Thin visor with rotating pawl mechanism

Abstract

The invention relates to a thin visor with a rotating pawl mechanism. The invention discloses an automobile sun visor. The automobile sun visor has enhanced functionality and aesthetic attraction to the interior of a vehicle. The visor includes a frame having a rotating pawl mechanism housed within a hinge tube, facilitating precise rotational movement and safe positioning. The frame is composed of two thermally welded plastic frame halves, eliminating the need for an expanded polypropylene layer, and reducing thickness. The visor is equipped with an integrated mirror made of a high-grade material, such as chimpanzee glass or polycarbonate, as well as an LED lamp for illumination. The rotating pawl mechanism includes a pawl lever, a pawl spring, and a pawl sub-frame that provides a click action for haptic feedback when the visor reaches the stowed position. The design of the visor allows axial adjustment and pivotal movement between a stowed position and an operative position, facilitating safety and comfort in the vehicle.

Description

Background Technology

[0001] Sun visors have become an indispensable integrated component of vehicle interiors, their primary function being to protect the eyes of drivers and passengers from glare. Glare can be a significant hazard, as it can impair driver vision, cause discomfort, and create potentially dangerous driving conditions. The design and function of sun visors have evolved over time to meet a variety of needs, including aesthetic preferences, safety regulations, and ergonomic considerations.

[0002] Traditionally, sun visors have been designed as flat panels that can be flipped down or rotated to block sunlight from the front or side windows. They are typically mounted on rotating parts above the windshield that allow this movement. The materials used to manufacture them vary, with early models often made of simple, rigid materials that provided basic functionality without much consideration for the vehicle's interior design.

[0003] As automotive design advances, the integration of sun visors with the overall aesthetics of a vehicle has become increasingly important. Designers strive to create sun visors that not only fulfill their intended function but also blend seamlessly with the rest of the interior. This has spurred exploration of various materials and shapes that contribute to a more luxurious and cohesive look.

[0004] Providing sufficient visibility while minimizing obstruction of the driver's view has always been a key consideration in sun visor design. The size and shape of the sun visors must be carefully considered to ensure they effectively block sunlight without becoming a visual obstruction. This balance is crucial for maintaining safety standards while also ensuring comfort and convenience for passengers inside the vehicle.

[0005] Another consideration in sun visor design is its impact on vehicle interior space. As vehicles become increasingly compact, there is a growing need to maximize headroom and maintain an open, well-ventilated cabin. This has prompted efforts to reduce the thickness and profile of sun visors, making them less obtrusive while still providing necessary sun protection.

[0006] Durability and ease of use are also key factors in the development of sun visors. They are frequently handled and adjusted as drivers react to changing light conditions, often with rapid, sometimes forceful, movements. Therefore, the mechanisms that allow the sun visors to move and be positioned must be robust and able to withstand repeated use throughout the vehicle's lifespan.

[0007] In addition to its primary function, the sun visor has been modified to include additional features for the convenience of vehicle occupants. These include mirrors, typically with an openable or closable cover, and lighting that improves visibility. Integrating these features requires additional engineering to ensure that the added components do not compromise the sun visor's functionality or durability.

[0008] Overall, the field of sun visor design has been driven by the need to balance functionality and aesthetics, durability and convenience, space-saving and cost considerations with safety requirements. The evolution of sun visors reflects broader trends in automotive design, where each component strives to contribute to the vehicle's performance, comfort, and appeal. Summary of the Invention

[0009] Some examples in this article relate to an automotive sun visor designed to enhance the functional and aesthetic appeal of a vehicle's interior while providing effective sun protection for occupants. Some examples incorporate a rotating pawl mechanism that facilitates precise rotational movement and secure positioning of the sun visor, ensuring it remains fixed in the desired orientation to block sunlight.

[0010] In some examples, the thickness and weight of the sun visor have been significantly reduced by using advanced materials, including polyoxymethylene for the ratchet mechanism and Gorilla glass or polycarbonate options for the mirror components. The hinge design of the sun visor incorporates extruded aluminum tubing, contributing to a smoother profile and a flush interface with the vehicle's headliner.

[0011] In some examples, the sun visor's structure attempts to improve upon the traditional design by eliminating the expanded polypropylene (EPP) layer, instead employing two plastic frame halves heat-welded together. This modification not only reduces the overall thickness of the sun visor but also simplifies the manufacturing process and saves costs.

[0012] Some examples are designed for all customer road vehicles, offering a competitive advantage over traditional sun visor designs by reducing unit weight and cost. Thinner, lighter, and more ergonomic sun visors meet modern vehicle design requirements, providing improvements in both functionality and aesthetics. Attached Figure Description

[0013] To facilitate discussion of any particular element or action, the most significant digit in the reference numerals refers to the reference numeral first introduced for that element.

[0014] Figure 1 This is a schematic view of an example motor vehicle interior, showing the sun visor in a retracted position flush with the vehicle's headliner.

[0015] Figure 2AThis is a schematic view of the sun visor, illustrating the main body or frame, mirror, and D-ring.

[0016] Figure 2B This is a schematic view of the sun visor, which details the internal hinge tubes and their relationship to the frame and mirror.

[0017] Figure 3 This is a cross-sectional view showing a sunshade bend that is rotatably supported in a mounting bracket.

[0018] Figure 4A This is a schematic view of the hinge tube of the sun visor.

[0019] Figure 4B This is a schematic view of the rotating pawl mechanism of the sun visor.

[0020] Figure 4C This is a schematic view of half of the sun visor frame.

[0021] Figure 4D This is a schematic view of the sun visor bend, showing the flat portion engaged with the rotating pawl mechanism.

[0022] Figure 4E This is a schematic view of the sun visor mirror component.

[0023] Figure 5 This is an exploded view of the sun visor, illustrating the assembly of its various components.

