Charging Flap Housing With 3D Flange for Left-Right Mounting
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Solution Overview
Problem
The development of customized housing bodies for vehicle charging, consumable fluids, or fuel filling systems is hindered by the need for individual adaptation to different vehicle models and installation situations, which complicates standardization and cost-effective production.
Innovation Solution
A housing body with a multi-dimensional, three-dimensional outer flange region that can be mounted in both left- and right-sided outer skin or outer body components of vehicles, ensuring flush integration with Class A surfaces regardless of the installation side.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the housing body is individually adapted to each vehicle model and installation situation, then the flush integration with Class A surfaces is achieved, but the device complexity and production cost increase
Solution Approach 1:
The housing body is divided into two main segments: a standardized basic housing body and an outer flange region. The outer flange region can be separately adapted or configured in different variants to match different vehicle outer skins and mounting conditions, while the basic housing body remains standardized for cost-effective production.
Solution Approach 2:
The basic housing body is designed as a universal component that can be used across different vehicle models and installation situations. Through the interchangeable outer flange region, the same basic housing body can accommodate various mounting requirements, achieving multi-functionality without requiring individual customization of the entire housing body.
2Ease of manufacture
If standardized housing bodies are used across different vehicle models, then production cost decreases, but the ability to achieve flush integration with different outer skin curvatures is reduced
Solution Approach 1:
Different parts of the housing body have different levels of standardization. The basic housing body maintains uniform quality and dimensions for standardized production, while the outer flange region allows for local variations in shape and curvature to adapt to different vehicle outer skins and mounting conditions.
Solution Approach 2:
The outer flange region is designed with three-dimensional shape variations that allow it to conform to different curvatures of vehicle outer skins. This dimensional flexibility enables the standardized basic housing body to be adapted to various installation situations without requiring complete customization.
3Adaptability or versatility
If the outer flange region is designed with mirror symmetry, then the housing body can be mounted on both left and right sides, but the design complexity increases
Solution Approach 1:
While the overall outer flange region maintains mirror symmetry for universal mounting capability, the basic housing body remains asymmetric to match the specific installation requirements. This selective application of symmetry allows versatility without unnecessary design complexity in all components.
Data Source
AI summary
A housing body (1) is designed in order to be mounted at least in regions in a mounting opening of an outer skin or outer body component (5) of a motor vehicle, and has an outer flange region (6), which surrounds the housing body (1) at least in regions and defines the outer geometry of the housing body at least in regions, the flange region having a multi-dimensional shape and being designed in order to rest against a support surface of the outer skin or outer body component (5) in the installed state of the housing body. The shape of the outer flange region (6) is designed such that the housing body (1) is mountable, as needed, in a mounting opening, mirrored relative to the motor vehicle longitudinal axis, in a left- or right-sided outer skin or outer body component, by moving the housing body from left to right.