EV Charging Port Cover Coupling Secured Against Ice Loads

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing devices for closing and releasing a power charging port of a motor vehicle may malfunction due to weather conditions, such as ice formation, which can apply large loads on the coupling mechanism, leading to unintentional opening and failure of the drive mechanism.

Innovation Solution

The coupling mechanism is associated with a mechanical securing mechanism that cooperates with the emergency actuation device to provide an additional form-fit coupling for secure power transmission, which is lifted upon activating the emergency actuation device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a coupling mechanism is used to connect the drive mechanism to the cover part, then the drive mechanism can transmit force and motion to the cover part, but the coupling mechanism may be unintentionally activated by large forces from ice formation or other weather conditions

Engineering Contradiction:

Improvefunctional security of drive mechanismVSAvoidweather conditions affecting coupling mechanism

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary anti-action by introducing a securing mechanism that proactively counteracts the harmful effect of weather conditions before they can cause unintentional activation. The securing mechanism is designed to preemptively secure the coupling mechanism against large forces from ice formation or other weather-related loads, preventing the coupling from disengaging when exposed to environmental factors.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The securing mechanism acts as an intermediary between the coupling mechanism and the external forces from weather conditions. It mediates the interaction by providing an additional securing connection that protects the coupling mechanism from direct exposure to harmful external forces, allowing the drive mechanism to transmit large driving forces without risk of unintentional disengagement.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the emergency actuation device is manually operable to open the cover part, then it can provide manual control, but it may be unintentionally activated by large forces acting on the coupling mechanism

Engineering Contradiction:

Improvemanual control of cover partVSAvoidunintentional activation of emergency actuation device

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The securing mechanism applies preliminary anti-action by preemptively preventing unintentional activation of the emergency actuation device. It secures the coupling mechanism in advance against large forces that could otherwise cause the emergency actuation device to activate inadvertently, ensuring that manual control operations remain intentional and reliable.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The securing mechanism provides beforehand cushioning by preparing an additional securing connection that absorbs and neutralizes large forces before they can reach the emergency actuation device. This cushioning effect protects the manual control system from being compromised by environmental forces such as ice formation on the cover part.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Power

If the coupling mechanism is designed to transmit large driving forces, then the drive mechanism can effectively move the cover part, but the coupling mechanism may be disabled unintentionally under large loads

Engineering Contradiction:

Improvedriving force transmissionVSAvoidcoupling mechanism stability under load

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent merges the coupling mechanism with an additional securing mechanism to create a combined connection system. This merging allows the drive mechanism to transmit large driving forces effectively while the integrated securing mechanism simultaneously provides protection against unintentional disengagement under load, resolving the contradiction between power transmission and stability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The securing mechanism provides beforehand cushioning by preparing an additional securing connection that absorbs and neutralizes large forces before they can cause the coupling mechanism to disable. This allows the drive mechanism to transmit full power while the cushioning effect prevents unintentional disengagement even under extreme loading conditions.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS12280658B2Device for closing and releasing a power charging port of a motor vehicle

Publication Date: 2025.04.22 BOS GMBH & CO KG

AI summary

Device for closing and releasing a power charging port of a motor vehicle having a cover part moveable by a guiding mechanism, fixed to the vehicle in an installed and ready to operate condition, between a closed position closing the power charging port and an open position releasing the power charging port. An emergency actuation device moves the cover part into the open position, and a drive mechanism controls movement of the cover part. A coupling mechanism activates the emergency actuation device and deactivates the drive mechanism, and is connected to the emergency actuation device. The coupling mechanism is associated with a mechanical securing mechanism, which cooperates with the emergency actuation device. When the emergency actuation device is deactivated, the securing mechanism produces an additional form fit to secure a power transmission of the drive mechanism. The additional form fit is lifted upon activating of the emergency actuation device.