[0024] Figure 6 This is a flowchart illustrating the assembly process of the sun visor.

[0025] Figure 7 This is a schematic view of the disassembled components of the rotating ratchet mechanism.

[0026] Figure 8 Various views of the assembled rotating ratchet mechanism are shown, including top view, bottom view, side view, front view, and isometric view.

[0027] Figure 9 This is a detailed view of the rotating ratchet mechanism located inside the hinged tube at the flat section of the bend.

[0028] Figure 10 The illustration shows a method for assembling a sun visor according to one embodiment. Detailed Implementation

[0029] A car sun visor is now described, designed to provide enhanced functional and aesthetic appeal to the vehicle interior. The example sun visor includes a frame with a rotating pawl mechanism housed within a hinged tube, facilitating precise rotational movement and secure positioning. The frame consists of two heat-welded plastic frame halves, eliminating the need for an expanded polypropylene layer and reducing thickness. The sun visor features an integrated mirror made of advanced materials such as Gorilla Glass or polycarbonate, as well as LED lights for illumination. The rotating pawl mechanism includes a pawl bar, a pawl spring, and a pawl subframe, providing a click action for tactile feedback when the sun visor reaches the retracted position. The sun visor's design allows for axial adjustment and pivoting movement between the retracted and operating positions, contributing to both safety and comfort within the vehicle.

[0030] Figure 1 This is a schematic view of the interior of an example motor vehicle according to an example embodiment, showing the example sun visor 102 in a retracted position flush with the headliner 104 inside the vehicle.

[0031] Figures 2A to 2B A schematic view of an example sun visor 102 is shown. Generally, the example sun visor 102 includes a body or frame 202, a mirror 204, and a D-ring 206 disposed towards one end of the sun visor 102. The frame 202 of the sun visor 102 may also be referred to as a sunshade or sunshade panel. In some examples, the frame 202 includes two frame halves thermally welded together, as described more fully below. In some examples, the mirror 204 may be covered by a mirror cap assembly 526 when not in use. The D-ring 206 is used to clamp the sun visor 102 to the headliner 104, and more generally, in… Figure 1 The retracted position is clamped to a complementary roof liner bracket or clip (not shown). The D-ring 206 of the sun visor 102 can be released from the roof liner 104 by the vehicle operator to release the sun visor 102 and allow it to swing horizontally about an upright swing axis 208 defined by a bend rotatably supported in the mounting bracket 210.

[0032] Mounting bracket 210 is designed to fit snugly in or above the headliner 104, for example... Figure 3 The cross-sectional view is shown in the figure. In this view, an example bend 302 carrying the sun visor 102 is shown rotatably supported in the mounting bracket 210. The bend 302 is hollow and can accommodate one or more power cables 308, or other components and wiring (not shown). As shown, the generally horizontal portion 304 of the bend 302 supports the sun visor 102 on the bend 302. The generally vertical portion 306 of the bend 302 defines an upright pivot axis 208, also shown.

[0033] Figure 2B The internal hinge tube 212 of the sun visor 102 is shown. The hinge tube 212 is slidably and rotatably supported on the bend 302. The slidable nature of the hinge tube 212 allows the sun visor 102 to be moved axially by the vehicle operator along the bend 302 to adjust the axial position of the sun visor 102 as needed during use. The sun visor 102 can also pivot upward, i.e., pivot to a retracted position about the longitudinal axis of the horizontal portion 304 of the bend 302, and pivot downward away from the headliner 104 to an operating position when needed as a sun visor to block, for example, glare from sunlight.

[0034] As described more fully below, some examples of the sun visor 102 include a rotating pawl mechanism designed to facilitate precise rotational movement and secure positioning of the sun visor 102 and to ensure that the sun visor 102 remains fixed in the desired orientation to block sunlight or glare.

[0035] Exemplary components of the sun visor 102 are shown in the figure. Figures 4A to 4E middle. Figure 4A A schematic view of an example hinge tube 212 is shown. In some examples, the hinge tube 212 is an extruded aluminum element with a wall thickness ranging from 0.3 mm to 0.6 mm, and in some examples, the wall thickness is 0.4 mm.

[0036] Figure 4B A schematic view of an example rotating pawl mechanism 402 is shown. In some examples, the rotating pawl mechanism 402 is located within the hinge tube 212 and is arranged such that one or more springs of the rotating pawl mechanism 402 actuate a flat pawl bar to engage a flat portion disposed on a bend tube 302, as described more fully below. Other example components and operation of the rotating pawl mechanism 402 are also described.

[0037] Figure 4C A schematic view of an example frame half 404 of the left-hand sun visor 102 is shown. In some examples, two frame halves 404 are thermally welded together to form the sunshade of the sun visor 102, which will also be described in more detail below.

[0038] Figure 4D A schematic view of an example bend 302 is shown. A generally horizontal portion 304 and a generally vertical portion 306 of the bend 302 defining a swing axis 208 are also shown. A flat portion 406 on the horizontal portion 304 of the bend 302 is also shown, which engages with a rotating pawl mechanism 402. The flat portion 406 engages with components of the rotating pawl mechanism 402 in a manner described more fully below.

[0039] at last, Figure 4EA schematic view of an example mirror 204 of the sun visor 102 is shown. The manner in which the mirror 204 and the mirror cap assembly 526 are installed into the sun visor 102 will also be described in more detail below.

[0040] These and other detailed components of the sun visor 102, such as Figure 5 As shown. In the illustrated case, sun visor 102 is a left-handed sun visor. In some examples, similar components are provided for a right-handed sun visor 102, but in some cases, these components may be provided in the opposite configuration or in a mirror-like form. In the provided view, the fully assembled sun visor 102 is shown above its components. The components are illustrated in exploded view and are arranged below the assembled sun visor 102. In some examples, sun visor 102 is an assembly comprising various parts designed to work together to provide both practicality and aesthetic enhancement.

