Thin Vehicle Visor With Integrated Electrical Contacts
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Solution Overview
Problem
Existing sun visors in vehicles face challenges in manufacturing efficiency, cost, and durability, often requiring complex assembly processes and multiple components, which can lead to increased weight, noise, and reduced strength, while also lacking a thin, lightweight design with integrated vanity lighting and sliding features.
Innovation Solution
A thin sun visor design featuring dual shell halves that engage to form a visor body with a pivot rod and carrier, incorporating electrical contacts for vanity lighting and a sliding vanity door, manufactured using injection molding with snap-fit and vibration welding techniques to reduce complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components (mounting pieces, journals, retainers) are used to assemble the visor body, then the visor can be constructed with adequate strength and durability, but the assembly process becomes time-intensive and complex
Solution Approach 1:
The patent integrates the mounting piece, journal, and retainer functions into a single molded visor body shell. The shell is formed with integrated features including a molded-in mounting piece with pivot rod reception, molded-in journals for sliding movement, and molded-in retainers for component retention. This consolidation eliminates the need for separate assembly steps to attach these components, reducing assembly time and complexity while maintaining structural integrity and durability.
Solution Approach 2:
The visor body shell serves multiple functions simultaneously: it provides structural support, contains molded-in mounting features for the pivot rod, includes molded-in journals for carrier sliding, and incorporates molded-in retainers for securing components. This multi-functional design eliminates the need for separate specialized components, simplifying the overall assembly process while ensuring reliable visor operation.
2Reliability
If additional mounting pieces, journals, and retainers are incorporated into the visor construction, then the visor can retain components securely, but the overall weight and cost of the visor increase
Solution Approach 1:
The mounting piece, journals, and retainers are merged into a single molded visor body shell rather than being separate components. This integration reduces the total weight by eliminating the mass of multiple discrete parts and their fastening hardware, while the molded features provide adequate retention and securement of the pivot rod and carrier components through their integrated design.
3Reliability
If additional mounting pieces, journals, and retainers are used in the visor construction, then components can be secured properly, but the number of parts and manufacturing expense increase
Solution Approach 1:
The visor body shell is molded as a single piece that integrates the mounting piece, journals, and retainers. This consolidation reduces the number of separate parts that need to be manufactured, inventoried, and assembled. The integrated molded features eliminate the need for separate fasteners and connection hardware, reducing both material costs and manufacturing complexity while ensuring reliable component retention through the molded-in design.
4Weight of moving object
If a thin visor design with reduced thickness is implemented, then the visor weight and material usage are reduced, but the structural strength and durability may be compromised
Solution Approach 1:
The patent employs a thin-walled molded visor body shell that achieves structural strength through optimized molding techniques and integrated reinforcement features. The shell incorporates molded-in mounting pieces, journals, and retainers that provide structural support and component retention without requiring additional thickening of the overall visor profile. This allows the visor to maintain a thin, lightweight design while ensuring adequate strength and durability for withstanding repeated use.
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 manufacturing efficiency, reduces weight and noise, improves durability, and integrates vanity lighting and sliding functionality within a thin profile, addressing the need for a cost-effective, robust, and feature-rich sun visor.
Implementation Method 1
a pivot rod (26) mounted to a carrier (28), wherein the pivot rod (26) and carrier (28) are captured within the visor shell portions (22, 24) when they are secured together
Implementation Method 2
The visor also comprises a first electrical contact arranged on an end of the pivot rod and a second electrical contact arranged on a surface of the carrier. The visor further comprises a third electrical contact arranged on a surface of the carrier.
Data Source
AI summary
A thin visor for a vehicle comprising a pivot rod and a first and second shell being engageable to form a visor body. The visor also comprises a vanity secured to the visor body. The visor comprises a carrier positioned in the visor body and engaged with the pivot rod. The visor also comprises a first electrical contact arranged on an end of the pivot rod and a second electrical contact arranged on a surface of the carrier. The visor further comprises a third electrical contact arranged on a surface of the carrier. The thin visor generally has a width of approximately seventeen to eighteen millimeters and allows for a sleek small profile ergonomically designed visor to be arranged within a vehicle.