CN117127864A - Fuel/charge port door assembly override system and method - Google Patents

Abstract

The present disclosure provides a "fuel/charge port door assembly override system and method". The present disclosure relates to a vehicle assembly including a movable door assembly. Examples of vehicle assemblies having a moveable door assembly include a charging port housing assembly and a fueling housing assembly. An exemplary vehicle assembly may include an override retainer. The override retainer may include a flexible flap or clip configured to deflect or otherwise deform to release the latch assembly from the door assembly when a manual override force is applied to the door assembly.

Description

Fuel/charge port door assembly override system and method

Technical Field

The present disclosure relates to vehicle assemblies including movable door assemblies, and more particularly to vehicle charging port/refuelling housing assemblies including an override retainer configured to allow manual release of the door assembly.

Background

Motor vehicles are known that include a fuel door and/or a charging port door configured to rotate between an open position and a closed position to selectively expose and cover a fuel inlet conduit or charging port. Some doors may be locked in a closed position. For example, plug-in hybrid electric vehicles (PHEVs) sometimes lock the fuel door when the fuel is pressurized.

Disclosure of Invention

A vehicle assembly according to an exemplary aspect of the present disclosure includes, among other things: a door assembly configured to move between a closed position and an open position; a latch assembly configured to selectively lock the door assembly in a closed position; and an override retainer configured to deflect to release the latch assembly from the door assembly when a manual override force is applied to the door assembly.

In another non-limiting embodiment of the foregoing vehicle assembly, the door assembly includes a fuel door or a charging port door.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, a manual override force is applied to the door assembly by a tool in response to a failure of the latch assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the override retainer includes a central ring and a pair of flexible retention wings extending outwardly from the central ring.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the centering ring is received around a barrel of the latch assembly and the flexible retention flap engages a surface of the hinge arm of the door assembly that is positioned adjacent the latch assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the pair of flexible retention wings are configured to deflect upon application of a manual override force to release the latch assembly from the door assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the override retainer includes a first retaining clip positioned adjacent a first side of the latch assembly and a second retaining clip positioned adjacent a second side of the latch assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, each of the first and second retention clips includes an attachment portion, a deflection portion, a reengagement portion, a shelf portion, and a free end portion.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the attachment portion is secured to a surface of a hinge arm of the door assembly, and the shelf portion is configured to engage a T-bar of the latch assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the deflection point of the deflecting portion deflects when a manual override force is applied. The deflection of the deflection point displaces the shelf portion in a direction away from the T-bar to release the latch assembly from the door assembly.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the latch assembly includes a T-bar movable between a first position and a second position transverse to the first position.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the vehicle assembly is part of a vehicle that includes a body member. The door assembly is movable relative to the body member when moving between a closed position and an open position.

In another non-limiting embodiment of any of the foregoing vehicle assemblies, the body component is a curb plate or a fender.

A method according to another exemplary aspect of the present disclosure includes, among other things, deflecting an override retainer to release a latch assembly from a door assembly of a vehicle charging port housing assembly or a vehicle refueling housing assembly during a manual override event in which a manual override force is applied to the door assembly.

In another non-limiting embodiment of the foregoing method, the override retainer is integrally formed with the hinge arm of the door assembly.

In another non-limiting embodiment of any of the foregoing methods, the override retainer is molded with the hinge arm as part of a two-shot molding process.

In another non-limiting embodiment of any of the foregoing methods, deflecting the override keeper includes allowing a T-bar of the latch assembly to be displaced from the override keeper.

In another non-limiting embodiment of any of the foregoing methods, deflecting the override holder includes deforming a flexible retention flap of the override holder.

In another non-limiting embodiment of any of the foregoing methods, deflecting the override holder includes deforming a flexible clip of the override holder.

In another non-limiting embodiment of any of the foregoing methods, the override keeper is configured to allow a portion of the latch assembly to return through the override keeper when the door assembly is closed after a manual override event, thereby re-engaging the override keeper, and thus the door assembly, relative to the latch assembly.

The embodiments, examples and alternatives of the foregoing paragraphs, claims or the following description and drawings (including any of their various aspects or corresponding individual features) may be employed independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

Various features and advantages of this disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.

Drawings

Fig. 1 shows a vehicle equipped with a charging port housing assembly.

Fig. 2 is an enlarged view of the charging port housing assembly of the vehicle of fig. 1.

Fig. 3A and 3B illustrate an unlocked position of the door assembly of the charging port housing assembly of fig. 1 and 2.