[0041] The illustrated portion of the example sun visor 102 includes a lower frame half or first frame half 502, an upper frame half or second frame half 504, one or more end inserts 506, a PCB support 508, a contact 510, a mirror latch magnet 512, a mirror backing 514, a hinge tube 212, a bend 302, a bend screw 516, a D-ring 206, a terminal housing 518, a heat shrink tube 520, decorative fabric 522, an LED light 524, a mirror cover assembly 526, a mounting bracket 210, a mounting bracket cover 528, a sun visor tip latch magnet 530, and a bottom frame contact 532.

[0042] The first frame half 502 and the second frame half 504 form the frame 202 or body of the sun visor 102. In some examples, these frame halves are made of a durable plastic material, such as polypropylene (PP GF20) with glass fibers, and are thermally welded together to form a robust, integrated structure. This configuration, in some examples, eliminates the need for an expanded polypropylene (EPP) layer, thereby reducing the overall thickness of the sun visor 102 and contributing to a more streamlined appearance.

[0043] Each end of the sun visor 102 is provided with an end insert 506, serving as a structural element to support and reinforce the connection between the sun visor and the bend 302. As described above, the engagement between the hinge tube 212 and the bend 302 allows the sun visor 102 to pivot vertically and / or rotate horizontally about the pivot axis 208. The bend 302 is hollow, allowing the power cable 308 to provide electrical connectivity to the LED light 524 and other components within the sun visor 102. The LED light 524 is integrated into the sun visor 102 to provide illumination, enhancing the functionality of the mirror 204. These lights are powered by the power cable 308 passing through the bend 302. Other components may include one or more of the following: contact 510, terminal housing 518, heat shrink tubing 520, and bottom frame contact 532. In some examples, these components are used to connect and power the LED light 524 when the sun visor 102 is pivoted open or closed, or, for example, when the mirror cover assembly 526 is open. In some examples, the LED 524 can be de-energized when the lens cover assembly 526 is closed. Other lighting fixtures are also possible. A printed circuit board (PCB) support 508 is provided for mounting electronic components, and contacts 510 facilitate electrical connections.

[0044] A bend screw 516 connects the bend 302 to the mounting bracket 210. In some examples, the mounting bracket 210 includes a mounting bracket cover 528, the color of which can be set to complement the color of the headliner 104 or other visible components inside the vehicle. The bracket cover 528 provides a flush fit with the headliner 104 of the vehicle.

[0045] The sun visor 102 incorporates a rotating pawl mechanism 402 housed within the hinge tube 212. The rotating pawl mechanism 402 is responsible for the precise and secure positioning of the sun visor 102. As further described below, in some examples, the rotating pawl mechanism 402 includes a pawl subframe, a pawl spring support, one or more pawl springs, a pawl bar, and a pawl cover. Once the desired position (typically the retracted position) or angle is reached, these components work together to provide a click or cam action that secures the sun visor 102 in place, preventing unnecessary movement during vehicle operation. In some examples, the click action may also be used to provide a pleasant or reassuring "feeling" to the operator of the sun visor 102. A sun visor tip latch magnet 530 helps secure the sun visor 102 to the retracted position.

[0046] In some examples, mirror 204 is attached to mirror backing 514, which provides a stable substrate for the reflective surface. Mirror 204 is typically made of a thin, high-strength material, such as Gorilla Glass or polycarbonate, to maintain the sun visor's tapered profile. Mirror 204 may also include a mirror cap assembly 526 and a mirror latch magnet 512 to protect the mirror when not in use.

[0047] Additional components of the sun visor assembly include a D-ring 206 for securing the sun visor to the headliner 104 or complementary bracket when not in use. The sun visor 102 also includes a decorative fabric 522 that wraps around the frame half to provide a perfect look and a soft touch.

[0048] refer to Figure 6 The following describes an example assembly process for the sun visor 102. In operation 1, a bottom frame contact 532 is attached to the lower frame half or the first frame half 502 using a heat-fused pin. In operation 2, the sun visor tip latch magnet 530 is attached to the upper frame half or the second frame half 504. In operation 3, the first frame half 502 and the second frame half 504 are placed together as a pair and wrapped with decorative fabric 522, with the first frame half 502 and the second frame half 504 in an open or "butterfly" configuration, as shown. In operation 4, a hinge subassembly is formed by assembling a rotating pawl mechanism 402, a hinge tube 212, and a bend 302 onto the fabric-wrapped first frame half 502 and the second frame half 504, with the latter two components in an open or butterfly configuration. In operation 5, the open first frame half 502 and the second frame half 504 are closed together and joined by heat welding. In operation 6, a fine wrapping is performed, particularly in the area of ​​mirror 204, for aesthetic finishing and a neat appearance. In operation 7, mirror latch magnet 512 and LED light 524 are attached to the lower frame half or first frame half 502 in the areas designated for these components shown in the view. In operation 8, mirror cap assembly 526 is assembled to the upper frame half or second frame half 504, for example, via a heat-fused post. In operation 9, mirror 204 is attached to mirror cap assembly 526. In operation 10, D-ring 206 is attached to the final assembly.

[0049] Although the flowcharts depict operations as a sequential process, many operations can be executed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when its operations are completed. A process can correspond to a method, procedure, algorithm, etc. A method's operations can be executed entirely or partially, can be combined with some or all of the operations from other methods, and can be executed by any number of different systems.

