Vehicle Visor LED Lighting Assembly Clamshell Design
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Solution Overview
Problem
Existing sun visors in vehicles face challenges in manufacturing efficiency, weight reduction, and durability while transitioning from incandescent bulbs to LEDs, with consumers resisting changes in light appearance and requiring more complex assembly processes.
Innovation Solution
A clamshell-type sun visor design incorporating a light emitting diode (LED) with a light guide system for even illumination, a frameless vanity with clear ends, and a light base capable of holding a circuit board in either orientation, simplifying assembly and reducing components, while using a wire for LED lighting integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If incandescent bulbs are used for vanity lighting, then consumers accept the light appearance, but current consumption and power usage increase
Solution Approach 1:
The patent changes the lighting technology parameter from incandescent bulbs to LEDs, which fundamentally alters energy consumption characteristics. LEDs consume significantly less current and power while providing adequate illumination, directly resolving the energy consumption issue while the integrated design handles the manufacturing complexity
Solution Approach 2:
The patent combines the LED light source, circuit board, and light base into an integrated assembly that is pre-mounted within the visor shell. This merging of components simplifies the manufacturing process by reducing the number of separate assembly steps required, despite the technological transition from incandescent to LED
2Loss of energy
If LED technology is implemented, then energy efficiency improves, but assembly process complexity increases
Solution Approach 1:
The circuit board with LED is pre-assembled and pre-positioned within the light base before final visor assembly. This preliminary action ensures proper alignment and electrical connections are established beforehand, reducing the complexity of the final assembly process while maintaining the energy efficiency benefits of LED technology
Solution Approach 2:
The patent employs a nested structure where the circuit board is mounted on the light base, which is then integrated into the visor shell. This nesting of components within each other creates a compact, organized assembly that simplifies manufacturing by reducing the number of separate installation steps
3Reliability
If multiple components are used in visor construction, then structural durability improves, but manufacturing time and weight increase
Solution Approach 1:
The patent merges multiple functional components into integrated assemblies. The light base, circuit board, and LED are combined into a single lighting assembly that is installed as one unit. The visor shell integrates mounting features for the pivot rod, vanity, and lighting assembly, reducing the number of separate assembly operations while maintaining structural durability
Solution Approach 2:
The visor shell is designed as a multi-functional component that provides structural support, housing for the vanity, mounting for the pivot rod, and integration for the lighting assembly. This universal design consolidates multiple functions into a single component, reducing manufacturing complexity and time while maintaining reliability
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 results in a more efficient, robust, and cost-effective sun visor with improved manufacturing ease, reliable LED lighting, and an aesthetically pleasing illumination system, addressing consumer acceptance and manufacturing complexity issues.
Implementation Method 1
a light emitting diode (LED) secured to a surface of the circuit board
Data Source
AI summary
A visor for use in a vehicle is disclosed. The visor comprises a pivot rod and a carrier arranged over the pivot rod. The visor also comprises a first and second shell being engagable to form a visor body and a vanity arranged therein. The visor also comprises a light base secured to the second shell and a circuit board engaging the light base. The visor also comprises a light emitting diode secured to a surface of the circuit board.