Self-Locking EV Charge Port Door Assembly With Flush Parallel Motion
Find Innovative SolutionsGenerate Solutions
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 accidental closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a latch or spring mechanism is used to maintain the charge port door closed or prevent closure, then the door can be kept secure, but additional devices are required that take space within the port and/or require a power supply
Solution Approach 1:
The mechanism uses the actuator's own output shaft and crank pin configuration to provide self-locking functionality. The crank pin's position on the actuator's output shaft creates a mechanical lock when the door is open, preventing manual closure without requiring additional latch devices or power supplies.
Solution Approach 2:
The invention changes the geometric parameters of the actuator mechanism by positioning the crank pin at a specific eccentric location on the output shaft. This geometric configuration creates the self-locking effect through mechanical advantage and position-dependent force transmission, eliminating the need for supplemental locking devices.
2Ease of operation
If levers are hinged to the charge port flap and actuator to drive the flap open, then the door can be actuated, but a fairly powerful and thus large actuator is required
Solution Approach 1:
The driving rod acts as an intermediary element between the actuator's crank pin and the lever system. It translates the rotary motion of the crank pin into linear motion that efficiently actuates the levers, providing mechanical advantage and reducing the force requirements on the actuator itself.
Solution Approach 2:
The mechanism transitions from direct rotary actuation to a combination of rotary and linear motion through the driving rod. This dimensional change in motion transmission allows for more efficient force application and reduces the power requirements of the actuator.
3Ease of operation
If the charge port door protrudes from the outer surface of the vehicle skin, then access is easier, but it creates safety hazards against accidental snatching
Solution Approach 1:
The door is designed to remain substantially flush with the vehicle skin surface during both closed and open positions, with only minimal protrusion when open. This partial protrusion provides sufficient access while dramatically reducing the safety hazards associated with significant door protrusion.
4Ease of operation
If the charge port door moves away from the vehicle skin during opening, then access is granted, but the movement is less parallel to the skin surface
Solution Approach 1:
The driving rod converts the rotary motion of the crank pin into linear motion that pulls the levers and door in a direction substantially parallel to the vehicle skin surface. This dimensional transformation of motion ensures the door opens flush with the skin rather than lifting away from it.
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 mostly parallel movement to the vehicle skin, reduces the force required for opening and closing, ensures good sealing, and prevents manual closure, enhancing safety and aesthetics by keeping the door flush and secure.
Implementation Method 1
an actuator fixed to the bracket and comprising a rotatable output shaft with an eccentric crank pin... an eccentric movement of the crank pin drives via the lever parallelogram the charge port flap between the closed and the open position
Implementation Method 2
at least one lever parallelogram with a first and a second levers... configured to drive the charge port flap between said open and closed position
Implementation Method 3
the driving rod acts as a force multiplier allowing for a more compact actuating mechanism, thanks to the lesser forces required to open and close the charge port door
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a vehicle charge port door assembly. It comprises : - a charge port flap (14), - a bracket (16) configured to be fixed to the vehicle, - a motorized actuation mechanism (18) configured to move the charge port flap (14) between a closed position and an open position, - an actuator (24) fixed to the bracket (16à and comprising a rotatable output shaft with an eccentric crank pin, - at least one lever parallelogram with a first (31) and a second (32) levers, hinged, at one end, to the charge port flap (14) and at, the other end, to the bracket (16) and configured to drive the charge port flap (14) between said open and closed position, and - a driving rod connecting said crank pin to a driving protrusion of the first lever (31) so that an eccentric movement of the crank pin drives, via the lever parallelogram, the charge port flap (14) between the closed and the open position and vice versa.