Vehicle Flap Cover for Sealed Hinge Space

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Solution Overview

Problem

Existing tank or charging flap arrangements for vehicles expose the receiving space when in the open position, allowing foreign bodies like snow to enter and making it difficult to access and maintain, particularly problematic for electric vehicle charging flaps which are often open for extended periods.

Innovation Solution

A cover is integrated onto the housing body or hinge arm that covers the receiving space when the tank or charging flap is in the open position, ensuring no foreign bodies can penetrate, using a spring preload or slotted guide for reliable contact and secure closure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the hinge arm protrudes out of the housing body when the flap is in the open position, then the flap can be properly opened and operated, but the receiving space becomes exposed to foreign bodies like snow

Engineering Contradiction:

Improveflap opening operationVSAvoidforeign body penetration into receiving space

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

A cover element is introduced as an intermediary component between the hinge arm and the external environment. This cover element moves together with the hinge arm when the flap opens but maintains a sealing contact with the housing body, thereby mediating between the need for hinge arm movement and the requirement to prevent foreign body penetration.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cover element is designed as a flexible or elastic component that can deform and adapt its shape. When the hinge arm protrudes during opening, the cover element flexes to accommodate the movement while maintaining continuous contact with the housing body, preventing snow and foreign bodies from penetrating into the receiving space.

Inventive Principle:

Principle #30Flexible shells and thin films

2Adaptability or versatility

If the receiving space is exposed when the flap is open, then the hinge arm has full movement freedom, but maintenance becomes difficult due to poor accessibility

Engineering Contradiction:

Improvehinge arm movement freedomVSAvoidmaintenance accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The cover element serves as a movable intermediary that opens together with the hinge arm to provide access for maintenance operations, then closes to seal the receiving space. This allows maintenance personnel to access the hinge arm when needed while maintaining protection during normal operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The cover element is designed to be dynamic rather than static - it moves and deforms in coordination with the hinge arm's movement. During opening, it retracts or deforms to allow access; during closing, it returns to seal the receiving space, providing both maintenance accessibility and operational protection.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If a cover is added to seal the receiving space when the flap is open, then foreign body penetration is prevented, but the device complexity increases

Engineering Contradiction:

Improveforeign body penetration preventionVSAvoidstructure complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The cover element is merged with the hinge arm assembly, moving together as an integrated unit. This combination eliminates the need for separate actuation mechanisms for the cover, reducing overall device complexity while maintaining the sealing function during flap opening.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cover element is designed to automatically open and close in coordination with the hinge arm's movement without requiring external control. As the hinge arm protrudes during opening, the cover element self-adjusts to maintain sealing contact, eliminating the need for additional actuators or control systems.

Inventive Principle:

Principle #25Self-service

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 cover effectively prevents foreign bodies from entering the receiving space, maintaining a sealed environment even when the flap is open, ensuring reliable operation and easy maintenance, especially during prolonged charging sessions.

Implementation Method 1

The cover is prestressed in contact with the hinge arm or the housing body

Methodology Applied

Scientific EffectSpring preload: Spring

Data Source

PatentUS11299039B2Tank flap or charging flap arrangement

Publication Date: 2022.04.12 ILLINOIS TOOL WORKS INC

AI summary

A tank flap or charging flap arrangement, for a vehicle, includes a housing body and a tank flap or charging flap which is mounted on the housing body via a hinge arm so as to be pivotable between a closed position and an open position. In the closed position, the hinge arm is received in a receiving space of the housing body and, in the open position, protrudes at least partially out of the receiving space. A cover is arranged on the housing body or the hinge arm and covers the receiving space when the tank or charging flap is in the open position.