Patent Publication Number: US-2023151669-A1

Title: Electrical Charging Flap

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority from U.S. Provisional Application No. 63/280,895 filed on Nov. 18, 2021, the contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The following description relates to a charge flap arrangement comprising an engagement feature, a sealing unit for said charge flap arrangement, a hinge arm assembly for said charge flap arrangement and a method for assembling said hinge arm assembly. 
     BACKGROUND OF THE INVENTION 
     Tank or charging modules for vehicles are used to close a tank filler pipe or a charging plug or other connections for refueling or repowering in a first position of a flap and to release it in a second, open position of the flap. For this purpose, the tank or loading flaps of the modules close flush with the surface of the vehicle body in the closed position and also seal the tank or loading trough against the environment via corresponding seals on the flap or on the trough body. With this arrangement it should be ascertained that no debris, such as water, dirt, ice and the like finds its way into the tank or loading trough. The trough body itself is fixed to the vehicle and has an opening through which the insertion tube or the charging plug is guided. 
     The (charge or tank) flap should securely rest in place in a first position when no tanking or charging operation is undertaken and should easily be opened using a simple opening mechanism. Furthermore, the charge flap should also rest in a second position during refueling or repowering situation, wherein the second position should not interfere with the refuel or repowering action. 
     Several problems arise in connection with such tank or charging modules. First, to ensure that the flap can be opened, a certain amount of pressure is needed in order to actuate a locking or unlocking mechanism. This amount of pressure can damage the opening mechanism, such as digital pressure sensors. Second, several sealings are necessary at different locations of the tank or charging modules to ensure that the inner part of the tank or charging modules, i.e. the housing thereof, is protected from different environmental influences such as water, snow, wind and/or dirt. This makes the overall design and preparation process of the tank difficult. Third, nowadays the tank or charge flap may be opened and closed by use of a motor. The current design for such a motor driven flap is characterized by the use of several different parts to link together the different necessary components, such as the motor (actuator), a drift shaft, a hinge arm, one or more sealings and a housing which fixes these components in place and which ensures a trouble-free functioning of the system. The amount of components implies a high complexity of the assembling process and furthermore it implies many weak points detrimental to the frequent use of such a charge flap arrangement. 
     SUMMARY 
     In embodiments of the present disclosure, a charge flap arrangement is provided comprising an engagement feature for controlling an opening mechanism for the charge flap. In embodiments, a sealing unit is provided that is adapted to be installed on a charge flap housing of a motor vehicle for simultaneously fulfilling several functions within the charge flap housing. In embodiments, a structurally simplified hinge arm assembly is provided for opening and closing the charge flap and a method is provided for a reduced complexity by assembling said hinge arm assembly. 
     In embodiments, the present disclosure provides a charge flap arrangement of a motor vehicle, comprising a frame including an aperture and a housing having an interior, a 2K charge flap to close the aperture and having an engaging feature absorbing compressive forces, a charging socket within the interior of the housing and a flap releasing button located on the charging socket and opposite the engaging feature, wherein the flap releasing button is adapted to control a locking arrangement of the charge flap, wherein the engaging feature has a shape and is made from a material that is capable of absorbing forces in the range of 5 to 100 N in order to protect the flap releasing button from over pressurizing and, wherein the engagement feature is adapted to actuate the flap releasing button. 
     According to one embodiment, the engaging feature may have any form and may be made from any material that is suitable to provide the necessary overpressure stability and/or force absorption capability. For example, the engaging feature may have a zig-zag shape, wave shape, folded shape, honeycomb shape, or combinations thereof, but is not limited thereto. The engaging feature may be of a rubber material or plastic material, but is not limited thereto. The force may be adapted according to any specific requirements, for example may be in the range of 5.5 to 52 N. The locking of the charge flap may be achieved by any suitable locking tool, such as by a mechanical arrangement, by a magnetic arrangement and/or by an electrical arrangement. 
     In embodiments, the present disclosure provides a motor vehicle comprising the charge flap arrangement provided herein. 
     In embodiments, the present disclosure provides a sealing unit adapted for sealing a charge flap housing of a motor vehicle, wherein the sealing unit is provided in form of a 2K component comprising a charge flap housing and at least three sealing zones that provide simultaneous sealing to one or more parts of the charge flap housing, wherein the at least three sealing zones each comprise at least one sealing lip. Different sealing lips may be provided in this aspect to provide different degrees of protection according to, for example, ISO 20653 and/or DIN EN 60529. 