[0050] refer to Figure 7 The components of the rotating pawl mechanism 402 will now be described. The view shows the pawl components in both illustrated and exploded form. Figure 8Top, bottom, side, front, and isometric views of the assembled rotary pawl mechanism 402 are shown. In some examples, the rotary pawl mechanism 402 includes a pawl subframe 702, a pawl spring support 704, one or more pawl springs 706, a pawl bar 708, and a pawl cover 710. A base 712 of the pawl subframe 702 supports the pawl spring support 704. A series of spring positioners 714 on the pawl spring support 704 are used to position the corresponding lower end (in the view) of each of the pawl springs 706. The pawl springs 706 are upright (in the view) and supported on the pawl spring support 704 within the pawl cover 710. The upper end of each pawl spring 706 acts on the pawl bar 708. The pawl lever 708 is movable vertically under the action of the pawl springs 706 and is guided within the pawl cover 710 by one or more guide rails 716 of the pawl subframe 702. Being a flat lever, the pawl lever 708 provides a wide “area” of engagement surface that can act on the flat portion 406 of the bend 302 during use. This avoids the single linear or point contact area of ​​conventional or exposed spring devices. The arrangement of three pawl springs 706 distributes the spring load along the length of the pawl lever 708. Other arrangements are also possible.

[0051] exist Figure 9 An example device can be seen, showing a rotating pawl mechanism 402 located within a hinge tube 212 at the flat portion 406 of the bend 302 of the sun visor 102. A pawl spring support 704 is shown supporting a pawl spring 706. The pawl spring 706 acts on a pawl bar 708. A pawl cover 710 housing the pawl spring support 704, the pawl spring 706, and the pawl bar 708 is supported by the inner wall of the hinge tube 212.

[0052] When the sun visor 102 rotates to press or push the cam edge 902 of the flat portion 406 of the bend 302 against or against the pawl bar 708, the pawl spring 706 retracts to the left (in the figure). The pawl spring 706 retracts axially because the tubular surface 904 pushing the pawl spring in this direction is relatively long radially from the longitudinal axis 906 of the bend 302 compared to the relatively short distance of the flat portion 406 to the longitudinal axis 906 of the bend 302. When retracted, the pawl spring 706 acts on the tubular surface 904 of the bend 302. Therefore, the cam edge 902 acts as a stepping discontinuity as the pawl bar 708 passes over it. In the illustrated example, the edge of the flat portion 406 defines two cam edges 902.

[0053] The pawl spring 706 can be released to extend its length to the right in the view. When extended, the pawl spring 706 acts on the flat portion 406 of the bend 302. In the illustrated device, the pawl spring 706 extends when the sun visor 102 is in the retracted position flush with the headliner 104 as shown. The pawl spring 706 continuously pushes the pawl lever 708 elastically against the tubular surface of the bend 302 and the flat portion 406. As the pawl lever 708 passes the cam edge 902, there is a stepping or "clicking" action (as described above) as the pawl lever 708 moves from the tubular surface 904 to the flat portion 406, which can be used to give a pleasant or reassuring "feel" when the sun visor 102 returns to its retracted position, as shown.

[0054] Some examples include method implementations. References Figure 10 A method 1000 for assembling a car sun visor includes: in operation 1002, attaching frame contacts to a first frame half of the car sun visor; in operation 1004, attaching a tip latch magnet to a second frame half of the car sun visor; in operation 1006, wrapping the first and second frame halves with decorative fabric; in operation 1008, assembling a hinge subassembly including a hinge tube and a rotating pawl mechanism to the first and second frame halves; in operation 1010, closing the first and second frame halves together and joining them by thermal welding to form an integrated frame structure; in operation 1012, attaching an LED light and a mirror latch magnet to the integrated frame structure; in operation 1014, thermally riveting a mirror cap to the second frame half; and in operation 1016, attaching a mirror to the mirror cap. In operation 1018, method 1000 attaches the D-ring to the integrated frame structure.

[0055] Method 1000 may further include integrating a power cable through a bend in the hinge subassembly to electrically connect the LED light to a vehicle power source. In some examples, wrapping the first and second frame halves with decorative fabric includes fine wrapping tuning in the area adjacent to the mirror. Method 1000 may further include attaching frame contacts to the first frame half using a thermoplastic post to secure the frame contacts to the first frame half. In some examples, assembling the hinge subassembly includes positioning a rotating pawl mechanism within the hinge tube and securing the hinge tube to the bend. Method 1000 may further include securing a mounting bracket to the vehicle's headliner, wherein the hinge subassembly is configured to engage with the mounting bracket to allow rotational movement of the vehicle sun visor about an upright swing axis defined by the bend. Other technical features will be apparent to those skilled in the art from the following figures, description, and claims.

[0056] Although the flowcharts depict operations as a sequential process, many operations can be executed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when its operations are completed. A process can correspond to a method, procedure, algorithm, etc. A method's operations can be executed entirely or partially, can be combined with some or all of the operations from other methods, and can be executed by any number of different systems.

[0057] In other examples, some designs mount the sun visor 102 directly to the headliner 104 without requiring the bracket 210. This also reduces the number of interfaces between parts, allowing for a cleaner design.

[0058] Some examples integrate wireless power and data transmission capabilities. These examples attempt to eliminate the need for traditional wiring harnesses within the sun visor assembly, thereby enabling a more streamlined design and reducing manufacturing complexity.

[0059] In some examples, the sun visor 102 incorporates a rechargeable energy source, such as a battery pouch or capacitor for wireless charging. The charging mechanism operates based on the principles of inductive energy transfer or a wireless charger. When the sun visor is in the retracted position, energy transfer occurs upon contact with the surface of the headliner, allowing the energy source to charge through the multilayer polymer substrate and fabric.

[0060] When the sun visor is deployed, charging stops, and the energy stored in the rechargeable battery pouch or capacitor is used to power the integrated LED vanity light. In some examples, this wireless charging feature simplifies the design of the sun visor by eliminating the need for a physical electrical connection and also enhances the user experience by providing uninterrupted functionality.

