vehicles
Solution Approach 1:
The hinge assembly provides dynamic positioning capability with multiple discrete positions. The door cover can be positioned perpendicular to the body panel at the first opened position for easy charge port access, or rotated further to be parallel to the body panel at the second opened position to reduce the projection and minimize clearance requirements when parked adjacent to other vehicles
Solution Approach 2:
The invention adds a second rotational dimension to the door cover movement. Instead of simple perpendicular opening, the door cover can now rotate through two steps: first to a perpendicular position for access, then further to a parallel position for compact storage. This dimensional change resolves the conflict between access ease and space efficiency
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
Enhances the rotation range of the charge port door, reducing the space required between parked vehicles and maintaining vehicle aesthetics by allowing the door cover to be positioned parallel with the body panel.
Implementation Method 1
a biasing member exerting a biasing force upon the retaining member to maintain the retaining member in the engaged position
Implementation Method 2
the hinge inlet defining a mating feature, where the hinge inlet independently rotates about a local axis of rotation of the two-step hinge assembly between a first step opened position and a second step opened position
Data Source
AI summary
A two-step hinge assembly for a door cover that provides access to an opening defined by a body panel includes a hinge inlet attached to the door cover, a hinge neck rotatably mounted to the body panel about a main axis of rotation, a retaining member actuated between an engaged position and a disengaged position, and a biasing member. The biasing member exerts a biasing force upon the retaining member to maintain the retaining member in the engaged position, where the retaining member is urged from the engaged position into the disengaged position when an actuation force that opposes the biasing force is exerted upon the retaining member. The retaining member disengages with a mating feature of the hinge inlet when urged into the disengaged position to allow the hinge inlet to rotate independently about a local axis of rotation.