     In embodiments, the sealing unit provides sealing to different parts of the charge flap housing. Generally, sealing may be provided to any part which needs to be sealed from any environmental influence. For example, sealing may be provided to one or more of a charge socket, to one or more body panels, a charge flap, a locking mechanism and/or a base. The sealing unit may provide sealing to one or more of the aforementioned parts, preferably two or more of the aforementioned parts. However, sealing to other parts of the charge flap housing may also be provided. For example, the sealing may be simultaneously provided to the charge socket, to one or more body panels, the charge flap, the locking mechanism and the base. Furthermore, the different sealing lips may be independently formed from different materials that provide sealing capability. Sealing capability, as used herein, means that the sealing is air-tight, water-tight, and/or dust-tight. In one embodiment, the sealing material is compressible. Suitable materials may be rubber or plastic materials. 
     In another embodiment, the present disclosure provides a charge flap housing of a motor vehicle comprising at least one sealing unit provided herein. 
     In another embodiment, the present disclosure provides a hinge arm assembly for a charge flap arrangement of a motor vehicle, the hinge arm assembly comprises a housing cap having at least one flexible hinge arm support; a charge flap housing coupled partially with the flexible hinge arm support; a hinge arm with a built-in drive shaft clipped into the housing cap and hold in place with clamping force; an actuator coupled to the built-in drive shaft; and at least one sealing component arranged between the actuator and the housing cap. This configuration in particular reduces the amount of components of recent hinge arm assemblies, wherein a direct contact with the driving actuator is provided. Still further, this configuration allows a less complex and time consuming assembly. 
     According to other embodiments, the housing cap may be made from a polymeric material, wherein in another aspect the polymeric material may be a self-lubricating material. Further, the hinge arm material may be selected from polymeric materials, glass-filled polymeric materials, metal materials and metal-alloy materials. In addition, the hinge arm assembly may further comprise a locking mechanism controlled by an electric actuator comprising at least one micro-switch. In another aspect, the locking mechanism may comprise a hook. 
     In another embodiment, the present disclosure provides a method for assembling a hinge arm assembly for a charge flap arrangement of a motor vehicle outlined above, comprising the steps providing a housing cap having at least one flexible hinge arm support; rotating and/or pushing and/or clipping a hinge arm with built-in drive shaft into the housing cap, wherein the at least one flexible hinge arm support provides an assembly space by being molded out of position; and pushing the at least one flexible hinge arm support into final assembled condition, by coupling a part of the charge flap housing to the at least one flexible hinge arm support. According to another embodiment, the method still further comprises the steps of attaching an actuator by pushing the same over the drive shaft; wherein at least one sealing unit is arranged between the actuator and the housing cap. 
     In another embodiment, pushing the at least one flexible hinge arm support into final assembled condition may be achieved by engaging a part of the charge flap housing into a pocket or recess of the hinge arm assembly, wherein the part of the charge flap housing and the pocket or recess form an interference fit. Furthermore, the housing cap may be made from a polymeric material. Still further, the polymeric material is a self-lubricating material. 
     The term “2K,” as used herein, refer to a component comprising at least two different materials. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Embodiments of the present disclosure will be discussed with reference to the accompanying drawings wherein: 
         FIG.  1    is a schematic view of an engaging feature of a charge flap. 
         FIG.  2    is a schematic view illustrating a cross section taken along line A-A of the engaging feature of the charge flap of  FIG.  1   . 
         FIG.  3    is a schematic view illustrating a cross section taken along line C-C of the charge flap arrangement showing a cross section of an embodiment of the sealing unit. 
         FIGS.  4   a  and  4   b    are a schematic views illustrating embodiments of the 2K charge flap housing. 
         FIG.  5    is a schematic view illustrating a cross section taken along line D-D of the charge flap arrangement showing a cross section of an embodiment of the sealing unit. 
         FIG.  6    is a schematic view illustrating a cross section of the charge flap hinge arm and the housing cap in a non-final assembly condition. 