[0061] Some example sun visors 102 include a hybrid screen / mirror. This feature allows for the display of useful information such as local weather, time, charging status, and other user interface (UI) related data. In some examples, information is wirelessly transmitted using the same sensing units mounted in both the sun visor and the headliner, allowing for seamless data flow without the need for physical connectors.

[0062] Eliminating wiring harnesses from the sun visor assembly reduces the cross-section of the metal rods or elbows that traditionally house the wiring. This reduction opens up new design possibilities for a smoother and more aesthetically pleasing sun visor shape. Furthermore, wireless technology facilitates pre-installation of the sun visor to the headliner at the supplier, which reduces part counting and assembly time at the factory.

[0063] The disclosed sun visor design also includes a feature that displays specific area warnings (such as child seat airbag notifications) directly on a screen integrated into the mirror. This feature adds an extra layer of safety and compliance by ensuring that critical information is easily visible to vehicle occupants.

[0064] Example

[0065] Therefore, some embodiments may include one or more of the examples below.

[0066] Example 1. A car sun visor comprising: a frame configured for mounting adjacent to a windshield of a vehicle; and a rotating pawl mechanism facilitating secure positioning of the car sun visor, the rotating pawl mechanism being housed within a hinge tube of the car sun visor, the rotating pawl mechanism including a pawl bar actuated by a plurality of pawl springs to engage a flat portion of a bend defining an axis of oscillation of the car sun visor, wherein the bend is configured to rotatably and slidably support the car sun visor on the car sun visor, allowing axial adjustment and pivoting movement of the car sun visor between a retracted position and an operational position.

[0067] Example 2. The car sun visor according to Example 1, wherein the frame comprises two frame halves made of durable plastic material, which are thermally welded together to form a single structure.

[0068] Example 3. The car sun visor of Example 2, wherein the durable plastic material of the two frame halves comprises polypropylene and fiberglass.

[0069] Example 4. A car sun visor according to any one of Examples 1 to 3, wherein the hinge tube comprises an extruded aluminum element with a wall thickness ranging from 0.3 mm to 0.6 mm.

[0070] Example 5. A car sun visor according to any one of Examples 1 to 4, the car sun visor further comprising a mirror integrated into a frame, the mirror comprising a material selected from the group including Gorilla Glass and polycarbonate, and having a mirror thickness in the range of 0.5 mm to 1 mm.

[0071] Example 6. A car sun visor according to any one of Examples 1 to 5, the car sun visor further comprising an LED light integrated into the frame and configured to provide illumination when the car sun visor is in the operating position.

[0072] Example 7. A car sun visor according to any one of Examples 1 to 6, wherein the rotating pawl mechanism includes a pawl subframe, a pawl spring support, a plurality of pawl springs, a pawl bar, and a pawl cover, the pawl bar being movable within the pawl cover and guided by a guide rail of the pawl subframe.

[0073] Example 8. A car sun visor according to any one of Examples 1 to 7, wherein the bend is hollow and configured to house one or more power cables for electrical components of the car sun visor.

[0074] Example 9. A rotating pawl mechanism for an automotive sun visor, the rotating pawl mechanism comprising: a pawl subframe configured to be received within a hinge tube of the automotive sun visor; a pawl spring support mounted on the pawl frame; a plurality of pawl springs supported by the pawl spring support; a pawl bar actuated by the plurality of pawl springs to engage with a flat portion of a bend, wherein the bend defines an axis of oscillation of the automotive sun visor, and the bend includes a cam edge that interacts with the pawl bar to provide a click action indicating that the automotive sun visor has reached a desired position; and a pawl cover receiving the pawl spring support, the plurality of pawl springs, and the pawl bar, wherein the pawl cover is supported by an inner wall of the hinge tube.

[0075] Example 10. A rotating pawl mechanism according to Example 9, wherein the pawl bar is a flat bar construction or includes a flat bar construction that provides an air engagement surface with a flat portion of a bend, and wherein a plurality of pawl springs are distributed along the length of the pawl bar to distribute the spring load thereon.

[0076] Example 11. A pawl system for fixing the position of an automotive sun visor, the pawl system comprising: a bend having a flat portion defining a cam edge, the bend defining a swing axis of the automotive sun visor and configured to support rotation and axial movement of the automotive sun visor within an automotive vehicle; a hinge tube slidably and rotatably mounted on the bend; a pawl bar disposed within the hinge tube and configured to engage with the flat portion of the bend; and a plurality of pawl springs configured to push the pawl bar against the flat portion of the bend, wherein when the automotive sun visor is moved to a fixed position, the plurality of pawl springs respond to the cam edge to provide step-by-step engagement.

[0077] Example 12. A ratchet system according to Example 11, wherein during the rotation of the car sun visor, when the ratchet lever engages with the edge of the cam, the ratchet lever facilitates the safe and precise positioning of the car sun visor by providing a clicking action.

[0078] Example 13. A pawl system according to Example 11 or 12, wherein the cam edge of the bend is configured to compress a plurality of pawl springs when the car sun visor rotates away from the retracted position, and wherein the plurality of pawl springs are configured to extend and push the pawl bar against the flat portion of the bend when the car sun visor is in the retracted position, thereby providing the user with tactile feedback indicating that the car sun visor is securely positioned.

[0079] Example 14. A car sun visor frame comprising: a first frame half and a second frame half, each frame half comprising a durable plastic material and configured to form an integral structure when joined; wherein the first frame half and the second frame half are thermally welded together along their respective edges; and wherein the integral structure includes an integrated channel for receiving a hinge tube for attaching a rotating pawl mechanism.

[0080] Example 15. A car sun visor frame according to Example 14, wherein a first frame half and a second frame half are thermally welded together, and there is no expanded polypropylene (EPP) layer between the first frame half and the second frame half.

[0081] Example 16. A car sun visor frame according to Example 13 or 14, wherein the durable plastic material comprises polypropylene with a glass fiber content of 20% by weight.