Fig. 4A and 4B illustrate a locked position of the door assembly of the charging port housing assembly of fig. 1 and 2.

Fig. 5 schematically illustrates a door assembly using a pry to manually open a charging port housing assembly.

FIG. 6 illustrates an exemplary door assembly of the charging port housing assembly.

Fig. 7 is an enlarged view of portions of the door assembly of fig. 6.

FIG. 8 illustrates another exemplary door assembly of a charging port housing assembly.

Fig. 9 is an enlarged view of the door assembly of fig. 8.

Fig. 10 shows a retaining clip of the door assembly of fig. 8-9.

FIG. 11 illustrates selected portions of a vehicle equipped with a refuel housing assembly.

Detailed Description

The present disclosure relates to a vehicle assembly including a movable door assembly. Examples of vehicle assemblies having a moveable door assembly include a charging port housing assembly and a fueling housing assembly. An exemplary vehicle assembly may include an override retainer. The override retainer may include a flexible flap or clip configured to deflect or otherwise deform to release the latch assembly from the door assembly when a manual override force is applied to the door assembly. These and other features of the present disclosure are described in more detail below.

FIG. 1 illustrates an exemplary motor vehicle 10. In one embodiment, the vehicle 10 is an motorized vehicle that includes any motorized driveline capable of applying torque from an electric machine to drive the drive wheels 12 of the vehicle 10. The vehicle 10 may be, for example, a plug-in hybrid electric vehicle (PHEV) or a Battery Electric Vehicle (BEV). Thus, the driveline may electrically propel the drive wheels 12 with or without internal combustion engine assistance.

The vehicle 10 of fig. 1 is schematically illustrated as a Sport Utility Vehicle (SUV). However, the teachings of the present disclosure may be applied to any type of vehicle, including but not limited to cars, trucks, vans, SUVs, and the like.

The vehicle 10 may include a charging port housing assembly 14 configured to charge an energy storage device (e.g., a battery cell of a traction battery pack) of the vehicle 10. The charging port housing assembly 14 may include a door assembly 16 movably mounted with respect to a body member 18. In one embodiment, the body member 18 is a rear side panel of the vehicle 10. However, the charging port housing assembly 14 may be disposed elsewhere on the vehicle 10, such as, for example, within the front fascia 19 of the vehicle 10. Further, while a charge port door assembly 16 is shown in this embodiment, similar door assemblies may be used with other types of vehicle assemblies, such as, for example, a fuel filler housing assembly (see, for example, the embodiment of fig. 11).

The door assembly 16 may include a charging port door 22 and a hinge arm 24 (see fig. 2) connected to the charging port door 22. The hinge arm 24 pivotally connects the charging port door 22 relative to the body member 18 to move between a closed position and an open position. The door assembly 16 is shown in a closed position in fig. 1 and in an open position in fig. 2. In the closed position, the door assembly 16 covers one or more charging ports 20 of the charging port housing assembly 14. The charging port 20 may be mounted within a housing 26 of the charging port housing assembly 14, and the housing 26 may be mounted with respect to the body member 18.

When it is desired to charge the vehicle 10 from an external power source, the door assembly 16 may be moved from the closed position shown in FIG. 1 to the open position shown in FIG. 2. The user may then couple the charger to the charging port 20 of the charging port housing assembly 14 so that power from an external power source may be provided for charging the energy storage device of the vehicle 10. The charging port 20 may be configured to receive AC power, DC power, or both from an external power source.

Referring now primarily to fig. 2, 3A, 3B, 4A and 4B, the charging port housing assembly 14 may additionally include a latch assembly 28 adapted to lock the door assembly 16 when moved to a closed position. The latch assembly 28 may be positioned within the housing 26 of the charging port housing assembly 14, such as at a location generally opposite the location of the housing 26 where the hinge arms 24 interface with the housing 26. However, the particular location of the latch assembly 28 arrangement relative to the housing 26 is not intended to limit the present disclosure.

The latch assembly 28 may be configured to allow locking of the door assembly 16 during normal conditions (i.e., during normal use). For example, an owner may wish to lock the door assembly 16 to prevent tampering with the charging port housing assembly 14.

The latch assembly 28 may include a T-bar 30 that interfaces with an opening 32 formed in the hinge arm 24. The T-bar 30 may be received through the opening 32 and into the space formed between the charging port door 22 and the hinge arm 24 to lock the door assembly 16.

The latch assembly 28 is shown in an unlatched position in fig. 3A and 3B. In this position, the T-bar 30 is oriented in a position substantially aligned with the longitudinal axis A of the opening 32, and thus, the door assembly 16 is free to move relative to the latch assembly 28.

