Sun Visor Slide-On-Rod Assembly for Thin Low-Rattle Positioning
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Solution Overview
Problem
Conventional sun visor assemblies for vehicles increase the thickness and roofline height when deployed, reducing occupant headroom, and existing solutions do not effectively manage the transition between stowage and usage positions without increasing complexity or cost.
Innovation Solution
A slide-on-rod assembly featuring a carriage with angled contact surfaces and a spring cage, along with biasing members, which allows the sun visor to rotate and translate between positions while minimizing thickness and reducing rattling noise, by using frictional resistance and angled contact surfaces to control movement and reduce the need for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a positioning assembly is added to enable the sun visor to rotate and slide between positions, then the functionality and ease of operation are improved, but the thickness of the sun visor increases, reducing occupant headroom
Solution Approach 1:
The patent combines the positioning assembly with the rod assembly by integrating the carriage mechanism directly onto the rod. The carriage includes contact surfaces that engage with the rod, allowing the sun visor to rotate and slide without requiring separate positioning components. This merging of functions reduces the overall thickness of the assembly while maintaining full positioning capability.
Solution Approach 2:
The carriage is nested within or around the rod structure, with the contact surfaces positioned to engage the rod directly. The biasing member is integrated into the carriage assembly, creating a compact nested configuration. This nesting approach allows multiple functions (rotation, sliding, biasing) to be contained within a minimal thickness envelope.
2Reliability
If a spring cage and biasing members are added to control movement and reduce rattling, then the reliability and noise reduction are improved, but the device complexity increases
Solution Approach 1:
The biasing member is integrated directly into the carriage assembly, eliminating the need for a separate spring cage. The biasing member is positioned to directly engage the rod and provide the necessary biasing force, combining the spring function with the carriage structure. This reduces the number of separate components while maintaining reliability and noise reduction capabilities.
Solution Approach 2:
The patent extracts the essential function of the spring cage (providing biasing force) and implements it through a simplified biasing member integrated into the carriage. This extraction removes unnecessary structural elements of the spring cage while retaining the core functionality, thereby reducing complexity without compromising reliability.
3Length of moving object
If the sun visor is made thinner to reduce headroom loss, then the length is improved, but the ability to effectively block sunlight and maintain structural integrity deteriorates
Solution Approach 1:
The positioning and support functions are merged into the rod and carriage assembly, which is integrated directly into the sun visor structure. This consolidation allows the sun visor to be thinner while maintaining structural integrity through the reinforced rod-carriage connection points, which provide structural support without adding significant thickness.
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 solution enables smooth transition between stowage and usage positions, reduces the thickness of the sun visor assembly, minimizes rattling noise, and lowers the complexity and cost by utilizing frictional resistance and angled contact surfaces, while maintaining effective sunlight blocking.
Implementation Method 1
a biasing member coupled to the at least one wing and to the body of the carriage. The biasing member is configured to drive the at least one first contact surface of the carriage into contact with the at least one corresponding first contact surface of the tube and the at least one second contact surface of the at least one wing into contact with the at least one corresponding second contact surface of the tube
Implementation Method 2
utilizing frictional resistance and angled contact surfaces to control movement
Data Source
Figure 1
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AI summary
A slide-on-rod assembly (38) includes a tube (40) and a carriage (50) configured to move within the tube (40). The carriage (50) has a first contact surface (74), the carriage (50) includes a wing (84) rotatably coupled to a body of the carriage, the wing (84) has a second contact surface (76), the first contact surface (74) of the carriage (50) is configured to contact a corresponding first contact surface (80) of the tube, and the second contact surface (76) of the wing (84) is configured to contact a corresponding second contact surface (82) of the tube. The slide-on-rod assembly (38) also includes a biasing member (56) coupled to the at least one wing (84) and to the body of the carriage (50). The biasing member (56) is configured to drive the first contact surface (74) of the carriage (50) into contact with the corresponding first contact surface (80) of the tube (40) and the second contact surface (76) of the wing (84) into contact with the corresponding second contact surface (82) of the tube (40).