Patent Description:
Electric vehicles and hybrid electric vehicles often have an electric charge port for charging an electric battery with an external power source. The charge port is typically externally mounted, thereby allowing easy access as well as the possibility to lock the passenger compartment while the vehicle is being charged. A charge port door, or charge port flap, usually covers the charge port and must be opened to access the charge port to charge the battery.

The opening and closing of the charge port door may be fully automated by the means of a mechanism assembly comprising one or more electric actuators. The mechanism is configured to transform the movement of the actuator by means of different linkages, among which arms or levers. The kinematic of the actuation mechanism may be configured to multiply the movement generated by the actuator. When an intense load is applied on the charge port door, for instance by an ill-intentioned person, the load exerted on the door is, due to the kinematic of the mechanism, multiplied towards the actuator. Therefore an intense load exerted on the charge port door can break the actuator. Such a situation must of course being avoided as much as possible. Examples of charging ports are disclosed in prior art documents <CIT>, <CIT>, <CIT> and <CIT>.

An object of the invention is to provide a charge port door assembly equipped with an actuation system for automatically opening and/or closing the charge port door, the actuation system being configured to safe the actuator when a high intensity load is exerted on the door, for example in case of a break-in attempt.

To this end, the invention relates to a charge port door assembly for a vehicle, comprising:.

the actuation lever assembly comprising an actuation lever and an elastic biasing device, the actuation lever being rotatably coupled at a first end to the output member of the actuator and being rotatably coupled at a second end to the actuation arm, the actuation lever being moveable relative to the output member between an engagement position and an extended position, the elastic biasing device being configured to bias the actuation lever towards the engagement position.

Thus, the charge port door assembly is protected against breakage and damage of the actuation system: thanks to the actuation lever assembly, the actuation system is able to withstand the loads that are transmitted to the actuation system when a very intense force is exerted on the door, for example during a break-in attempt. In such a case, the actuation lever moves to an extended configuration, thereby letting the door move from its closed position towards its open position without inducing excessive loads on the actuation system, and in particular on the actuator. The actuation lever assembly according to the invention therefore provides a safety feature that prevents breakage of the actuation system, and in particular of the actuator, in case a very intense force is exerted in the door, for example during a break-in attempt.

The charge port door assembly may comprise the following features, considered either alone or in any technically possible combination:.

When the output member is in the first position and the actuation lever is in the engagement position, the door is in the closed position, and when the output member is in the first position and the actuation lever is in the extended position, the door is in the open position.

When the actuation lever is in the engagement position, a blocking part of the output member bears on a bearing part of the actuation lever.

The elastic biasing device is configured to allow the actuation lever moving from the engagement position when the actuation lever is subjected to a load which is higher than a specified load.

The specified load is lower than a load likely to damage the actuation system, and in particular the actuator.

The specified load is higher than a maximum load to which the actuation lever is subjected during normal operation of the actuation system.

The elastic biasing device is a spring, for example a coil torsion spring.

The spring rate of the spring is such that the actuation lever reaches the extended position when the actuation lever is subjected to a load, the value of which is lower than the value of a load likely to damage the actuation system, and in particular the actuator.

The elastic biasing device is a coil torsion spring positioned around a cylindrical portion of the output member, in such a way that the spring biases the blocking part and the bearing part towards each other.

The actuator is an electric rotary actuator.

The linkage includes a first lever and a second lever, each of the first and second levers being hinged, at one end, to the support and being hinged, at an opposite end, to the door, the first and second levers being configured as a parallelogram mechanism.

The actuation system includes a mechanical actuation device, the mechanical actuation device comprising a mechanical link, such as a Bowden cable or a rod, connected to the actuation lever.

The invention also relates to a vehicle comprising a charge port mounted on a support and a charge port door assembly as disclosed above.

<FIG> illustrates a vehicle <NUM> having at least one electric propulsion motor, such as an electric vehicle or a plug-in hybrid electric vehicle. The vehicle is equipped with a charge port (not shown) configured to be connected to a charge plug when the car needs to be charged. The vehicle <NUM> is also equipped with a charge port door assembly <NUM> according to the invention, in order to cover and protect the charge port when the latter is not in use.

<FIG> illustrate an embodiment of a charge port door assembly according to the invention.

The charge port door assembly <NUM> comprises a door <NUM> moveable between a closed position (shown in <FIG>), in which the door blocks access to the charge port, and an open position (shown in <FIG>), in which the door permits access to the charge port.

The charge port door assembly <NUM> is mounted onto a charge port support (not shown) which is fixed relative to the vehicle <NUM>. In its closed position, the door <NUM> is flush with an outer surface of an exterior panel 1a of the vehicle <NUM>, for example a front fender 1a as shown in <FIG>. In its open position, the door <NUM> uncovers an opening in the panel 1a, thereby allowing access to the charge port.

