Integrated Flap Hinge Actuator for Cleaner Vehicle Body Gaps
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Solution Overview
Problem
Existing systems for opening and closing tank or charging flaps in motor vehicles are either structurally complex or visually unappealing due to displacement mechanisms, and require high rigidity and strength, leading to increased development effort and visual joint patterns between the flap and the vehicle body.
Innovation Solution
A hinge system with two articulated lever arms, where one lever arm is connected to the tank or charging flap and the other to a vehicle component, utilizing an actuator drive to pivot the arms about a pivot axis, allowing for integration of additional functions like sensors and lighting, and simplifying installation by eliminating complex mechanisms and enabling standardization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complicated levers and gear mechanisms are provided on the inside of the vehicle body to enable opening or closing of the tank or charging flap, then the opening/closing function is achieved, but the structural complexity increases significantly
Solution Approach 1:
The patent extracts the drive mechanism from the vehicle body interior and relocates it to the hinge assembly itself. The actuator is mounted on one of the lever arms, eliminating the need for complicated mechanisms within the vehicle body while maintaining the opening/closing function.
Solution Approach 2:
Instead of having the vehicle body provide the drive mechanism and connect it to the flap, the patent inverts the approach by making the hinge assembly self-contained with the actuator integrated into it. This reverses the traditional architecture and simplifies the overall system.
2Reliability
If the displacement mechanism is positioned to enable flap operation, then the opening/closing function is achieved, but visual joint patterns are created between the tank or charging flap and the vehicle body
Solution Approach 1:
The patent merges the drive mechanism with the hinge assembly, making them a single integrated unit. This eliminates separate displacement mechanisms that would create visible joint patterns, as the actuator is concealed within the hinge structure itself.
3Reliability
If high rigidity and strength are required for the mechanism to enable flap operation, then the opening/closing function is reliable, but the development effort increases
Solution Approach 1:
The patent segments the system into a standardized hinge assembly that includes the actuator, lever arms, and mounting components. This modular segmentation allows for standardized production with controlled rigidity and strength requirements, reducing overall development effort while maintaining reliability.
Solution Approach 2:
The hinge assembly with integrated actuator is designed as a universal component that can be applied to different tank or charging flap applications. This multi-functionality reduces development effort by reusing the same standardized mechanism across different vehicle models and applications.
4Reliability
If complex mechanisms are used inside the vehicle body, then the opening/closing function is achieved, but the installation effort increases
Solution Approach 1:
The actuator is pre-integrated into the hinge assembly during manufacturing, rather than being installed separately in the vehicle body. This preliminary action of assembling the drive mechanism with the hinge beforehand significantly reduces installation effort at the vehicle assembly stage.
Data Source
AI summary
A hinge for opening and closing a tank or charging flap has two lever arms which are connected to one another in an articulated manner. A first lever arm is designed for connection to a tank or charging flap and a second lever arm is designed for connection to a component fastened to a vehicle. A drive is provided in order to pivot the two lever arms relative to one another about a pivot axis. The drive is an actuator that is received on or in one of the lever arms.