The latch assembly 28 is shown in the locked position in fig. 4A and 4B. This position may occur when the charging port door 22 is pushed closed. When the charging port door 22 is pushed to the closed position, the charging port door 22 pushes against a vertical rod 25 disposed in the space between the charging port door 22 and the hinge arm 24. When the charging port door 22 is pushed, the vertical rod 25 contacts the T-bar 30, thereby linearly moving the T-bar 30 relative to the barrel 34 of the latch assembly 28, and then rotating about 90 °. Upon rotation, the T-bar 30 is oriented in a transverse position relative to the longitudinal axis A of the opening 32. In the rotated position, the outer ear portion 36 of the T-bar 30 may engage the tab 38 of the hinge arm 24 to prevent the T-bar 30 from moving rearward through the opening 32, thereby locking the door assembly 16. To unlock the door assembly 16, the charging port door 22 may be pushed again, triggering the reverse order of rotation of the T-bar 30 back to the position shown in fig. 3A and 3B.

The door assembly 16 of the charging port housing assembly 14 may be undesirably held in a closed position. For example, the latch assembly 28 may fail. Further, the latch assembly 28 may hold the door assembly 16 closed during a fuel tank pressurization sequence (such as those typically used on HEVs). A user may confuse this with a faulty latch and/or door assembly, and thus the user may attempt to pry open the door assembly 16.

Regardless, a user may use tool 40 (see, e.g., fig. 5) to pry open door assembly 16. Specifically, the user may use the tool 40 to apply a manual override force of sufficient magnitude to disengage the door assembly 16 from the latch assembly 28. The tool 40 may be a known tool such as, for example, a flat head screwdriver, or may be a specific tool such as, for example, the tool disclosed in U.S. patent publication 2020/0346541 assigned to ford global technology liability company (Ford Global Technologies, LLC). The particular design of tool 40 is not intended to limit the present disclosure.

Fig. 6 and 7 illustrate an exemplary override retainer 42 that may be incorporated as part of the charging port housing assembly 14. The override retainers 42 are configured to provide manual release of the door assembly 16 when a manual override force is applied thereto.

The override retainers 42 may be fixed relative to the hinge arms 24 of the door assembly 16. In one embodiment, the override retainer 42 is directly attached to the hinge arm 24 near the opening 32. In another embodiment, the override retainers 42 are integrally molded into the hinge arms 24 at the location of the openings 32. The override keeper 42 may be mounted/molded at any location sufficient to interface with the T-bar 30 of the latch assembly 28.

The hinge arm 24 and override retainer 42 may be injection molded using a two shot molding process. The first material shot (i.e., the hard shot) provides the hinge arms 24. The second material shot (i.e., soft shot) provides the override keeper 42. The secondary injection process facilitates incorporation of the override retainers 42 within the hinge arms 24 during the molding process.

The override retainer 42 may include a central ring 44 and two more flexible retention wings 46 extending outwardly from the central ring 44. A central ring 44 surrounds the central opening 45 and may be received around the barrel 34 of the latch assembly 28. Each of the flexible retention wings 46 may extend along a curved path and may engage a surface 48 of the hinge arm 24 that is positioned adjacent to the latch assembly 28.

The override retainers 42 may be constructed of a flexible material to allow bending, deflection, deformation, etc. thereof. Exemplary materials include rubber, polypropylene, and glass reinforced thermoset polyester sheets. However, other flexible materials are also contemplated within the scope of the present disclosure. The geometry and material stiffness of the override holder 42 may be adjusted to achieve a desired level of flexibility within the flexible retention wings 46 of the override holder 42.

The override retainers 42, and in particular the flexible retention wings 46, are configured to deflect or otherwise deform when a threshold amount of manual override force is applied to the door assembly 16. When the flexible retention wings 46 are deformed, the T-bar 30 of the latch assembly 28 may slide through the central opening 45, thereby releasing the latch assembly 28 from the door assembly 16 and allowing the door assembly 16 to swing open.

The flexibility of the override retainer 42 may also allow the T-bar 30 to return through the central opening 45 when the door assembly 16 is subsequently closed again. Thus, the override retainers 42 may be repeated for multiple door opening/closing cycles.

Fig. 8, 9 and 10 illustrate another exemplary override retainer 50 that may be incorporated as part of the charging port housing assembly 14. The override keeper 50 embodies a different design than the override keeper 42 discussed above. Like the override retainers 42, the override retainers 50 are configured to permit manual release of the door assembly 16 when a manual override force of a sufficient threshold is applied thereto.

