Magnetic Sun Visor Retention System
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Solution Overview
Problem
Existing sun visor attachment systems in vehicles, particularly the hook-and-pin configuration, are prone to high operational force variability with temperature changes, difficulty in disengagement due to directional constraints, and manufacturing tolerance issues, leading to potential damage, noise, and usability challenges, especially for shorter individuals.
Innovation Solution
A sun visor assembly using a magnetic retention system with a cylindrical pin and an arcuate mount, where the pin is engaged over less than half its circumference and held by magnetic attraction, allowing for broader directional disengagement and reduced temperature sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hook-and-pin attachment system is used with a polymeric hook, then the hook can be manufactured with simpler materials and processes, but the retention force becomes highly sensitive to temperature changes and manufacturing tolerances
Solution Approach 1:
The patent changes the retention mechanism from mechanical (hook geometry and elasticity) to magnetic (magnetic field strength). The magnetic retention force is determined by magnetic material properties and field strength rather than temperature-sensitive polymeric elasticity, making the retention force consistent across temperature variations while maintaining ease of manufacture through simple magnet insertion.
Solution Approach 2:
The patent replaces the mechanical hook-and-pin retention system with a magnetic retention system. Instead of relying on polymeric hook elasticity and mechanical interlocking, the invention uses magnetic attraction between a magnet in the mount and a ferromagnetic pin to provide temperature-insensitive retention force.
2Object-affected harmful factors
If the hook opening faces toward the windshield to allow forward disengagement during high acceleration, then damage to impacting objects is reduced, but disengagement becomes difficult for persons of short stature and may cause injury to the operator
Solution Approach 1:
The magnetic retention system provides multi-directional disengagement capability, making the system universal for different user needs and situations. Users can disengage the visor in any direction (forward, backward, sideways) regardless of their stature or position, while the system still provides protection during high acceleration events.
Solution Approach 2:
The magnetic retention system allows dynamic, multi-directional disengagement rather than being constrained to a single fixed direction. The magnetic field can be overcome from any direction, providing adaptability to different user scenarios while maintaining safety during unexpected acceleration events.
3Strength
If the pin is engaged over more than half the circumference of the pin in the hook, then the retention is stronger, but the disengagement requires excessive force and may fracture the hook at low temperatures
Solution Approach 1:
The patent changes the engagement geometry from extensive circumferential contact (more than half circumference) to limited contact (less than half circumference) with magnetic retention. The magnetic force provides sufficient retention strength without requiring excessive disengagement force, allowing easy release even when the pin is only partially engaged in the mount.
Solution Approach 2:
The patent replaces mechanical retention through extensive circumferential contact with magnetic retention. The magnetic attraction provides strong retention with minimal contact area, and disengagement simply requires overcoming the magnetic force by pulling the pin out, without requiring force to spread apart rigid hook walls.
4Reliability
If manufacturing tolerances are tightened to ensure reasonable performance under expected operating conditions, then retention force consistency improves, but manufacturing cost increases
Solution Approach 1:
The patent changes the critical retention parameters from geometric dimensions (hook opening size, pin diameter, engagement depth) to magnetic parameters (magnet strength, magnetic material properties). Magnetic components can be manufactured with standard tolerances and still provide consistent retention force, eliminating the need for expensive tight tolerance machining of hook and pin geometries.
Solution Approach 2:
The patent replaces precision mechanical fitting with magnetic attraction, which is inherently more tolerant of dimensional variations. The magnetic field provides a compliant retention mechanism that accommodates manufacturing variations without requiring tight tolerances, significantly reducing manufacturing cost while maintaining performance consistency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The magnetic retention system provides consistent performance across temperature variations, easier disengagement in various directions, and reduced risk of damage or noise, enhancing usability and manufacturing reliability.
Implementation Method 1
The opening faces generally downward when installed and the pin is held in the mount by magnetic attraction
Data Source
AI summary
A sun visor assembly includes a sun visor in which the corners associated with one of the longer edges are rotatably mounted to an automotive vehicle, one corner of which is fixed and the other corner being removable from a mount affixed to the vehicle. The removable corner has a cutout with a cylindrical pin coupled to the cutout at both ends of the pin. The mount has an arcuate cradle to engage the pin over less than half of its circumference. The opening to gain access to the cradle faces generally downward when installed and the pin is held in the mount by magnetic attraction.