Vehicle Sun Visor Pin Riveting for Noise Reduction
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Solution Overview
Problem
Existing sun visor designs for vehicles, where shell-shaped halved bodies are joined using vibration welding, often result in insufficient welding finishes that can cause relative movement between the halved bodies when the sun visor is turned, leading to strange noises.
Innovation Solution
The sun visor incorporates a pin portion with an umbrella-like riveted end that restricts relative movement between halved bodies, allowing for visual inspection and correction of the riveting state, ensuring a secure joint and preventing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vibration welding is used to join the pin portion and insertion hole, then the assembly process is simplified, but the welding quality cannot be visually checked leading to insufficient welding
Solution Approach 1:
The patent applies ultrasonic riveting to form an umbrella-like portion at the front end of the pin portion, creating a visible structural change that indicates proper welding. This allows visual inspection of the welding quality without complicating the assembly process, as the riveted umbrella-like structure serves as both the joining mechanism and the visual indicator of proper assembly.
2Ease of manufacture
If vibration welding is used to join the halved bodies, then the assembly is simplified, but relative movement occurs causing strange noises
Solution Approach 1:
The patent performs ultrasonic riveting at the front end of the pin portion before final assembly, creating an umbrella-like portion that pre-reinforces the joint. This preliminary action ensures that when the pin is inserted into the insertion hole, the riveted structure prevents relative movement between the halved bodies, eliminating the source of strange noises while maintaining assembly simplicity.
3Device complexity
If the pin portion is inserted into the insertion hole without riveting, then the assembly is simple, but the halved bodies move relative to each other in the thickness direction
Solution Approach 1:
The patent applies ultrasonic riveting at the front end of the pin portion to create an umbrella-like portion that extends in the thickness direction. This dimensional change allows the riveted structure to engage with the insertion hole and surrounding material, restricting relative movement between the halved bodies in the thickness direction while maintaining a relatively simple pin-and-hole joining 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 prevents strange noises by ensuring a secure joint between the halved bodies, allowing the sun visor to be turned smoothly between in-use and storage positions without relative movement, enhancing the product's quality and appearance.
Implementation Method 1
A front end of the pin portion has an umbrella-like portion formed by riveting so as to restrict a relative movement between the halved body of the one half and the halved body of the other half in a thickness direction
Implementation Method 2
the vibration-welding the inserted front end of the pin portion 142 to the insertion hole 146 of the boss 148
Data Source
AI summary
A sun visor for a vehicle, includes a sun visor body including a pair of shell-shaped halved bodies that are joined to each other at multiple positions, and an arm. At least one joining structure of multiple joining structures including a pin portion projecting from an inner surface of the halved body of one half and an insertion hole of the halved body of the other half through which the pin portion can be inserted. A front end of the pin portion has an umbrella-like portion formed by riveting so as to restrict a relative movement between the halved body of the one half and the halved body of the other half in the thickness direction.