Clamshell Visor Body with Molded Channels for Pivot Rod
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Solution Overview
Problem
Existing sun visor designs for vehicles require complex assembly processes and multiple components, leading to increased manufacturing costs, weight, and potential flimsiness, which can result in dislodging or breaking under repeated torque actions.
Innovation Solution
A clam shell type sun visor design with integrally molded longitudinal channels in two shell halves that align to capture a pivot rod and slider assembly in a single step, eliminating the need for separate carriers and reducing the number of components, while using a support arm and flexible cover member to enhance durability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional sun visor designs with separate carriers and mounting pieces are used, then the visor can be constructed with multiple components for retention, but the assembly process becomes time-intensive and component count increases
Solution Approach 1:
The patent combines the carrier, mounting pieces, and retention mechanisms into an integrated visor body structure. The clamshell halves are molded with built-in channels and features that directly retain the pivot rod and slider assembly, eliminating the need for separate carriers and mounting components. This merging reduces both assembly steps and total component count.
Solution Approach 2:
The visor body halves serve multiple functions: they provide the exterior surface, contain the pivot rod, retain the slider assembly, and provide structural support. The integrated design makes the visor body a multi-functional component that replaces several separate parts, simplifying both manufacturing and assembly.
2Reliability
If additional mounting or journaling pieces are incorporated for retention of the pivot rod, then the visor can be securely assembled, but the construction becomes relatively time-intensive and expensive
Solution Approach 1:
The mounting and retention features are pre-formed during the molding of the clamshell halves. The channels, recesses, and retention structures are built into the visor body itself before assembly, allowing the pivot rod and slider to be installed directly without requiring separate mounting operations. This preliminary action during molding significantly speeds up production.
Solution Approach 2:
The visor body structure provides its own mounting and retention features through the integrated clamshell design. The halves self-contained channels and recesses that automatically retain the pivot rod and slider assembly when closed, eliminating the need for external mounting pieces or additional assembly steps.
3Ease of manufacture
If the number of components is reduced to simplify manufacturing, then production cost and assembly time decrease, but the visor construction may become flimsy and insufficient to withstand repeated torque actions
Solution Approach 1:
The patent employs a composite construction where the clamshell halves are molded from polypropylene or similar durable material, providing both weight reduction and structural strength. The integration of metal reinforcement or strategically designed rigid features within the plastic body creates a composite structure that maintains durability despite reduced component count.
Solution Approach 2:
The clamshell design utilizes curved, contoured surfaces that distribute mechanical stresses more effectively than flat rigid structures. The molded-in channels and recesses are designed with appropriate radii and transitions to prevent stress concentration points, allowing the reduced component design to withstand repeated torque actions.
4Reliability
If separate carriers and mounting pieces are used, then the visor can be securely assembled, but the overall weight and expense of the visor increase
Solution Approach 1:
By merging the carrier and mounting functions into the visor body itself, the patent eliminates the weight of separate metal carriers, brackets, and mounting pieces. The integrated plastic structure with molded-in retention features provides equivalent security with significantly reduced weight.
Solution Approach 2:
The patent replaces expensive metal mounting components with molded plastic features that are lighter and sufficient for the application. The integrated design uses the visor body material itself for retention, eliminating the need for additional expensive hardware while maintaining assembly security.
Data Source
AI summary
A sun visor for use in a vehicle is disclosed. The sun visor includes a first and second visor body shell. The shells define a retaining channel for a slider on a visor pivot rod and may be engaged and enclosed about the slider. It is also contemplated that the sun visor has a combination slider and detent slidably supported in channels molded into the first and second visor shells. A support arm may be provided and is readily offset from the combination slider and detent and is slidable relative thereto.