[0082] Example 17. A method of assembling a car sun visor, the method comprising: attaching frame contacts to a first frame half of the car sun visor; attaching a tip latch magnet to a second frame half of the car sun visor; wrapping the first and second frame halves with a decorative fabric; assembling a hinge subassembly including a hinge tube and a rotating pawl mechanism to the first and second frame halves; closing the first and second frame halves together and joining them by thermal welding to form an integral frame structure; attaching an LED light and a mirror latch magnet to the integral frame structure; thermally riveting a mirror cap to the second frame half; attaching a mirror to the mirror cap; and attaching a D-ring to the integral frame structure.

[0083] Example 18. According to the method of Example 17, the method further includes integrating a power cable through a bend in the hinge subassembly to electrically connect the LED light to the vehicle power supply.

[0084] Example 19. The method according to Example 16 or 17, wherein wrapping the first frame half and the second frame half with decorative fabric includes fine wrapping and tuning in the area adjacent to the mirror.

[0085] Example 20. The method of any one of Examples 16 to 19, wherein attaching the frame contact to the first frame half includes securing the frame contact to the first frame half using a thermoplastic column.

[0086] Example 21. The method according to any one of Examples 16 to 20, wherein assembling the hinge subassembly includes positioning the rotating pawl mechanism within the hinge tube and securing the hinge tube to the bend.

[0087] Example 22. The method of any one of Examples 16 to 21, further comprising securing a mounting bracket to the roof liner of a vehicle, wherein a hinge sub-assembly is configured to engage with the mounting bracket to allow rotational movement of the vehicle sun visor about a vertical swing axis defined by a bend.

[0088] Example 23. A car sun visor comprising: a body configured to be mounted to a headliner of a vehicle; an integrated wireless power and data transmission unit; a rechargeable energy source located within the body, the rechargeable energy source being wirelessly charged when the car sun visor is in a retracted position against the headliner; and an integrated display screen capable of displaying user interface data wirelessly transmitted to the integrated wireless power and data transmission unit.

[0089] Example 24. A car sun visor according to Example 23, wherein the body is configured to be directly mounted to the roof liner so that the car sun visor is flush with the roof liner without the intervention of a mounting bracket.

[0090] Example 25. A car sun visor according to Example 23 or 24, wherein the integrated wireless power and data transmission unit is capable of inductive energy transfer through one or more polymer substrates and / or fabrics.

[0091] Example 26. A car sun visor according to any one of Examples 23 to 25, wherein the rechargeable energy source includes a battery bag or a capacitor.

[0092] Example 27. A car sun visor according to any one of Examples 23 to 26, wherein when the car sun visor is deployed, rechargeable energy can power an integrated LED vanity light.

[0093] Example 28. A car sun visor according to any of Examples 23 to 27, wherein the integrated display is a hybrid screen / mirror capable of switching between a reflective surface and a display for presenting information.

[0094] Example 29. A car sun visor according to any of Examples 23 to 28, wherein the information displayed on the hybrid screen / mirror includes at least one of local weather, time, charging status, and area-specific warnings.

[0095] Example 30. A car sun visor according to any one of Examples 23 to 29, the car sun visor further comprising equipment for pre-installing the car sun visor to the roof liner.

[0096] Although exemplary embodiments of the subject matter of this invention have been described in detail above, various alternatives, modifications, and equivalents may be used. Therefore, the above description should not be construed as limiting the scope of the subject matter of this invention as defined by the appended claims.

[0097] It should be noted that the above description and accompanying drawings are merely illustrative of the principles of this subject matter and the examples described herein, and should not be construed as limiting the subject matter. Therefore, it should be understood that various devices can be designed, which, although not explicitly described or shown herein, embody the principles of this subject matter. Furthermore, all statements and specific examples of the principles, aspects, and implementations of this subject matter listed herein are intended to cover their equivalents.

[0098] It should be understood that not all objectives or advantages may be achieved according to any particular example described herein. Therefore, for example, those skilled in the art will recognize that some examples may operate in a manner that achieves or optimizes one or more advantages taught herein, without necessarily achieving other objectives or advantages taught or suggested herein.

[0099] All processes described herein can be embodied in software code modules executed by a computing system, including a computer or processor, and can be fully automated through these modules. The code modules can be stored on any type of non-transitory computer-readable medium or other computer storage device. Some or all of the methods can be embodied in dedicated computer hardware.

[0100] As will be apparent from this disclosure, many other variations exist besides those described herein. For example, depending on the example, some actions, events, or functions of any algorithm described herein may be performed in a different order, may be added, combined, or omitted entirely (e.g., not all described actions or events are necessary for the practice of the algorithm). Furthermore, in some examples, actions or events may be performed concurrently, rather than sequentially, for example, through multithreading, interrupt handling, or multiple processors or processor cores, or on other parallel architectures. Moreover, different tasks or processes may be performed by different machines and / or computing systems that can work together.

[0101] The various illustrative logic blocks and modules described in conjunction with the examples disclosed herein can be implemented or executed by a machine such as a processing unit or processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination designed to perform the functions described herein. The processor may be a microprocessor, but alternatively, it may be a controller, a microcontroller, or a state machine, a combination thereof, etc. The processor may include circuitry means for processing computer-executable instructions. In some examples, the processor includes an FPGA or other programmable device that performs logical operations without processing computer-executable instructions. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, a microprocessor incorporating a DSP core, or any other such configuration.