         FIG.  7    is a schematic view illustrating a cross section of the charge flap hinge arm and the housing cap in a final assembly condition. 
     
    
    
     In the following description, like reference characters designate like or corresponding parts throughout the figures. 
     DETAILED DESCRIPTION 
     Dimensional attributes used herein, such as upwards, upper, downwards, lower, inwards, inner, outwards, outer and the like are to be understood in the context of a motor vehicle, in particular a four-wheeled motor vehicle, and its main direction of travel. Furthermore, the ground supporting the motor vehicle is to be considered. 
     Referring now more specifically to  FIG.  1    an enlarged view of an engaging feature  2  mounted in a charge flap arrangement  1 , for example on the charge flap hinge arm  50  or on the inside of the charge flap cover, is shown. According to this embodiment, the engaging feature  2  is located on the left side of the charge flap arrangement  1  opposite to the emerging hinge arm  50 . Pressing the engaging feature  2  leads to an unlocking of the charge flap housing, wherein the engaging feature  2  prevent a flap releasing button  3  from over pressurizing. The force applied to the engaging feature is distributed equally due to the specific form of the engaging feature and/or the material thereof. The engaging feature may be made from a rubber material that provides the necessary stability and force distribution. The engaging feature in this embodiment has a wave form, but may have any other form suitable to provide the necessary overpressure stability. Forces in the range of 5 to 100 N, 5 to 75 N, 5.5. to 52 N or the like can be absorbed. The mechanism is shown in detail in  FIG.  2   . According to the embodiment of  FIG.  2    the flap releasing button  3  is located on the charging socket  30  opposite to the engaging feature  2 . In this embodiment the flap releasing button  3  is a pressure sensor sensing the pressure that is provided by the engaging feature  2  when pressed by a user. The locking in this embodiment (not shown) may be achieved by any means known in the art, such as a mechanical locking mechanism, a magnetic locking mechanism, an electrical locking mechanism, any combination thereof, or the like. 
     Referring to  FIG.  3   , an exemplary embodiment of the inventive sealing unit is depicted. In this embodiment, a cross section along the line C-C of the charge flap arrangement  1  for a motor vehicle comprising a sealing unit  20  is shown. In this embodiment, the charge flap housing  21  comprises the charge flap cover  51  which is the outmost part that can be seen when the charge flap is closed, so that protection of the interior parts of the charge flap housing is provided. The charge flap arrangement  1  comprises charging socket  30 , a body panel  40 , a charge flap hinge arm  50 , a charge flap cover  51  and an inner panel  31 . The sealing unit  20  is formed as an 2K component arranged on the 2K charge flap housing  21  having an inner sealing portion  22  with one sealing lip  23  sealing to the charging socket  30 , an outer sealing portion  24  with two sealing lips  25  sealing to the body panel  40  and one sealing lip  26  sealing to the 2K charge flap hinge arm  50 . With this arrangement several sealing zones are created which may provide similar or different sealing qualities or sealing properties. For example, these sealing lips may provide a different degree of protection according to ISO 20653 and/or DIN EN 60529, such as protection against hazardous parts and the ingress of solid foreign objects (such as dust and the like) and/or protection against spraying water, splashing of water, water jets, immersion in water and the like. The level of protection can be managed by specifically selecting form and amount of the sealing lips and/or the material for each sealing lip. For example, the sealing lips may independently be formed from rubber or plastic material. 
     In other words, the sealing unit  20  is adapted to provide simultaneous sealing to the charging socket  30 , for example of the IP5k4k type, via the one sealing lip  23 , the body panel  40 , for example of the IP6k9k type, via the two sealing lips  25  and the charge flap hinge arm  50 , for example of the IP5k4k type, via the one sealing lip  26 . The amount of sealing lips as well as the sealing device in form of the sealing lips can be varied according to the general knowledge of one skilled in the art. Furthermore, it is well known from those skilled in the art, that the sealing lips can be folded when pressing the charge flap inward and/or the lips can compensate the movement of the pressed charge flap. 
     For example, according to the embodiment of  FIG.  3    a water flow channel and wind noise area X is provided by the outer sealing component  24 , the body panel  40 , charge flap hinge arm  50  and charge flap cover  51 . According to other embodiments, the charge flap cover  51  and the 2K charge flap hinge arm  50  are the same component. 
