Thin Sun Visor Rotary Detent for Precise Stowed Positioning
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Solution Overview
Problem
Existing sun visors in vehicles face challenges in balancing functionality, aesthetics, durability, and space-saving while providing effective sun glare protection, with traditional designs often compromising on one or more of these aspects.
Innovation Solution
A sun visor design featuring a rotary detent mechanism, constructed with advanced materials like polyoxymethylene and gorilla glass, and a sleek hinge system, allowing precise rotational movement and secure positioning, along with integrated LED lamps and a streamlined profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional sun visor designs are used, then basic sun glare protection is provided, but the visor thickness and profile are excessive, reducing headroom and cabin space
Solution Approach 1:
The sun visor is segmented into multiple functional layers: a thin reflective layer for glare protection, a structural frame for support, and a trim layer for aesthetics. This segmentation allows each layer to be optimized independently, achieving effective sun blocking with minimal overall thickness
Solution Approach 2:
The sun visor employs composite material construction combining thin metallic or dielectric reflective coatings with lightweight structural polymers and fabric trim layers. This composite approach provides effective sun glare protection while minimizing the visor's thickness and weight
2Volume of moving object
If sun visor thickness is reduced, then headroom and cabin space are improved, but the structural integrity and durability are compromised
Solution Approach 1:
The structural support function is separated from the sun-blocking function, with a lightweight frame providing structural integrity while thin reflective and trim layers provide sun protection. This segmentation allows the structure to be strong without requiring excessive thickness
Solution Approach 2:
High-strength, thin-gauge materials are used in the frame construction, combining rigid support elements with lightweight polymers. This composite material approach maintains structural integrity while minimizing overall visor thickness
3Reliability
If advanced materials like polyoxymethylene and gorilla glass are used, then durability and precision are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The rotary detent mechanism replaces complex multi-component locking systems with a simplified cam-based detent system using polyoxymethylene materials. This substitution maintains durability and precision while reducing part count and manufacturing complexity
Solution Approach 2:
The use of polyoxymethylene (POM) for the detent mechanism and gorilla glass or polycarbonate for the mirror integrates multiple functions (structural support, wear resistance, precision positioning) into single materials, simplifying assembly while maintaining high durability
Data Source
AI summary
An automotive sun visor is disclosed with enhanced functionality and aesthetic appeal for vehicle interiors. The sun visor includes a frame with a rotary detent mechanism housed within a hinge tube, facilitating precise rotational movement and secure positioning. The frame is constructed from two heat-welded plastic frame halves, eliminating the need for an expanded polypropylene layer, and reducing thickness. The sun visor features an integrated mirror made from advanced materials such as gorilla glass or polycarbonate, and LED lamps for illumination. The rotary detent mechanism comprises a detent bar, detent springs, and a detent subframe, providing a clicking action for tactile feedback when the sun visor reaches a stowed position. The sun visor's design allows for axial adjustment and pivotal movement between stowed and operational positions, contributing to safety and comfort within the vehicle.