Sun Visor Support Plate Insert-Molding Design
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Solution Overview
Problem
Conventional sun visor structures with large bases to support attachment components, such as ticket holders, face design restrictions due to interference with other components like vanity mirrors, limiting their placement flexibility.
Innovation Solution
A sun visor structure featuring a support plate with elastic engagement hooks and a guide pin, integrated into the foamed resin body, allowing for secure attachment and flexible placement of components like ticket holders with cantilevered elastic tongues and opposed hooks, which distribute external forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large base is used to support the attachment component, then the support reliability is improved, but the design freedom for component placement is reduced due to interference with other components
Solution Approach 1:
The support function is segmented from the attachment component base and transferred to a separate support plate structure. The support plate is insert-molded into the sun visor body, creating independent support points that do not require a large continuous base area, thus resolving the conflict between support reliability and design freedom.
Solution Approach 2:
A support plate acts as an intermediary element between the sun visor body and the attachment component. This mediator provides reliable support through its integration with the visor body while maintaining a compact footprint that does not interfere with other components like vanity mirrors.
2Reliability
If a large base area is occupied inside the sun visor body, then the attachment component can be supported reliably, but it interferes with other components such as vanity mirrors
Solution Approach 1:
The support structure is divided into discrete engagement points on the support plate rather than requiring a large continuous base area. This segmentation allows reliable support through multiple localized attachment points while minimizing interference with other components.
Solution Approach 2:
The support function is achieved by utilizing the depth dimension through insert-molding the support plate into the visor body, rather than occupying horizontal space. This dimensional transition allows reliable support without increasing the footprint area that would interfere with vanity mirrors or other components.
3Reliability
If the engagement holes are made smaller to secure the elastic hooks, then the support reliability is improved, but the insertion difficulty increases
Solution Approach 1:
The support plate is insert-molded into the sun visor body during the manufacturing process, creating precisely fitted engagement holes before the attachment component is assembled. This preliminary action ensures accurate positioning and appropriate clearance for the elastic hooks to engage reliably without requiring forceful insertion later.
Solution Approach 2:
The elastic hooks are designed to automatically engage with the engagement holes on the support plate through their elastic deformation capability. The hooks self-adjust to fit the hole dimensions, providing reliable engagement without requiring precise manual alignment or excessive insertion force.
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
Enables reliable support of attachment components while providing design flexibility, reducing interference with other components and enhancing structural rigidity and resistance to external forces.
Implementation Method 1
a support plate that is insert-molded in the sun visor body
Implementation Method 2
The attachment component has a first elastic engagement hook and a second elastic engagement hook
Implementation Method 3
the attachment component has a guide pin, and the support plate has a positioning hole for inserting the guide pin to position the attachment component
Data Source
AI summary
A sun visor structure includes a sun visor body made of foamed resin, a support plate that is insert-molded in the sun visor body, and an attachment component supported by the support plate. The attachment component has a first elastic engagement hook and a second elastic engagement hook. The sun visor body has insertion holes for inserting the first elastic engagement hook and the second elastic engagement hook. The support plate has engagement holes to engage the first elastic engagement hook and the second elastic engagement hook. The engagement holes are smaller than the insertion holes and concentric with the insertion holes. The attachment component has a guide pin. The support plate has a positioning hole for inserting the guide pin to position the attachment component.