The override retainers 50 may be fixed relative to the hinge arms 24 of the door assembly 16. In one embodiment, the override holder 50 is directly attached to the hinge arm 24 near the opening 32. In another embodiment, the override retainers 50 are integrally molded into the hinge arms 24 at the location of the openings 32. The override keeper 50 may be mounted/molded at any location sufficient to interface with the T-bar 30 of the latch assembly 28.

The hinge arm 24 and override retainer 50 may be injection molded using a two shot molding process. The first material shot (i.e., the first hard shot) provides the hinge arms 24. The second material shot (i.e., the second hard shot) provides an override holder 50. The secondary injection process facilitates incorporation of the override holder 50 within the hinge arm 24 during the molding process.

The override retainer 50 may include a first retention clip 52 and a second retention clip 54. The first and second retention clips 52, 54 may be disposed on opposite sides of the latch assembly 28 and configured to interface with the T-bar 30. Each retention clip 52, 54 may include a U-shape or V-shape and may engage a surface 56 of the hinge arm 24.

Each retention clip 52, 54 may be constructed of a rigid plastic material. The material composition of the retention clips 52, 54 may be specifically tailored to provide a desired level of flexibility when deflected or otherwise deformed. In one embodiment, the retention clip 52 is made of the same material as the hinge arms 24.

The first retention clip 52 of the override retainer 50 is further illustrated with reference to fig. 10. It should be appreciated that the second retention clip 54 will comprise substantially the same design as the first retention clip 52.

The first retention clip 52 may include an attachment portion 58, a deflection portion 60, a reengagement portion 62, a shelf portion 64, and a free end portion 66. The attachment portion 58 may be fixed to or integrally formed within the surface 56 of the hinge arm 24. The deflection portion 60 may be connected to the attachment portion 58 and establish a deflection point 68 of the first retention clip 52. The reengaging portion 62 may be connected to the deflecting portion 60 and may extend at an angle between the deflecting portion 60 and the shelf portion 64. The shelf portion 64 may be located at an end of the reengaging portion 62 opposite the deflecting portion 60. The free end portion 66 may extend away from the shelf portion 64 and be free to swing relative to the hinge arm 24.

When a manual override force of sufficient magnitude is applied to the door assembly 16, the free end portion 66 of each retention clip 52, 54 may move in the direction of arrow 70 (i.e., toward the charging port door 22), resulting in a deflection at the deflection point 68 of the deflection portion 60. The deflection causes the shelf portion 64 to displace in the direction of arrow 75 (i.e., away from the T-bar 30), thereby releasing the latch assembly 28 from the door assembly 16 and allowing the door assembly 16 to swing open.

When the door assembly 16 is then pushed closed again, the T-bar 30 may engage the reengaged portion 62 of each of the retention clips 52, 54 to guide the retention clips 52, 54 back into place. When the T-bar 30 engages the reengaged portion 62, deflection occurs at a deflection point 68 of the deflected portion 60. The deflection allows the shelf portion 64 to reposition itself to reengage the T-bar 30 and allow the door assembly 16 to close properly. Thus, the override retainers 50 may be repeated for multiple door opening/closing cycles.

Fig. 11 shows selected portions of another vehicle 110. Vehicle 110 may be a car, truck, van, SUV, or any other type of vehicle. Vehicle 110 may also be a conventional internal combustion engine-driven vehicle, a traction battery-driven Hybrid Electric Vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), or the like.

The vehicle 110 includes a fuel-filled housing assembly 72 for delivering fuel to a fuel tank (not shown) that stores fuel (e.g., gasoline, diesel, etc.) necessary to power a power source (e.g., an internal combustion engine) of the vehicle 110. The fueling housing assembly 72 may include a door assembly 74 movably mounted relative to a body member 118 (e.g., a curb plate, a trim plate, etc.). Door assembly 74 is substantially similar to door assembly 16 of the charging port housing assembly discussed above.

The door assembly 74 is movable between an open position and a closed position to selectively expose and cover the fuel compartment 76. A fuel inlet conduit 78 connected to a fuel tank of the vehicle 110 is located in the fuel compartment 76. The housing 80 may extend between the fuel inlet conduit 78 and the body member 118 to cover the gap therebetween. To fuel the vehicle 110, a fuel dispensing nozzle of a fuel pump (not shown) may be inserted through the inlet opening 82 of the fuel inlet conduit 78.

The fueling housing assembly 72 of fig. 11 may include a latch assembly substantially similar to the latch assembly 28 of the charging port housing assembly 14 shown in fig. 2-4B. Thus, the door assembly 74 may be locked when moved to the closed position.