     According to the specific embodiment of  FIG.  3    the 2K charge flap housing  21  is substantially L-shaped and comprises an inner end supporting the inner sealing portion  22  and an outer end supporting the outer sealing portion, wherein the 2K charge flap housing  21  is adapted to emerge in an outwards direction substantially parallel to a ground (not shown) from its inner end, to bend in an upwards direction, to then continue in an outwards direction substantially parallel to the ground and to bend in an upwards direction substantially orthogonal to the ground to form the outer end of the central sealing portion  21 . The inner sealing portion  22  is formed at the inner end of the central ceiling portion  21 , wherein the inner sealing portion  22  is adapted to emerge in a substantially downwards direction and to form the sealing lip  23  by bending in an outwards direction. The outer sealing portion  24  comprises an upper end and a lower end and is formed at and substantially parallel to the outer end of the 2K charge flap housing  21 , wherein the lower end of the outer sealing portion  24  is adapted to emerge in a substantially outwards direction to form the sealing lip  26 , and the upper end of the outer sealing portion  24  is adapted to emerge in a substantially upwards and inwards direction to form one of the two sealing lips  25  and is adapted to emerge in a substantially upwards and outwards direction to form the other one of the two sealing lips  25 . Other configurations are also encompassed by the present invention. 
     In an installed configuration, the sealing lip  23  of the inner sealing portion  22  is in contact with the charging socket  30 , the two sealing lips  25  of the outer sealing portion  24  are in contact with the body panel  40  and the sealing lip  26  of the outer sealing portion  24  is in contact with the charge flap hinge arm  50 . According to other embodiments, the sealing lip  26  of the outer sealing portion  24  may be in contact with the charge flap cover  51 . 
       FIGS.  4   a  and  4   b    show embodiments of the 2K charge flap housing  21  comprising the sealing unit  20  of  FIG.  3    and a secondary sealing unit  27  for sealing the secondary actuator M 2 . The sealing unit  20  is formed around the inner rim of a primary opening of the 2K charge flap housing  21  and adapted to provide sealing between the 2K charge flap housing  21  and the charge flap hinge arm  50  and subsequently the charge flap cover  51  in a closed configuration. The secondary sealing unit  27  is formed around the inner rim of a secondary opening of the 2K charge flap housing  21  and adapted to provide sealing between a secondary actuator M 2  and the 2K charge flap housing  21 . The secondary actuator M 2  is adapted to lock and unlock the 2K charge flap hinge arm  50  in a closed configuration via a locking part  100  that may be formed as a hook. Further, the secondary actuator M 2  may be configured as an electromotive actuator having a micro-switch that may be controlled by the first actuator M 1  that actuates the 2K charge flap hinge arm  50 . According to the an embodiment, the secondary actuator M 2  operates with an electrical forward rotation but with a reverse rotation via spring return and a soft touch button (not shown). 
       FIG.  5    shows a cross section defined by the section cut D-D of the 2K charge flap arrangement  1  comprising the charge flap hinge arm  50 , wherein the 2K charge flap housing  21  of the 2K charge flap arrangement  1  comprises a housing cap  70 . Further, it is shown another section of the sealing unit  20  sealing the housing cap  70  with an upper sealing portion  62  and one sealing lip  63 . The sealing lip  63  of the upper sealing portion  62  is adapted to provide sealing for example of the IP4k5k type. Other sealing types are also encompassed by this embodiment. 
     In an assembled configuration of this embodiment, the sealing lip  63  of the upper sealing portion  62  is in contact with an outer surface of the housing cap  70 , wherein the upper sealing portion  62  is in contact with a lower surface of the housing cap  70 . In addition, the 2K charge flap housing  21  is in contact with an outer and a lower surface of the housing cap  70 . 
