Vehicle Charging Socket Recess With Integrated Light-Guided Sealing

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Solution Overview

Problem

Charging and fueling wells for hybrid and electric vehicles lack effective sealing mechanisms to protect against dirt, dust, and water, necessitating additional components or complex sealing systems, which complicate manufacturing and operation.

Innovation Solution

A charging or fueling well with an outer opaque plastics body and an inner translucent plastics region, formed integrally through multi-component injection molding, allows for backlighting and serves as a light guide, providing clear visibility and simplified assembly while maintaining a compact, maintenance-free design with integrated sealing and centering functions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If conventional opaque plastics material is used for the entire charging well, then manufacturing is simple and cost-effective, but visibility and illumination of the charging area are insufficient

Engineering Contradiction:

Improvevisibility and illumination of charging areaVSAvoidmanufacturing complexity

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The charging well is manufactured with a localized translucent region within the opaque plastic body, allowing light to pass through only in the specific area where visibility is needed (around the through-opening), while the rest of the structure remains opaque for simple manufacturing and aesthetic purposes

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The charging well combines two different plastic materials - an opaque base material and a translucent material - to create a single component that exhibits both properties, achieving local transparency without requiring the entire structure to be transparent

Inventive Principle:

Principle #40Composite materials

2Reliability

If additional sealing components are added to protect the charging terminal, then protection against dirt, dust and water is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveprotection against environmental influencesVSAvoidnumber of sealing components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sealing function is merged into the main charging well structure itself, where the interaction between the outer well body and inner well region creates the sealing effect, eliminating the need for separate sealing components

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The multi-component injection molded structure serves multiple functions simultaneously: structural support, sealing, and illumination, with the interface between different plastic materials providing both mechanical integrity and environmental protection

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of operation

If a closure element with push-push kinematics is used, then opening and closing operation is simplified, but sealing reliability is compromised due to missing seal between closure element and charging well

Engineering Contradiction:

Improveopening and closing operationVSAvoidsealing reliability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The sealing function is integrated into the well structure itself through the multi-component injection molded design, where the interface between outer and inner well regions provides sealing without requiring additional sealing elements that would complicate the closure mechanism

Inventive Principle:

Principle #5Merging (Combining)

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 ensures reliable sealing and illumination of the charging or fueling area, enhancing operational simplicity and reducing production costs by eliminating the need for additional sealing components and lighting devices, while maintaining protection from environmental influences.

Implementation Method 1

the transparent or translucent plastics material is part of a light guide structure and is designed to couple out light, coupled into the light guide structure with the aid of a light source

Methodology Applied

Scientific EffectLight guide: Waveguide (optics)

Implementation Method 2

formed integrally through multi-component injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS11820242B2Charging socket recess or fuel filler recess for inserting into a vehicle body opening of a motor vehicle

Publication Date: 2023.11.21 ILLINOIS TOOL WORKS INC

AI summary

A charging or fueling well for insertion into a body opening of a motor vehicle, wherein the charging or fueling well has an outer well body and an inner well region, which surrounds a through opening, into which a charging plug connector for charging a battery of the motor vehicle or a fuel nozzle or tank filler pipe can be inserted. The outer well body includes, at least in some region or regions, a preferably opaque or only slightly translucent plastics material. The inner well region includes, at least in some region or regions, a transparent or translucent plastics material and is formed integrally with the material of the outer well body.