Multi-Blade Charge Port Cover With Compact Translating Retraction
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Solution Overview
Problem
Existing electric vehicle charge port covers are bulky, expensive to manufacture, and aesthetically unpleasing due to their complex design and excessive components, which also makes them more vulnerable when open.
Innovation Solution
A charge port cover arrangement featuring a plurality of charge port blades that move through a combination of translating and transformation movements, facilitated by a single actuation unit and a control assembly that includes a helix rod and gear system, allowing for a more compact and efficient design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrically controlled charge port covers are used, then the charge port is protected when not in use, but the design becomes bulky and expensive due to excessive components
Solution Approach 1:
The charge port cover is divided into multiple individual blades (typically four) that can move independently. Each blade is a separate segment that can be actuated individually or collectively, replacing the conventional single-piece cover design. This segmentation allows for a more compact overall structure while maintaining protective functionality.
Solution Approach 2:
The charge port cover transitions from a static conventional design to a dynamic multi-blade system that can change its configuration. The blades can move between closed (protective) and open (access) positions, and can also adopt intermediate states. This dynamic capability is achieved through a simplified actuation mechanism that controls each blade's position independently.
2Reliability
If conventional electrically controlled charge port covers are used, then the charge port is protected, but the manufacturing cost increases due to excessive components
Solution Approach 1:
By dividing the cover into standardised blade segments, each blade can be manufactured independently using identical or similar processes, enabling economies of scale. The modular nature allows for simplified tooling and assembly operations, reducing overall manufacturing complexity and cost despite the multi-component design.
Solution Approach 2:
Multiple functional elements are merged into integrated components. For example, the actuation mechanism combines rotational and translational movements in a single integrated system, and the blades themselves integrate structural support, protective covering, and aesthetic functions into unified elements, reducing the total number of separate parts that need to be manufactured and assembled.
3Ease of operation
If conventional charge port covers are opened, then access to charge port is provided, but the cover protrudes outwardly making it bulky and vulnerable
Solution Approach 1:
The blade movement incorporates translational motion in addition to rotation, allowing blades to move not only angularly but also linearly along their hinges. This multi-dimensional movement enables the blades to retract partially or fully into the vehicle body when open, eliminating the conventional protruding appearance and reducing vulnerability while maintaining charge port accessibility.
Solution Approach 2:
The charge port cover system dynamically adjusts its configuration based on operational requirements. When access is needed, the blades can be partially opened or fully retracted, providing flexible access control. When protection is prioritized, all blades return to their closed position, creating a sleek, non-protruding appearance that enhances aerodynamics and aesthetics.
4Length of moving object
If multi-dimensional movement of charge port blades is implemented, then compactness is improved, but the actuation mechanism becomes more complex
Solution Approach 1:
A single actuation unit performs multiple functions: it simultaneously controls the rotational movement of multiple blades and coordinates their translational retraction. The actuation mechanism is designed to deliver compound motion (rotation plus translation) through an integrated system, eliminating the need for separate actuators for each movement type and reducing overall mechanical complexity despite the multi-dimensional blade trajectories.
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 results in a charge port cover that is more compact, less complex, and energy-efficient, while also being aesthetically pleasing and less vulnerable when open, thereby improving manufacturing convenience and overall performance.
Implementation Method 1
The control assembly is configured to move the plurality of blades from one of said states to the other state by a translating movement, and a transformation movement performed at least partly in a sequence, wherein said translating movement is arranged to move the charge port blades in a direction perpendicular to said first plane
Implementation Method 2
The transformation movement moves the charge port blades away from each other, or towards each other until they form a common circle that covers the charge port of the vehicle
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
The present disclosure relates to a charge port cover arrangement (1) comprising a control assembly (10) comprising an actuation unit (11), and a plurality of charge port blades (2a, 2b, 2c, 2d). The charge port cover arrangement (1) is arranged to alternate between a closed state in which said charge port blades (2a, 2b, 2c, 2d) form a common perimeter coincident with a first plane (p1), wherein the plurality of charge port blades (2a, 2b, 2c, 2d) are arranged to jointly cover a charge port opening of said vehicle, and an open state in which said charge port blades (2a, 2b, 2c, 2d) are arranged to expose said charge port opening of said vehicle to an environment. The control assembly (10) is configured to, in response to actuation of said actuation unit (11) move the plurality of blades (2a, 2b, 2c, 2d) from one of said states to the other state by a translating movement, and a transformation movement performed at least partly in a sequence.