Vehicle Charging Port Sealing for Hidden Tolerance Compensation
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Solution Overview
Problem
Conventional charging devices for electric or hybrid vehicles face issues with water and dirt penetration through the transition between the holding element and connection element, compromising both sealing reliability and aesthetic appearance, while also failing to accommodate component tolerances and elastic deformations.
Innovation Solution
A charging device with a dual-component sealing unit, comprising a deformable and non-deformable material, is designed to surround the connection element, ensuring a hidden seal that compensates for tolerances and deformations, maintaining a high-quality appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soft component sealing is used between the holding element and connection element, then sealing reliability is improved, but visual appearance deteriorates due to visible seals affecting design requirements
Solution Approach 1:
The sealing function is extracted from the visible front region and relocated to the rear side of the holding element. The sealing unit is positioned behind the connection element, so that only the connection element is visible from the front, while the sealing occurs in the hidden rear region. This separates the sealing function from the aesthetic region, maintaining both reliable sealing and high visual quality.
2Reliability
If a soft component sealing is used to compensate for tolerances and elastic deformations, then sealing reliability is improved, but device complexity increases due to additional special measures required for installation
Solution Approach 1:
The sealing unit incorporates a deformable sealing element that can dynamically adapt to tolerance variations and elastic deformations of the connection element. The soft component can deform elastically to accommodate manufacturing tolerances and operational deformations, providing reliable sealing without requiring complex adjustment mechanisms or special installation procedures.
3Reliability
If the sealing surface is increased to ensure sealing in boundary layers, then sealing reliability is improved, but manufacturing precision requirements worsen due to standards that prevent surface increase
Solution Approach 1:
The sealing unit employs a soft, flexible sealing element that can conform to the connection element's surface irregularities and tolerance variations. This flexible sealing component creates an effective seal without requiring large sealing surfaces or extremely tight manufacturing tolerances, as the soft material adapts to the actual geometry of the mating surfaces.
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 reliable sealing without visible seals, enhances aesthetic appeal, and accommodates component tolerances and deformations, ensuring a high-quality charging device design.
Implementation Method 1
a first component (23), which is made from a deformable material, and a second component (24), which is made from a hard or non-deformable material
Data Source
AI summary
A charging device for mounting in a bodywork opening of a motor vehicle has a holding element, which is designed for attachment to a bodywork part and has a through-opening. During mounting, a connecting element is inserted into the opening in order to produce a plug-in connection with an electrical charging station and/or with a fuel supply line for supplying fuel. A sealing unit is arranged on the rear side of the holding element, which surrounds a receiving area for the connecting element located behind the opening of the holding element, whereby the inserted connecting element is sealed towards the holding element. The sealing unit is attached to the holding element in such a way that it is covered by the connecting element after it has been inserted, so that it is not visible from the outside and seals against the connecting element.