[0102] Although this document primarily describes digital technologies, processors may also primarily comprise analog components. The computing environment can include any type of computer system, including but not limited to microprocessor-based computer systems, mainframe computers, digital signal processors, portable computing devices, device controllers, or computing engines within devices. Elements of the methods, processes, routines, or algorithms described in conjunction with the embodiments disclosed herein may be directly embodied in hardware, software modules executed by the processor device, or a combination of both. Software modules may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disks, removable disks, CD-ROMs, or any other form of non-transitory computer-readable storage medium. Exemplary storage media may be coupled to the processor device, enabling the processor device to read information from and write information to the storage medium. Alternatively, the storage medium may be integrated into the processor device. The processor device and storage medium may reside in an ASIC. The ASIC may reside in a user terminal. Alternatively, the processor device and storage medium may reside as discrete components in the user terminal.

[0103] The processes described herein or illustrated in the accompanying drawings can be initiated in response to events, such as according to a predetermined or dynamically determined schedule, at the request of a user or system administrator, or upon other events. When such a process is initiated, a set of executable program instructions stored on one or more non-transitory computer-readable media (e.g., hard disk drives, flash memory, removable media, etc.) can be loaded into the memory (e.g., RAM) of a server or other computing device. The executable instructions can then be executed by the hardware-based computer processor of the computing device. In some embodiments, such processes, or portions thereof, can be implemented serially or in parallel on multiple computing devices and / or multiple processors.

[0104] Although the flowcharts described herein can show operations as a sequential process, many operations can be executed in parallel or simultaneously. Furthermore, the order of operations can be rearranged. A process terminates when its operations are completed. A process can correspond to a method, program, algorithm, etc. The operations of a method can be executed entirely or partially, can be combined with some or all of the operations from other methods, and can be executed by any number of different systems, such as the system described herein or any part thereof, such as a processor included in any system.

[0105] Unless otherwise expressly stated, conditional language such as “can,” “could,” “might,” or “may” (among other things) is understood in context to generally convey that some examples include, while others do not, certain features, elements, and / or steps. Therefore, such conditional language is not generally intended to imply that features, elements, and / or steps are used in any way in an example, nor does it imply that the example must include logic for determining whether such features, elements, and / or steps are included in any particular example or whether they will be executed in any particular example, with or without user input or prompts.

[0106] Unless otherwise specifically stated, disjunctive language such as the phrase “at least one of X, Y, or Z” should be understood in conjunction with the context in which items, terms, etc., can be X, Y, or Z or any combination thereof (e.g., X, Y, and / or Z). Therefore, such disjunctive language is generally not intended to, nor should it imply, that some examples require the presence of at least one of X, at least one of Y, or at least one of Z.

[0107] Any process descriptions, elements, or blocks depicted in the flowcharts described herein and / or in the accompanying drawings should be understood as potentially representing modules, segments, or code portions that include executable instructions for specific logical functions or elements during implementation. Alternative examples are included within the scope of the examples described herein, wherein elements or functions may be omitted, performed not in the order shown or discussed, including substantially simultaneously or in reverse order, depending on the functions involved, as understood by those skilled in the art.

[0108] It should be emphasized that various variations and modifications can be made to the above examples, and its elements should be understood as examples of other acceptable examples. All such modifications and variations are intended to be included within the scope of this disclosure.

[0109] Any process descriptions, elements, or blocks depicted in the flowcharts described herein and / or in the accompanying drawings should be understood as potentially representing modules, segments, or code portions that include executable instructions for specific logical functions or elements during implementation. Alternative implementations are included within the scope of the examples described herein, wherein elements or functions may be omitted, performed not in the order shown or discussed, including substantially simultaneously or in reverse order, depending on the functions involved, as understood by those skilled in the art.

[0110] Unless otherwise expressly stated, the article “a” or “an” should generally be interpreted as including one or more of the described items. Therefore, phrases such as “devices configured to…” are intended to include one or more of the described devices. Such one or more described devices may also be configured together to perform the stated descriptions. For example, “processors configured to perform descriptions A, B, and C” could include a first processor configured to perform description A working in conjunction with a second processor configured to perform descriptions B and C.

[0111] It should also be recognized that one or more of the components shown in the drawings / figures may also be implemented in a more separate or integrated manner, or even removed or rendered inoperable in some cases, which may be useful depending on the specific application.

Claims

1. A car sun visor, comprising: A frame, configured to be mounted on the windshield of an adjacent vehicle; A rotating pawl mechanism facilitates the secure positioning of the vehicle sun visor, the rotating pawl mechanism being housed within the hinge tube of the vehicle sun visor; The rotating pawl mechanism includes a pawl bar actuated by a plurality of pawl springs to engage a flat portion of a bend that defines the swing axis of the vehicle sun visor, wherein the bend is configured to rotatably and slidably support the vehicle sun visor thereon, allowing axial adjustment and pivoting movement of the vehicle sun visor between a retracted position and an operating position.

2. The automotive sun visor of claim 1, wherein the frame comprises two frame halves made of a durable plastic material, the two frame halves being thermally welded together to form an integral structure.

3. The automotive sun visor of claim 2, wherein the durable plastic material of the two frame halves comprises polypropylene and glass fiber materials.

4. The automotive sun visor according to claim 1, wherein the hinge tube comprises an extruded aluminum element with a wall thickness ranging from 0.3 mm to 0.6 mm.

5. The automotive sun visor of claim 1, further comprising a mirror integrated into the frame, the mirror comprising a material selected from the group consisting of Gorilla Glass and polycarbonate, and having a mirror thickness in the range of 0.5 mm to 1 mm.

6. The automotive sun visor of claim 1 further includes an LED light integrated in the frame and configured to provide illumination when the automotive sun visor is in the operating position.

7. The automotive sun visor according to claim 1, wherein the rotating pawl mechanism comprises a pawl subframe, a pawl spring support, the plurality of pawl springs, the pawl bar, and a pawl cover, the pawl bar being movable within the pawl cover and guided by a guide rail of the pawl subframe.

8. The automotive sun visor of claim 1, wherein the bend is hollow and configured to house one or more power cables for electrical components of the automotive sun visor.