The door <NUM> is attached to the support by means of an actuation system <NUM>. The actuation system <NUM> is configured for automatically moving the door from its closed position to its open position and inversely. To this end, the actuation system <NUM> includes a linkage <NUM> and an actuator <NUM>. The actuator <NUM> is fixed relative to the support of the charge port and is for example an electric rotary actuator.

The linkage <NUM> connects the door <NUM> to the support. The linkage <NUM> includes a lever parallelogram. More particularly, the linkage <NUM> includes a first lever <NUM> and a second lever <NUM>. The first lever <NUM> is hinged at one end <NUM> to the support and is hinged at an opposite end <NUM> to the door <NUM>. In the embodiment of <FIG> and <FIG>, the first lever <NUM> comprises two connecting arms 22a, 22b, each of the connecting arms having an end 222a, 222b hinged to the door <NUM>. The second lever <NUM> is hinged at one end <NUM> to the support and is hinged at an opposite end <NUM> to the door <NUM>. The first lever <NUM> and the second lever <NUM> are thus configured as a parallelogram mechanism (or parallelogram four-bar linkage), which allows maintaining a constant orientation of the door <NUM> during its motion. It will however being understood that the actuation system could be configured to achieve a different kind of movement for the door without departing from the scope of the invention.

The linkage <NUM> comprises an actuation lever assembly <NUM> which is connected to a rotating output shaft <NUM> of the actuator <NUM>, and an actuation arm <NUM> which is connected to the first lever <NUM>. The actuation lever assembly <NUM> includes an actuation lever <NUM> which is connected, via a releasable rotational connection, to the output shaft <NUM> at a first end <NUM> and is rotatably coupled to the actuation arm <NUM> at an opposite, second end <NUM>. The actuation arm <NUM> is rotatably coupled, at a first end <NUM>, to the actuation lever <NUM> and is rotatably coupled, at an opposite, second end <NUM>, to the first lever <NUM>. The actuation arm <NUM> is connected to the first lever <NUM> at a pivot point, which is distinct of the pivot point between the first lever <NUM> and the support. The linkage <NUM> is thus configured to transmit, during normal actuation of the charge port door assembly, the rotational movement of the output shaft <NUM> of the actuator <NUM> to the first lever <NUM>, via the actuation lever <NUM> and the actuation arm <NUM>.

According to the invention, the connection between the actuation lever <NUM> of the actuation lever assembly <NUM> and the output shaft <NUM> is a releasable rotational connection. In particular, the rotational connection is released if the torque exerted by the actuation lever <NUM> on the output shaft <NUM> exceeds a specified value. To this end, the actuation lever <NUM> can rotate relative to the output shaft <NUM> between an engagement position and an extended position, and the actuation lever assembly <NUM> includes an elastic biasing device <NUM>, such as a torsion spring <NUM>, configured to bias the actuation lever <NUM> towards the engagement position.

As the actuation lever <NUM> is biased by the elastic biasing device <NUM>, the actuation lever <NUM> may rotate relative to the output shaft <NUM>, from its engagement position to its extended position (or to any intermediate position), only if the actuation lever <NUM> is subjected to a load opposite and higher than the load exerted by the spring <NUM>. In such a case, as shown in <FIG> and <FIG>, the rotation of the actuation lever <NUM> will result in the displacement of the actuation arm <NUM> and therefore of the first lever <NUM>, in particular when a high intensity force is exerted on the door <NUM> and the actuator <NUM> is not energized. In an embodiment, the actuation lever assembly <NUM> is configured to allow the door <NUM> moving from its closed position to its open position without involving any movement of the output shaft <NUM>, thereby preventing any damage to the actuator <NUM>. More particularly, the actuation lever assembly <NUM> is configured to let the actuation lever <NUM> rotate relative to the output shaft <NUM> upon application of a pulling force F on the door <NUM>, the pulling force F inducing on the actuation lever assembly a load having an intensity higher than a specified intensity, in particular when the actuator <NUM> is not energized. Of course, the actuation lever assembly <NUM> is configured not to let the actuation lever <NUM> rotate when it is subjected only to loads generated during normal actuation of the charge port door assembly. This is achieved thanks to the tuning of the value of the spring rate of the elastic biasing device <NUM>. In particular, the spring rate value is such that the elastic biasing device will allow the actuation lever <NUM> moving from the engagement position when subjected to a load lower than a load likely to damage or break the actuator <NUM>. The actuation lever assembly <NUM> according to the invention therefore provides a safety feature that prevents breaking of the actuation system, and in particular of the actuator <NUM>, in case a very intense force is exerted in the door <NUM>, for example during a break-in attempt.

