EV Charge Port Door Linkage for Flush Self-Locking Sealing

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Solution Overview

Problem

Existing charge port door assemblies for electric vehicles require large actuators and supplemental devices, leading to increased space usage and potential safety issues due to protrusion from the vehicle skin, and lack effective sealing and self-locking mechanisms.

Innovation Solution

A charge port door assembly with a motorized actuation mechanism featuring a rotatable output shaft with an eccentric crank pin, lever parallelogram, and driving rod, which allows for a compact and self-locking design that maintains the door flush with the vehicle skin and prevents manual operation, ensuring good sealing and safety.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a motorized actuation mechanism with levers hinged to the charge port flap is used, then the charge port door can be opened automatically, but a fairly powerful and thus large actuator is required, increasing the space usage and causing the door to protrude from the vehicle skin

Engineering Contradiction:

Improveautomatic openingVSAvoidactuator size

Core Design Contradiction:

Extent of automationVSVolume of moving object

Solution Approach 1:

The patent inverts the conventional linkage arrangement by hinging both levers to the fixed bracket instead of hinging one lever to the movable charge port flap. This reversal transforms the kinematic relationship, allowing a smaller actuator to achieve the same opening function while keeping the door flush with the vehicle skin.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent introduces a driving rod as an intermediary element that connects the actuator's crank pin to the driving protrusion on the lever. This mediator transmits and transforms the motion, enabling compact actuator design while maintaining the required opening capability and flush door position.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a latch or spring mechanism is used to maintain the charge port door closed or open, then the door remains secure, but supplemental devices are required that take space within the inside of the port and/or a power supply

Engineering Contradiction:

Improvedoor securityVSAvoidsupplemental devices

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The parallel linkage mechanism inherently maintains the charge port door in its closed position through its geometric configuration, eliminating the need for separate latch or spring mechanisms. The system serves itself by using the actuation mechanism's structure to provide both opening capability and closed position stability.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If the charge port door protrudes from the outer surface of the vehicle skin, then the door can be easily opened, but it creates safety hazards against accidental snatching

Engineering Contradiction:

Improvedoor accessibilityVSAvoidaccidental snatching

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

By inverting the linkage configuration to hinge both levers on the fixed bracket, the patent achieves automatic opening without requiring the door to protrude. The inverted mechanism provides sufficient mechanical advantage to open the flush-mounted door automatically, thereby eliminating the safety hazard while maintaining ease of operation.

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of operation

If a conventional actuation mechanism is used, then the charge port door can be opened, but the movement is not parallel to the outer vehicle skin, compromising sealing and aesthetics

Engineering Contradiction:

Improvedoor openingVSAvoidsealing alignment

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The driving rod acts as a mediator that transforms the actuator's rotational motion into precise linear motion of the lever, ensuring the charge port door moves parallel to the vehicle skin surface. This intermediary element provides the necessary motion control to achieve both opening function and precise sealing alignment.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 achieves a compact actuation mechanism with reduced force requirements, maintains the charge port door flush with the vehicle skin for safety and aesthetics, and ensures self-locking in the open position to prevent accidental closure, while providing effective sealing against rainwater.

Implementation Method 1

an actuator fixed to the bracket and comprising a rotatable output shaft with an eccentric crank pin

Methodology Applied

Scientific EffectEccentric mechanism: Eccentric

Data Source

PatentUS12146362B2Self-locking electronic vehicle charge port door assembly

Publication Date: 2024.11.19 MINEBEA ACCESSSOLUTIONS ITALIA SPA

AI summary

A vehicle charge port door assembly includes a charge port flap, a bracket to be fixed to the vehicle, a motorized actuation mechanism to move the charge port flap between a closed position and an open position, an actuator fixed to the bracket and including a rotatable output shaft with an eccentric crank pin, at least one lever parallelogram with a first and a second levers, hinged, at one end, to the charge port flap and at, the other end, to the bracket and able to drive the charge port flap between the open and closed position, and a driving rod connecting the crank pin to a driving protrusion of the first lever so that an eccentric movement of the crank pin drives, via the lever parallelogram, the charge port flap between the closed and the open position and vice versa.