Vehicle Sun Visor Arcuate Contact Rotation Range
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Solution Overview
Problem
Conventional vehicle sun visors have a limited range of rotation angles where the conductor end portions can be energized due to the design of the columnar conductor end portions and spring terminals, resulting in an incomplete energized state.
Innovation Solution
The vehicle sun visor design features arcuate plate-shaped contact parts on the cylindrical-end portions of the non-conductive arm, with small-diameter and large-diameter cylindrical-end portions, and cutouts to prevent deformation, allowing for a wider contact range and ensuring the sun visor remains in an energized state across a broader rotation angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If columnar conductor end portions are used with spring terminals, then the structure is simple, but the contact range is limited and the circuit shuts off at certain rotation angles
Solution Approach 1:
The patent applies curvature by changing the contact part shape from columnar to arcuate plate shape. The arcuate plate-shaped contact parts follow the rotational movement of the arm, maintaining continuous contact with the terminals across a wider range of rotation angles, thereby preventing circuit shutdown while preserving structural simplicity.
Solution Approach 2:
The patent changes the geometric parameters of the contact parts by using arcuate plate shapes instead of columnar shapes. This parameter change allows the contact surfaces to accommodate various rotation angles, expanding the operational range from a limited angular position to a broader spectrum of orientations while maintaining reliable electrical contact.
2Reliability
If the contact parts are designed for wide contact range, then the energized state is maintained, but the terminal spring may deform during assembly
Solution Approach 1:
The patent segments the cylindrical-end portion into multiple sections with alternating cutouts. This segmentation creates discrete contact zones that prevent the terminal spring from deforming during assembly, as the cutouts provide clearance and reduce interference between the arm and terminal components while maintaining continuous electrical contact through the arcuate plate-shaped contact parts.
Solution Approach 2:
The patent extracts material by forming cutouts in the cylindrical-end portion. These removed portions eliminate potential interference points that could cause terminal spring deformation, allowing the arcuate plate-shaped contact parts to maintain wide contact range without compromising the structural integrity of the terminal assembly.
3Adaptability or versatility
If arcuate plate-shaped contact parts are used on both cylindrical-end portions, then contact range is widened, but the structure becomes more complex
Solution Approach 1:
The patent applies universality by using the same arcuate plate-shaped contact part design on both the small-diameter and large-diameter cylindrical-end portions. This standardized multi-functional design simplifies manufacturing and assembly while achieving wide contact range, as the identical contact part geometry can accommodate various rotation angles without requiring different structural configurations.
Data Source
AI summary
A vehicle sun visor has a sun visor body including an electrical component, an arm including a cylindrical-end portion with contact parts of a pair of conductors and rotatably holding the sun visor body, a mounting bracket for mounting the arm to a vehicle, and a connector including a pair of terminals to contact with a corresponding contact part of the pair of conductors. On the upper side and the lower side of the cylindrical-end portion exposed outside an arm-supporting portion of the mounting bracket, a small-diameter cylindrical-end portion and a large-diameter cylindrical-end portion are provided. The small-diameter cylindrical-end portion and the large-diameter cylindrical-end portion are provided with cutouts provided at alternate positions. First arcuate plate shape contact part is arranged on an outer peripheral surface of the small-diameter cylindrical-end portion, and second arcuate plate shape contact part is arranged on an outer peripheral surface of the large-diameter cylindrical-end portion.