Sun Visor Core Retention Member Design
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Solution Overview
Problem
The existing sun visors with plastic cores and foam pads lack sufficient strength and rigidity to efficiently retain a flexible cover, limiting the range of materials and tools that can be used for the cover application.
Innovation Solution
A sun visor core with a retention member featuring an aperture and projections to securely engage the cover, allowing for the use of various cover materials like PVC, woven, or non-woven fabrics, and enabling the same tools and processes for different cover applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If foam pads are used to provide softness and light weight, then tactile feel and weight are improved, but strength and rigidity are insufficient to retain the cover
Solution Approach 1:
The sun visor body combines foam pads (for softness and light weight) with a plastic core structure (for strength and rigidity). The core includes retention members with apertures and projections that provide mechanical retention of the cover, while the foam pads maintain tactile comfort. This composite structure resolves the contradiction between lightweight/soft materials and strong/rigid retention structures.
2Adaptability or versatility
If different cover materials are used, then versatility and customer choice are improved, but specific tools and processes are required for each material type
Solution Approach 1:
The retention member with aperture and projections is designed to universally retain different types of covers (PVC, woven fabric, non-woven fabric) through a single mechanical engagement mechanism. The same core structure and retention members are used regardless of cover material, eliminating the need for different tools and processes for different material types.
3Ease of operation
If a sock-like cover is used, then ease of application is improved, but insufficient retention strength prevents efficient cover retention
Solution Approach 1:
The retention member is segmented into an aperture for receiving the cover and multiple projections for engaging the cover material. This segmentation allows the cover to be easily inserted through the aperture while the projections provide secure mechanical retention, combining ease of application with reliable retention.
Solution Approach 2:
The projections act as intermediaries between the cover and the core structure. They penetrate or engage the flexible cover material to provide retention while allowing the cover to maintain its flexible, easy-to-application characteristics. The projections transfer the retention force from the rigid core to the flexible cover.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A sun visor core (10) comprises two major surfaces (11) and a perimeter (12). In correspondence with one portion of the perimeter (12) the core comprises a retention member (13) for retaining a portion of a flexible cover, the retention member (13) comprising an aperture (130) for receiving the portion of the flexible cover. The retention member (13) further comprises, in said aperture (130), a plurality of projections (130a, 130b) adapted for engaging the flexible cover.