9. A rotating ratchet mechanism for an automobile sun visor, comprising: A ratchet frame, the ratchet frame being configured to be received within the hinge tube of the vehicle sun visor; A pawl spring support member, which is mounted on the pawl subframe; Multiple pawl springs, wherein the multiple pawl springs are supported by pawl spring supports; A pawl lever, actuated by the plurality of pawl springs to engage with a flat portion of a bend, wherein the bend defines the swing axis of the vehicle sun visor and includes a cam edge that interacts with the pawl lever to provide a click action instructing the vehicle sun visor to reach a desired position; and A pawl cover that houses the pawl spring support, the plurality of pawl springs, and the pawl bar, wherein the pawl cover is supported by the inner wall of the hinge tube.

10. The rotary pawl mechanism of claim 9, wherein the pawl bar is a flat bar construction or includes a flat bar construction, the flat bar construction providing an air engagement surface with the flat portion of the bend, and wherein the plurality of pawl springs are distributed along the length of the pawl bar to distribute the spring load thereon.

11. A pawl system for fixing the position of a car sun visor, the pawl system comprising: The bend has a flat portion defining a cam edge, the bend defines the swing axis of the vehicle sun visor, and is configured to support the vehicle sun visor to rotate and move axially within the vehicle. A hinge tube, which is slidably and rotatably mounted on the bend; A ratchet lever, which is disposed within the hinge tube and configured to engage with the flat portion of the bend; as well as Multiple pawl springs are configured to push the pawl bar against the flat portion of the bend, wherein when the vehicle sun visor is moved to a fixed position, the multiple pawl springs respond to the edge of the cam to provide step-by-step engagement.

12. The pawl system of claim 11, wherein during rotation of the vehicle sun visor, when the pawl lever engages with the edge of the cam, the pawl lever facilitates the safe and precise positioning of the vehicle sun visor by providing a clicking action.

13. The pawl system of claim 12, wherein the cam edge of the bend is configured to compress the plurality of pawl springs when the vehicle sun visor rotates away from the retracted position, and wherein the plurality of pawl springs are configured to extend and push the pawl bar against the flat portion of the bend when the vehicle sun visor is in the retracted position, thereby providing the user with tactile feedback indicating that the vehicle sun visor is securely positioned.

14. A car sun visor frame, comprising: The first frame half and the second frame half, each frame half comprising a durable plastic material and configured to form an integral structure when joined together; The first frame half and the second frame half are thermally welded together along their respective edges; and The integrated structure includes an integrated channel to accommodate a hinge tube for attaching a rotating pawl mechanism.

15. The automotive sun visor frame of claim 14, wherein the first frame half and the second frame half are thermally welded together, and there is no expanded polypropylene (EPP) layer between the first frame half and the second frame half.

16. The automotive sun visor frame of claim 14, wherein the durable plastic material comprises polypropylene with a glass fiber content of 20% by weight.

17. A method for assembling a car sun visor, the method comprising: The frame contacts are attached to the first frame half of the vehicle sun visor; A tip-locking magnet is attached to the second frame half of the vehicle sun visor; Wrap the first frame half and the second frame half with decorative fabric; The hinge subassembly, including the hinge tube and the rotating pawl mechanism, is assembled to the first frame half and the second frame half. The first frame half and the second frame half are closed together and joined together by thermal welding to form an integrated frame structure; Attach the LED lights and mirror latch magnets to the integrated frame structure; The mirror cover is heat-riveted to the second frame half; Attach the mirror to the mirror cover; as well as The D-ring is attached to the integrated frame structure.

18. The method of claim 17, further comprising integrating a power cable via a bend in the hinge subassembly to electrically connect the LED light to a vehicle power source.

19. The method of claim 17, wherein wrapping the first frame half and the second frame half with the decorative fabric includes fine wrapping and tuning in the area adjacent to the mirror.

20. The method of claim 17, wherein attaching the frame contact to the first frame half comprises securing the frame contact to the first frame half using a thermoplastic post.

21. The method of claim 17, wherein assembling the hinge subassembly includes positioning the rotating pawl mechanism within the hinge tube and securing the hinge tube to the bend.

22. The method of claim 21, further comprising securing a mounting bracket to the roof liner of a vehicle, wherein the hinge sub-assembly is configured to engage with the mounting bracket to allow rotational movement of the vehicle sun visor about a vertical swing axis defined by the bend.

23. A car sun visor, comprising: The main body is configured to be installed into the roof liner of a vehicle; Integrated wireless power and data transmission unit; The rechargeable energy source is located within the main body and can be wirelessly charged when the car sun visor is in the retracted position against the roof liner. as well as An integrated display screen is provided, which is capable of displaying user interface data that is wirelessly transmitted to the integrated wireless power and data transmission unit.

24. The automotive sun visor of claim 23, wherein the body is configured to be directly mounted to the roof liner such that the automotive sun visor is flush with the roof liner without the need for mounting brackets.

25. The automotive sun visor of claim 23, wherein the integrated wireless power and data transmission unit is capable of inductive energy transfer through one or more polymer substrates and / or fabrics.

26. The automotive sun visor of claim 23, wherein the rechargeable energy source comprises a battery pack or a capacitor.

27. The automotive sun visor of claim 23, wherein when the automotive sun visor is deployed, the rechargeable energy source is capable of powering an integrated LED vanity light.

28. The automotive sun visor of claim 23, wherein the integrated display screen is a hybrid screen / mirror capable of switching between a reflective surface and a display for presenting information.

29. The automotive sun visor of claim 28, wherein the information displayed on the hybrid screen / mirror includes at least one of local weather, time, charging status, and area-specific warnings.

30. The automotive sun visor of claim 23, further comprising equipment for pre-installing the automotive sun visor onto the roof liner.

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