Vehicle Charging Port Sealing Assembly for Compact Universal Fit
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Solution Overview
Problem
Existing charging port assemblies for electric and hybrid electric vehicles are bulky due to common parts and sealing mechanisms, which increase size and complexity, and fail to effectively prevent contamination and manufacturing tolerances.
Innovation Solution
A charging port assembly with a unified interface holding element and housing, featuring a single deformable sealing member that seals the passage opening and interfaces, reducing size, increasing robustness, and simplifying design while accommodating various market plugs, including European and US types, by forming a shallow housing with reduced components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If common parts and sealing mechanisms are used for all markets, then the charging port assembly can be universally applied, but the overall size increases
Solution Approach 1:
The interface holding element is designed with a unified structure that can accommodate different interface members for various markets (Europe, US, China, Japan). This single universal holding element replaces the need for market-specific components, achieving universal applicability without increasing size.
Solution Approach 2:
The sealing member integrates multiple sealing functions into a single component. It simultaneously seals the interface between the interface holding element and housing, and seals the passage opening when the cover element is closed. This merging of functions eliminates the need for separate sealing components, reducing overall size.
2Reliability
If multiple sealing components are used to seal different interfaces, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
A single sealing member performs multiple sealing tasks: sealing the interface between the interface holding element and housing, and sealing the passage opening when the cover element is closed. This consolidation reduces the number of components while maintaining comprehensive sealing effectiveness.
Solution Approach 2:
The sealing member is designed with deformable characteristics, allowing it to change its shape and sealing contact points based on operational conditions. This adaptability enables one component to effectively seal multiple interfaces that would traditionally require separate rigid sealing elements.
3Reliability
If the housing is made deeper to accommodate sealing mechanisms, then sealing capability is improved, but contamination risk increases
Solution Approach 1:
The sealing functions are integrated into a compact arrangement where the sealing member operates within the existing housing depth. The deformable sealing member can effectively seal interfaces without requiring additional deep housing structures, thus minimizing the opening area and reducing contamination risk.
4Manufacturing precision
If separate sealing components are used for different interfaces, then sealing precision is improved, but manufacturing cost increases
Solution Approach 1:
The sealing member is manufactured as a single integrated component with deformable sections designed for different sealing interfaces. This reduces the number of parts, assembly steps, and quality control checkpoints, thereby lowering manufacturing costs while maintaining sealing precision through the deformable design.
Solution Approach 2:
The deformable sealing member incorporates material or structural parameters that allow it to adapt to tolerance variations in different interfaces. This flexibility compensates for manufacturing tolerances without requiring precision-machined separate sealing components, reducing manufacturing complexity and cost.
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 reduces the overall size and complexity of the charging port assembly, enhances robustness, minimizes contamination risk, and lowers production costs by using a single sealing member to handle multiple sealing functions, ensuring compatibility with diverse market standards.
Implementation Method 1
The sealing member is configured to be deformed when the cover element is in a closed position to seal the passage opening of the housing
Data Source
Figure 1~2B
Figure 2C~3
AI summary
The disclosure relates to a charging port assembly (100) for a vehicle, comprising: an interface holding element (102) being insertable into the vehicle and configured to hold an interface member (112) in position, a housing (104) configured being mountable on the vehicle and having a passage opening (114) for providing access to the interface member (112), a cover element (106) being configured to releasably close the passage opening (114) of the housing (104), and a sealing member (108) being arranged at the interface holding element (102) and configured to sealingly connect the interface holding element (102) and the housing (104) and configured to be deformed when the cover element (106) is in a closed position to seal the passage opening (114) of the housing (104). Furthermore, the disclosure relates to a vehicle, comprising such charging port assembly (100).