Charge port door with electromagnetic latching assembly

• US 8,720,968 B2
• Filed: 05/29/2012
• Issued: 05/13/2014
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Zalan, Daryl, Ferguson, Joshua Willard, Nergaard, Troy Adam, Kalayjian, Nicholas Robert
• Primary Examiner(s): PEDDER, DENNIS H
• Application Number:
  US13/482,900
• Publication Number:
  US 20130076059A1
• Time in Patent Office: 714 Days
• Field of Search: 296/97.22, 292/251.5
• US Class Current: 296/97.22
• CPC Class Codes: B60K 2015/053 with hinged connection to the vehicle body
• CPC Class Codes: B60K 2015/0546 Arrangements for checking the position of the inlet cover
• CPC Class Codes: B60K 2015/0561 Locking means for the inlet cover
• CPC Class Codes: B60L 53/16 Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles
• CPC Class Codes: E05B 83/34 for fuel inlet covers essentially flush with the vehicle surface
• CPC Class Codes: E05C 19/166 electromagnetic
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10T 292/11 Magnetic

Abstract

A door latching system for the door covering the charge port of an electric vehicle, or for the door covering the fuel filler port of a conventional vehicle, is provided. The door latching system is comprised of a ferromagnetic member attached to an interior surface of the door, and a latching assembly integrated into the port housing, where the latching assembly includes an assembly case, an electromagnet, and a permanent magnet that maintains the door in a closed position when the electromagnet is not energized and releases the door when the electromagnet is energized. The latching assembly may include a magnetic flux sensor that monitors when the port door is open or closed. The magnetic flux sensor may be coupled to a system controller that performs a preset response when the magnetic flux sensor determines that the door is open.

Claims

1. A port door assembly of a vehicle, comprising:

a housing integrated into a vehicle reflector and lamp assembly of said vehicle, said housing providing access to a vehicle port;

a door coupled to said housing by a hinge, wherein in a closed position said door covers said vehicle port and in an open position said door provides access to said vehicle port;

a door latching system, comprising;

a ferromagnetic member attached to an interior surface of said door;

a latching assembly integrated into said housing, wherein an exterior surface of said latching assembly contacts said ferromagnetic member when said door is in said closed position, wherein said latching assembly further comprises;

a latching assembly case;

an electromagnet mounted within said latching assembly case, the electromagnet forming the exterior surface of the latching assembly; and

a permanent magnet mounted within said latching assembly case on an opposite side of the electromagnet relative to the ferromagnetic member, wherein said permanent magnet attracts said ferromagnetic member and said latching assembly maintains said door in said closed position when said electromagnet is not energized, and wherein said latching assembly releases said door when said electromagnet is energized.

2. The port door assembly of claim 1, further comprising a spring, wherein said spring loads said door towards said open position both when the door is moving toward the open position and when the door is in the closed position, and wherein when said electromagnet is energized and said latching assembly releases said door said spring forces said door from said closed position to said open position.

3. The port door assembly of claim 1, further comprising a reflector that covers an exterior surface of said door, wherein opening the door does not displace the lamp assembly, wherein said reflector integrates into said vehicle reflector and lamp assembly when said door is in said closed position.

4. The port door assembly of claim 1, wherein said ferromagnetic member is comprised of a material selected from the group consisting of ferromagnetic metals and ferromagnetic composites.

5. The port door assembly of claim 1, wherein said vehicle is an electric vehicle and said vehicle port further comprises a charge port.

6. The port door assembly of claim 5, further comprising a sealing member attached to said interior surface of said door, wherein said sealing member is compressed against a charge port inlet surface when said door is in said closed position.

7. The port door assembly of claim 6, wherein said sealing member is selected from the group consisting of natural and synthetic rubbers.

8. The port door assembly of claim 1, further comprising a switch that controls when said electromagnet is electrically connected to a power source and energized.

9. The port door assembly of claim 8, wherein said switch is a soft button on a touch-screen display.

10. The port door assembly of claim 8, wherein said switch may be remotely and wirelessly activated.

11. The port door assembly of claim 1, said latching assembly further comprising a magnetic flux sensor coupled to a sensor circuit, wherein said sensor circuit outputs a first control signal when said door is closed and said ferromagnetic member is adjacent to said latching assembly, and wherein said sensor circuit outputs a second control signal when said door is open and said ferromagnetic member is not adjacent to said latching assembly.

12. The port door assembly of claim 11, wherein said magnetic flux sensor is mounted within a ferromagnetic core of said electromagnet.

13. The port door assembly of claim 11, wherein said magnetic flux sensor is comprised of a reed switch.

14. The port door assembly of claim 11, wherein said magnetic flux sensor is comprised of a Hall sensor.

15. The port door assembly of claim 11, further comprising a system controller coupled to said sensor circuit, wherein said system controller performs a preset response upon receipt of said second control signal.

16. The port door assembly of claim 15, further comprising a warning indicator, wherein said preset response comprises activating said warning indicator.

17. The port door assembly of claim 15, further comprising a vehicle port light, wherein said preset response comprises activating said vehicle port light.

18. The port door assembly of claim 15, further comprising a notification subsystem coupled to said system controller, wherein said preset response comprises transmitting a notification message via said notification subsystem.

19. The port door assembly of claim 1, wherein said vehicle is an electric vehicle and said vehicle port door comprises a charge port for a charge port of the electric vehicle, the port door assembly further comprising:

a spring configured to force the charge port door into the open position upon release by the latching assembly;

wherein an outer edge of the charge port, and the exterior surface of the latching assembly, are substantially flush with an externally facing surface of the port door assembly.

20. The port door assembly of claim 19, wherein when the charge port door is in the closed position the charge port door is flush with a surrounding vehicle surface that is parallel with the externally facing surface of the port door assembly.