Protected Guide Rail Charging Flap Module for EV Port Access
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing charging flap modules in electric vehicles are prone to dirt and water penetration, leading to jamming and inaccessibility of the charging plug, and lack effective protection against environmental conditions.
Innovation Solution
Integration of a guide rail within the charging flap module, protected from dirt and water, along with a sealant and drain elements, ensures reliable operation and protection against environmental factors, while optimizing kinematics and reducing component count through injection molding and weight optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the guide rail is arranged externally on the charging flap module, then the structure is simpler and easier to manufacture, but the guide rail is exposed to dirt and water causing jamming and reliability issues
Solution Approach 1:
The guide rail is integrated into the housing of the charging flap module, with the housing serving as a protective enclosure. The guide rail is positioned within the housing structure, nested inside the protective shell, which shields it from environmental contaminants while maintaining its guiding function for the charging flap.
Solution Approach 2:
The housing acts as an intermediary protective element between the guide rail and the external environment. It provides a barrier against dirt and water, preventing direct contact with the guide rail while still allowing the charging flap to move along the guide rail within the protected interior space.
2Object-affected harmful factors
If the guide rail is integrated into the housing of the charging flap module, then protection against dirt and water is achieved, but manufacturing complexity increases
Solution Approach 1:
The guide rail and housing are merged into a single integrated structure. The guide rail is formed as an integral part of the housing, eliminating the need for separate assembly steps and reducing the number of components. This integration simplifies the manufacturing process while maintaining the protective function against environmental factors.
3Object-affected harmful factors
If the charging flap module uses multiple separate components for guide rail and housing, then manufacturing and assembly are easier, but protection against environmental factors is reduced
Solution Approach 1:
The guide rail and housing are combined into a single integrated component structure. This merging reduces the number of separate parts that need to be assembled and sealed, thereby improving protection against dirt and water penetration while simplifying the overall component count and assembly process.
Data Source
AI summary
An electric vehicle has a charging flap module. The electric vehicle includes a body having a body interior, which has a body element having an outer skin. The body element has an element opening, in which a charging cradle of the charging flap module is arranged. The charging cradle is designed to be fixed to the body and to incorporate a charging flap. The charging flap is designed to be movable in a guided manner between an open position and a closed position for opening and closing a cradle opening of the charging cradle. For guiding the charging flap, the charging cradle includes at least one guide rail, which is arranged in the charging flap module integrated into the housing so that it is protected against penetrating dirt and/or water.