       FIG.  6    shows an exemplary cross section of an embodiment of the charge flap hinge arm  50 , further comprising a built-in driveshaft  52  in a non-final assembly condition, wherein the charge flap hinge arm  50  has been clipped into the housing cap  70 . In this embodiment, the housing cap  70  comprises a flexible hinge arm support  71  and two natural bearing surfaces  72 . The two natural bearing surfaces  72  may be formed from any material suitable for supporting the charge flap hinge arm  50  in stability and movement. For example, the housing cap  70  may be made from a polymeric material but is not limited thereto. In the embodiment here, the housing cap  70  and thus the bearing surfaces  72  are made from a self-lubricating polymer. A self-lubricating material is generally preferred. The dashed-dotted line represents the rotational axis of the built-in driveshaft  52  of the charge flap hinge arm  50 . The built-in driveshaft  52  of the charge flap hinge arm  50  is supported by only one natural bearing surface  72  and the flexible hinge arm support  71 , wherein the flexible hinge arm support  71  providing the second natural bearing surface  72  is bent away from the in-built driveshaft  52  in the non-final assembly condition and thus providing an assembly space  75 . 
     Furthermore,  FIG.  6    shows an assembly portion  80  of the charge flap housing  21 , that are prepared to be assembled into the respective pocket  74  of the housing cap  70 . Further, the sealing component  90  and primary actuator M 1  are shown in a non-assembled condition. According to this embodiment, the primary actuator M 1  is provided as an active grille shutter actuator and is adapted to have integrated LIN electronics as well as diagnostics and a follow control, wherein the secondary actuator M 2  (shown in  FIG.  4   b   ) may be controlled by the status of the primary actuator M 1 . Both the primary actuator and the secondary actuator is not limited to this specific embodiment and any actuator known in the art to be suitable for this purpose can be used. 
       FIG.  7    shows the same cross section as  FIG.  6    but in a final assembling condition, wherein the flexible hinge arm support  71  providing the second natural bearing surfaces  72  is bent towards the built-in drive shaft  52  by the assembly portion  80  of the charge flap housing  21  in a final position. Further, in the final assembling position, the built-in driveshaft  52  of the charge flap hinge arm  50  is now supported by two natural bearing surfaces  72 . The sealing component  90  is pushed onto the housing cap  70  and built-in driveshaft  52  for sealing the first natural bearings  72  and in some embodiments to reduce flutter in the system. The primary actuator M 1  is pushed onto the built-in drive shaft  52 , after the sealing component  90  is in its final position. 
       FIGS.  6  and  7    furthermore illustrate the steps to be done of the assembly of the charge flap arrangement  1 : The charge flap hinge arm  50  comprising the built-in driveshaft is assembled by being rotated, pushed and/or clipped into the housing cap  70 . To facilitate the assembly of the charge flap hinge arm  50 , the housing cap  70  is moulded with a flexible hinge arm support  71  which is adapted to be flexible in both directions within the elastic limit of its material. While the charge flap hinge arm  50  is clipped into the housing cap  70 , the flexible hinge arm support  71  is bent away from the built-in drive shaft  52 , in order to provide an assembly space  75 . To finalize the assembly of the charge flap arrangement  1 , the assembly portion  80  of the charge flap housing  21  is pushed into a pocket  74  of the housing cap  70 , causing the flexible hinge arm support  71  to be bent towards the built-in drive shaft  52 , thereby rotatably fixating the charge flap hinge arm  50  in the final position in the housing cap  70 . 
     Variations and modifications of the foregoing are within the scope of the present disclosure. It is understood that the disclosure disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present disclosure. The embodiments described herein explain the best modes known for practicing the teaching of the present disclosure and will enable others skilled in the art to utilize the teaching of the present disclosure. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use herein of “including”, “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items and equivalents thereof. 
     Various features of the disclosure are set forth in the following claims. 
     REFERENCE SIGN LISTING 
     
         
           1  charge flap arrangement 
           2  engaging feature 
           3  flap releasing button 
           20  sealing unit 
           21  2K charge flap housing 
           22  inner sealing portion 
           23  sealing lip 
           24  outer sealing portion 
           25  sealing lip 
           26  sealing lip 
           27  secondary sealing unit 
           30  charging socket 
           31  inner panel 
           40  body panel 
           50  2K charge flap hinge arm 
           51  charge flap cover 
           52  built-in driveshaft 
           62  upper sealing portion 
           63  sealing lip 
           70  housing cap 
           71  flexible hinge arm support 
           72  natural bearing surface 
           74  assembly pocket 
           75  assembly space 
           80  assembly portion of the charge flap housing 
           90  sealing component 
           100  locking part 
         X water flow channel and wind noise area 
         M 1  primary actuator 
         M 2  secondary actuator