The fuel fill housing assembly 72 may additionally include an override retainer substantially similar to the override retainer 42 of fig. 6-7 or the override retainer 50 of fig. 8-10. Thus, even in the event of a malfunction, the door assembly 74 of the fuel fill housing assembly 72 may be manually opened.

The vehicle assembly of the present disclosure employs an override retainer to manually release the moveable door assembly upon application of a manual override force thereto. Thus, the proposed assembly provides for ready operation of the movable door assembly even in the event of a malfunction. The proposed assembly also avoids the need for a relatively expensive cable system for manually releasing the movable door assembly.

Although various non-limiting embodiments are shown with specific components or steps, embodiments of the present disclosure are not limited to these specific combinations. Some features or components from any of the non-limiting embodiments may be used in combination with features or components from any of the other non-limiting embodiments.

It should be understood that the same reference numerals indicate corresponding or analogous elements throughout the several views. It should be understood that while particular component arrangements are disclosed and illustrated in the exemplary embodiments, other arrangements may benefit from the teachings of this disclosure.

The above description should be construed as illustrative and not in any limiting sense. Those of ordinary skill in the art will appreciate that some modifications may occur within the scope of the present disclosure. For these reasons, the following claims should be studied to determine the true scope and content of this disclosure.

Claims (20)

1. A vehicle assembly, comprising:

a door assembly configured to move between a closed position and an open position;

a latch assembly configured to selectively lock the door assembly in the closed position; and

an override retainer configured to deflect to release the latch assembly from the door assembly when a manual override force is applied to the door assembly.

2. The vehicle assembly of claim 1, wherein the door assembly comprises a fuel door or a charging port door.

3. The vehicle assembly of claim 1, wherein the manual override force is applied to the door assembly by a tool in response to a failure of the latch assembly.

4. The vehicle assembly of claim 1, wherein the override retainer includes a central ring and a pair of flexible retaining wings extending outwardly from the central ring.

5. The vehicle assembly of claim 4, wherein the centering ring is received around a barrel of the latch assembly, and further wherein the flexible retention wing engages a surface of a hinge arm of the door assembly positioned adjacent the latch assembly.

6. The vehicle assembly of claim 4, wherein the pair of flexible retention wings are configured to deflect upon application of the manual override force to release the latch assembly from the door assembly.

7. The vehicle assembly of claim 1, wherein the override retainer includes a first retaining clip positioned adjacent a first side of the latch assembly and a second retaining clip positioned adjacent a second side of the latch assembly.

8. The vehicle assembly of claim 7, wherein each of the first and second retention clips includes an attachment portion, a deflection portion, a reengagement portion, a shelf portion, and a free end portion.

9. The vehicle assembly of claim 8, wherein the attachment portion is secured to a surface of a hinge arm of the door assembly, and further wherein the shelf portion is configured to engage a T-bar of the latch assembly.

10. The vehicle assembly of claim 9, wherein a deflection point of the deflection portion deflects when the manual override force is applied, and further wherein the deflection of the deflection point displaces the shelf portion in a direction away from the T-bar to release the latch assembly from the door assembly.

11. The vehicle assembly of claim 1, wherein the latch assembly comprises a T-bar movable between a first position and a second position, wherein the second position is transverse to the first position.

12. A vehicle comprising the vehicle assembly of claim 1, wherein the vehicle comprises a body component and the door assembly is movable relative to the body component when moving between the closed position and the open position.

13. The vehicle of claim 12, wherein the body component is a curb plate or a fender.

14. A method, comprising:

the override retainer is deflected during a manual override event that applies a manual override force to the door assembly to release the latch assembly from the door assembly of the vehicle charging port housing assembly or the vehicle refueling housing assembly.

15. The method of claim 14, wherein the override retainer is integrally molded with a hinge arm of the door assembly.

16. The method of claim 15, wherein the override retainer is molded with the hinge arm as part of a two-shot molding process.

17. The method of claim 14, wherein deflecting the override holder comprises:

a T-bar of the latch assembly is allowed to displace from the override keeper.

18. The method of claim 14, wherein deflecting the override holder comprises:

the flexible retention flap of the override retainer is deformed.

19. The method of claim 14, wherein deflecting the override holder comprises:

deforming a flexible clip of the override holder.

20. The method of claim 14, wherein the override retainer is configured to allow a portion of the latch assembly to return through the override retainer when the door assembly is closed after the manual override event, thereby reengaging the override retainer and thus the door assembly relative to the latch assembly.