Four-Joint Plug Cover Hinge for EV Charging Seal and Locking
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Solution Overview
Problem
Existing plug cover flaps with hinges have limited motion, affecting their ability to form a reliable seal, secure locking, and imposing design limitations on the connector.
Innovation Solution
A four-joint hinge system with two flap-side and two fastening-side joints, allowing for a cover flap to move along a non-circular path, providing enhanced sealing and secure locking in both open and closed positions, and incorporating a spring element for locking and a drive device for manual or automatic operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a rotating hinge is used to connect the cover flap to the connector housing, then the cover flap can be moved between open and closed positions, but the movement is limited to a circular path which restricts the opening angle and affects sealing and locking reliability
Solution Approach 1:
The hinge is divided into four separate joint elements (first and second flap-side joint elements, first and second fastening-side joint elements) that work together in a parallelogram configuration. This segmentation allows the cover flap to move through a larger angular range while maintaining stable positioning in open and closed states, improving both operability and sealing/locking reliability.
Solution Approach 2:
The hinge mechanism transitions from a simple circular rotation to a parallelogram-based multi-dimensional movement. The four joint elements create a geometric constraint system that guides the cover flap through a controlled elliptical or arcuate path, enabling larger opening angles while maintaining reliable contact for sealing and locking.
2Device complexity
If a rotating hinge with limited circular motion is used, then the structure is simple, but the design flexibility of the connector is reduced
Solution Approach 1:
The four-joint parallelogram hinge serves multiple functions: it provides the mechanical connection between cover flap and housing, enables large-angle opening for accessibility, maintains stable closed position for sealing, and allows for adjustable geometric parameters to adapt to different connector designs. This multi-functionality increases design flexibility without proportionally increasing complexity.
Solution Approach 2:
The hinge mechanism allows dynamic adjustment of the cover flap's movement path and opening angle by modifying the positions and dimensions of the four joint elements. This dynamic configurability enables the same basic hinge structure to adapt to various connector designs and applications.
3Device complexity
If the cover flap is moved along a circular path, then the hinge structure is simple, but the opening angle is restricted which affects accessibility
Solution Approach 1:
By segmenting the hinge into four separate joint elements arranged in a parallelogram, the system achieves a larger effective opening angle compared to a simple circular hinge. The distributed joint configuration allows the cover flap to clear obstacles and provide better access to the charging connection while maintaining structural simplicity.
Solution Approach 2:
The four-joint parallelogram mechanism acts as an intermediary between the simple circular hinge and the requirement for large opening angle. It transforms the limited circular motion into a more favorable movement path that achieves both accessibility and structural simplicity.
Data Source
AI summary
A plug cover hinge of a charging connection of an electric vehicle includes a cover or cover flap for selectively covering a socket or plug of the charging connection, and a four-joint hinge. The four-joint hinge defines two flap-side joints attached to the cover flap, and two fastening-side joints attachable to a frame. The four-joint hinge includes two joint elements, with each joint element connecting one of the flap-side joints to one of the fastening-side joints.