Sliding Visor Floating Carrier Assembly
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Solution Overview
Problem
Existing sun visor designs for vehicles are complex and costly to manufacture, often requiring multiple assembly steps and additional components that can lead to weight, noise, and reduced strength, while also lacking a simple and secure fastening mechanism for vanity systems.
Innovation Solution
A sliding visor design featuring a floating carrier with a spring mechanism and 45° angled surfaces interacting with visor body halves, using ultrasonic weld joints and profile snaps for assembly, and a snap-in vanity system without screws, which simplifies assembly and enhances durability and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional clam shell design with multiple assembly steps is used, then manufacturing precision can be maintained, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple components (mounting pieces, journaling pieces, slides, retainers) into an integrated floating carrier assembly that is pre-assembled as a single unit. This merging eliminates the need for separate assembly steps when attaching these components to the visor body, directly reducing device complexity while maintaining manufacturing precision through the integrated design.
Solution Approach 2:
The floating carrier is pre-assembled with all necessary mounting and journaling features before being attached to the visor body. This preliminary action allows the entire assembly to be installed in a single step rather than requiring multiple assembly operations, thereby simplifying the manufacturing process without compromising the precision of individual component fitments.
2Reliability
If additional mounting pieces and journaling pieces are added for retention, then reliability of pivot rod retention is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The mounting pieces and journaling pieces are merged into a single integrated floating carrier structure. The floating carrier incorporates both the mounting function (to attach the pivot rod) and the journaling function (to guide and support it) within one component, maintaining reliability while reducing the total number of parts and assembly steps.
3Strength
If slides, journals, and retainers are added to the construction, then durability of the visor is improved, but weight, cost, and noise increase
Solution Approach 1:
The slides, journals, and retainers are combined into the floating carrier assembly, which is designed to provide all necessary structural support and movement guidance through its integrated construction. This merging reduces the total weight compared to having separate components while maintaining durability through the robust integrated design.
Solution Approach 2:
The patent extracts unnecessary intermediate components from the traditional design. By using the floating carrier as an integrated assembly, the design eliminates redundant parts that would add weight and cost, keeping only the essential functional elements needed for durability.
4Adaptability or versatility
If multiple components are used in construction, then functionality is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The floating carrier is pre-assembled with all functional components (mounting features, journaling surfaces, retention mechanisms) before installation. This preliminary action ensures that all necessary functionality is integrated into a single unit that can be quickly attached to the visor body, maintaining versatility while dramatically improving assembly speed and productivity.
5Reliability
If traditional fastening mechanisms with screws are used for vanity system, then secure attachment is achieved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent removes screws and other complex fastening mechanisms from the vanity attachment system. Instead, the vanity is directly integrated into the visor body through molded-in features or snap-fit mechanisms that provide secure attachment without requiring additional fasteners, thereby simplifying manufacturing and assembly while maintaining reliability.
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 design reduces manufacturing complexity and cost by enabling a robust, lightweight visor with improved durability and reduced noise, while maintaining a secure and aesthetically pleasing assembly with a snap-in vanity system.
Implementation Method 1
a spring arranged between first and second fingers of a body of the carrier, wherein the spring exerts a force against the fingers in an outward direction
Implementation Method 2
using ultrasonic weld joints and profile snaps for assembly
Data Source
AI summary
A sliding sun visor for use in a vehicle is disclosed. The sun visor includes a first and second visor body shell. At least one of the shells having a retaining channel for engaging and retaining a floating carrier on a visor pivot rod. It is also contemplated that the sun visor may have a snap in vanity system and rotating pin on a D-ring associated therewith. The visor body also may include a wire routing option to route a wire from the electrical system of a vehicle to a light bulb in a vanity.