The actuation lever assembly <NUM> is shown more in detail in <FIG>. As mentioned above, the actuation lever <NUM> is connected to the output shaft <NUM> at a first end <NUM> and is connected to the actuation arm <NUM> at an opposite, second end <NUM>. At its first end <NUM>, the actuation lever <NUM> comprises a first connecting part <NUM> having a circular opening 304a configured to be positioned around the output shaft <NUM>. At its second end <NUM>, the actuation lever <NUM> comprises a second connecting part <NUM> having at least one circular opening 306a configured to be connected to the actuation arm <NUM>, for example by means of an axle (not shown). As shown in <FIG>, the connecting part may have two openings 306a, each opening being part of a respective wall 306b, the two walls being spaced so that the first end <NUM> of the actuation arm <NUM> can be located within the space delimited by the two walls 306b. It will be understood that the distance between the center of the circular opening 304a of the first connecting part <NUM> and the center of the circular opening(s) 306a of the second connecting part <NUM> will be not null, so as to provide a lever arm allowing the actuation arm <NUM> to exert a torque on the actuation lever <NUM> when a pulling force F is exerted on the door <NUM>.

The circular opening 304a of the first connecting part <NUM> is positioned around a cylindrical portion <NUM> of the output shaft <NUM>. The cylindrical portion <NUM> is located between a first connecting part <NUM> and a second connecting part <NUM> of the output shaft <NUM>. The first connecting part <NUM> is configured to be connected to an output connecting part (not shown) of the actuator <NUM>. The second connecting part <NUM> has a cylindrical portion <NUM> which is configured to be received within the elastic biasing device <NUM>, which is a coil torsion spring <NUM>, the latter being arranged around the cylindrical portion <NUM>. The second connecting part <NUM> has a blocking part <NUM> protruding, for example along a radial direction, from the cylindrical portion <NUM>. The blocking part <NUM> is configured to bear, when the actuation lever <NUM> is in the engagement position, on a corresponding bearing part <NUM> provided on the actuation lever <NUM> (for example at a bottom end of the wall(s) 306b, thereby preventing relative rotation of the actuation lever <NUM> and the output shaft <NUM>. The blocking part <NUM> is, at least partially along an axial direction, spaced from the outer surface of the cylindrical portion <NUM>, thereby allowing a portion of the spring <NUM> to be positioned between the blocking part <NUM> and the cylindrical portion <NUM>. A first end <NUM> of the spring <NUM> bears against the blocking part <NUM> whereas an opposite, second end <NUM> of the spring <NUM> bears against the bearing part <NUM> of the actuation lever <NUM>, thereby allowing the spring <NUM> to bias the bearing part <NUM> and the blocking part <NUM> towards each other, that is, biasing the actuation lever <NUM> towards its engagement position.

Claim 1:
A charge port door assembly (<NUM>) for a vehicle (<NUM>), comprising :
- a charge port door (<NUM>);
- an actuation system (<NUM>), configured to move the charge port door (<NUM>) between a closed position, in which the door (<NUM>) is intended to cover a charge port of a vehicle (<NUM>) and to remain flush with an outer surface of the vehicle (<NUM>), and an open position, in which the door (<NUM>) is intended to permit access to the charge port, the actuation system (<NUM>) comprising a linkage (<NUM>) connecting the door (<NUM>) to a support intended to be fixed relative to the vehicle (<NUM>), and an actuator (<NUM>) configured to actuate the linkage (<NUM>) to move the door (<NUM>),
the actuation system (<NUM>) further comprising at least an actuation arm (<NUM>), the actuation arm (<NUM>) being connected, at a first end (<NUM>), by the means of an actuation lever assembly (<NUM>), to an output member (<NUM>) of the actuator (<NUM>), and being directly or indirectly connected at an opposite, second end (<NUM>) to the door (<NUM>), the output member (<NUM>) being movable between a first position corresponding to the closed position of the door (<NUM>) and a second position corresponding to the open position of the door (<NUM>),
characterized in that
the actuation lever assembly (<NUM>) comprising an actuation lever (<NUM>) and an elastic biasing device (<NUM>), the actuation lever (<NUM>) being rotatably coupled at a first end (<NUM>) to the output member (<NUM>) of the actuator (<NUM>) and being rotatably coupled at a second end (<NUM>) to the actuation arm (<NUM>), the actuation lever (<NUM>) being moveable relative to the output member (<NUM>) between an engagement position and an extended position, the elastic biasing device (<NUM>) being configured to bias the actuation lever (<NUM>) towards the engagement position.