Thin Sun Visor Rotary Detent for Secure Positioning
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Solution Overview
Problem
Existing sun visors struggle to balance functionality, aesthetics, durability, and space-saving requirements while providing effective sun glare protection, often compromising visibility and interior design.
Innovation Solution
A sun visor design featuring a rotary detent mechanism, advanced materials like polyoxymethylene and gorilla glass, a sleek hinge design, and a streamlined construction with a rotary detent mechanism housed within an extruded aluminum tube, allowing for precise rotational movement and secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional sun visor designs are used, then basic sun blocking function is provided, but thickness and weight are excessive, compromising interior space and aesthetics
Solution Approach 1:
The sun visor is divided into multiple functional layers: a thin reflective layer for sun blocking, a structural frame for support, and a mounting mechanism. This segmentation allows the reflective function to be achieved with minimal thickness while maintaining structural integrity through the frame system.
Solution Approach 2:
The patent employs composite construction combining lightweight materials (aluminum alloy frame, plastic components) with a reflective coating layer. This composite approach provides effective sun blocking through the reflective layer while the lightweight frame structure minimizes overall thickness and weight, resolving the contradiction between thinness and functional effectiveness.
2Volume of moving object
If sun visor thickness is reduced for space-saving, then interior headroom is improved, but the mechanism for secure positioning becomes more complex
Solution Approach 1:
The rotary detent mechanism is nested within the hinge tube structure, with the detent bar and springs housed inside the hollow hinge tube. This nesting eliminates the need for separate positioning mechanism housings, maintaining a sleek thin profile while incorporating a functional detent system for secure positioning.
Solution Approach 2:
The patent employs a rotary detent mechanism that provides dynamic positioning capability, allowing the sun visor to be rotated to multiple angular positions and locked securely at each position. This dynamic system replaces static thick structures with a lightweight rotating assembly that achieves secure positioning through mechanical engagement of the detent bar with positioning notches.
3Reliability
If advanced materials like gorilla glass and polyoxymethylene are used, then durability and aesthetic appeal are enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent specifies precise material parameters and properties (e.g., polyoxymethylene for its self-lubricating properties and dimensional stability, gorilla glass for scratch resistance and thinness). By carefully selecting materials with specific parameters optimized for their functions, the design achieves high durability while keeping manufacturing processes straightforward through standard fabrication methods for these well-established materials.
4Shape
If the sun visor design is streamlined for aesthetics, then visual appeal is improved, but the hinge and mounting structure becomes more challenging to engineer
Solution Approach 1:
The hinge tube serves multiple functions simultaneously: it acts as the rotational axis for the sun visor, houses the rotary detent mechanism for positioning, provides structural support, and contributes to the sleek aesthetic profile. This merging of functions into a single integrated component achieves the desired streamlined appearance while managing engineering complexity through multi-functionality rather than adding separate components.
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 design enhances functionality and aesthetic appeal, reduces thickness and weight, and ensures secure, precise positioning, aligning with modern vehicle design requirements.
Implementation Method 1
a rotary detent mechanism including a detent bar urged by a plurality of detent springs to engage with a flat portion of an elbow tube
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
An automotive sun visor (102) is disclosed with enhanced functionality and aesthetic appeal for vehicle interiors. The sun visor (102) includes a frame (202) with a rotary detent mechanism (402) housed within a hinge tube (212), 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 (204) made from advanced materials such as gorilla glass or polycarbonate, and LED lamps for illumination. The rotary detent mechanism (402) comprises a detent bar (708), detent springs (706), and a detent subframe (702), 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.