Vehicle Sunshade Operating Beam With Variable Height and Controlled Width
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Solution Overview
Problem
Existing vehicle sunshade assembly operating beams face challenges in achieving sufficient stiffness while minimizing height to maximize headspace, leading to material waste or uneven dimensions.
Innovation Solution
A method of manufacturing an operating beam with variable height and controlled width by folding and stamping metal plate parts to create a rolled section and upstanding portion, ensuring consistent width and varying height profiles to fit vehicle roof contours without waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the height of the operating beam is increased to provide sufficient stiffness, then the stiffness and gravity endurance are improved, but the headspace in the vehicle is reduced
Solution Approach 1:
The operating beam is designed with variable height along its length, with the middle section having greater height than the end sections. This local variation in dimensions provides enhanced stiffness where needed (middle section) while maintaining smaller dimensions at the ends, thereby maximizing headspace without compromising overall structural performance
Solution Approach 2:
The patent transitions from a uniform cross-section design to a variable cross-section design, where the height dimension varies along the length of the beam. This dimensional variation allows the beam to achieve optimal stiffness-to-volume ratio, providing sufficient stiffness in the critical middle region while minimizing the volume occupied in the vehicle's headspace
2Volume of moving object
If the operating beam is shaved or cut to reduce height at ends, then the headspace is maximized, but material waste is generated
Solution Approach 1:
The variable height profile of the operating beam is incorporated into the initial shaping process of the extruded profile, rather than requiring subsequent machining or shaving operations. This preliminary formation of the final geometry eliminates the need for material removal at the ends, thereby maximizing headspace without generating material waste
Solution Approach 2:
The patent changes the geometric parameters of the operating beam along its length, specifically varying the height parameter while maintaining controlled width. This parameter variation is achieved through profile extrusion technology that can directly produce the desired variable cross-section, eliminating the need for post-processing material removal
3Volume of moving object
If the operating beam is pressed down to flatten ends, then the headspace is improved, but the width becomes uneven and manufacturing complexity increases
Solution Approach 1:
The variable height profile and controlled width are established during the profile extrusion process itself, before any assembly or installation steps. This preliminary formation ensures that the width remains consistent and controlled throughout the manufacturing process, eliminating the need for subsequent pressing or flattening operations that would compromise width uniformity
Solution Approach 2:
The patent employs parameter changes in the extrusion process to achieve the variable height profile while maintaining controlled width. By adjusting the die geometry and extrusion parameters, the manufacturing process directly produces the desired variable cross-section with consistent width, avoiding the need for post-processing operations
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 provides an operating beam with enhanced stiffness and optimal fit to vehicle roofs, minimizing material waste and maintaining consistent dimensions.
Implementation Method 1
folding the first metal plate part along a first side in the transversal direction thereby creating a rolled section for fixating a sunscreen, folding the first metal plate part along a second side in the transversal direction thereby creating an upstanding portion opposed to the rolled section
Implementation Method 2
stamping an end portion of the second metal plate part towards the first metal plate part, wherein the stamped portion of the second metal plate flows within the perimeter between the rolled section and the upstanding portion of the first metal plate part
Data Source
AI summary
A method of manufacturing an operating beam of a sunshade assembly having a variable height while controlling the width in manufacturing is provided. An operating beam manufactured as such and the use of said operating beam in a vehicle are also provided.