Vehicle Sun Visor Assembly With Adaptive PDLC Shading
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Solution Overview
Problem
Existing sun visor assemblies for vehicles are not lightweight or space-efficient while providing effective shading against luminous radiation, such as solar radiation and high beams from other vehicles.
Innovation Solution
A sun visor assembly with a dimensionally stable frame surrounding a flexible, light-transmitting carrier layer, where an electrically activatable light-inhibiting functional layer, such as a PDLC film, is applied extensively. The carrier layer is mounted taut within the frame, providing thin and lightweight protection, and can be configured with textile fabric or injection-molded plastics, with electrical activation and optional sensor systems for adaptive shading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional rigid sun visor structure is used, then structural strength and stability are ensured, but weight and space consumption increase
Solution Approach 1:
The patent employs a flexible carrier layer (textile or plastic) as the base structure instead of traditional rigid materials, significantly reducing weight while maintaining sufficient mechanical strength through the tensioned membrane structure. The frameless or minimal-frame design with tensioned edges allows the visor to achieve lightweight construction without sacrificing structural integrity.
Solution Approach 2:
The sun visor combines multiple materials with complementary properties: a flexible carrier layer (textile woven/knitted fabric or plastic membrane), electrochromic functional layers for light control, and transparent conductive coatings. This composite structure achieves both lightweight construction and adequate strength while adding functional capabilities.
2Object-affected harmful factors
If a thick rigid visor structure is used, then shading effectiveness is improved, but space efficiency and weight are worsened
Solution Approach 1:
The patent uses electrochromic functional layers that can dynamically change their optical properties (light transmission, shading density) in response to electrical activation. This allows a thin visor structure to provide variable shading effectiveness, replacing the need for thick rigid structures with fixed high shading properties.
Solution Approach 2:
The sun visor incorporates dynamically adjustable electrochromic layers that can change their light-blocking properties on demand, allowing a thin structure to achieve the shading effectiveness of thicker structures when needed. The dynamic adaptation eliminates the need for excessive material thickness.
3Adaptability or versatility
If an electrically activatable functional layer is added, then adaptive shading capability is improved, but device complexity increases
Solution Approach 1:
The flexible carrier layer serves multiple functions simultaneously: structural support, electrical conduction (when made with conductive materials), mechanical tensioning, and substrate for the electrochromic functional layers. This multi-functionality reduces the need for separate components, thereby reducing overall device complexity despite adding adaptive capabilities.
Solution Approach 2:
The patent merges the structural carrier layer with the electrical conduction function by using transparent conductive coatings or conductive textile bases. The frame structure is minimized or eliminated, merging the support function into the tensioned membrane itself. This consolidation reduces component count and assembly complexity while maintaining adaptive shading functionality.
4Weight of moving object
If the carrier layer is made taut and thin, then weight and thickness are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The tensioned carrier layer structure is designed to self-adjust and self-stabilize through its elastic properties and edge constraints. The material's inherent elasticity allows it to distribute tension evenly and maintain its shape without requiring extremely precise manufacturing tolerances. The system compensates for minor manufacturing variations through its flexible, tension-based structure.
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 offers a lightweight, space-saving, and effective sun shading system that provides dazzle protection against external luminous radiation, with adaptive darkening capabilities and reduced visibility of finger marks on the PDLC film, suitable for various transportation modes.
Implementation Method 1
The light-inhibiting functional layer may take the form of a PDLC film
Implementation Method 2
the light-inhibiting functional layer may be configured as an SPD film, as an electrochromic layer
Implementation Method 3
or as nanotubes applied to a transparent substrate, wherein the nanotubes unroll on electrical activation into a microscopic planar element, so resulting in increased darkening of the transparent substrate
Data Source
AI summary
A sun visor assembly for a vehicle interior and motor vehicle. The sun visor assembly has a visor arranged to be displaceable between a functional position and a resting position. The visor part has a dimensionally stable frame which surrounds at least one light-transmitting, flexible carrier layer, on which an electrically activatable light-inhibiting functional layer is extensively applied.