Vehicle Visor Light Base Integration for LED Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sun visors in vehicles face challenges in manufacturing complexity, weight, and cost due to the use of incandescent bulbs and complex assembly processes, while consumers may resist the aesthetic changes brought by LED lighting.
Innovation Solution
A clamshell-type sun visor design with integrated LED lighting using a light base and circuit board, allowing for easy assembly and reduced component count, with a light guide system for even illumination, and the ability to hold the LED in either horizontal or vertical positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If incandescent bulbs are used for vanity lighting, then the light output is sufficient and warm, but the current consumption and power usage are high
Solution Approach 1:
The patent changes the lighting technology parameter from incandescent to LED, which fundamentally alters the energy-to-light efficiency ratio. The LED vanity light consumes significantly less current while providing adequate illumination, directly resolving the contradiction between energy consumption and light output.
2Strength
If multiple mounting pieces and journals are added to the visor construction, then the structural strength and retention are improved, but the manufacturing time and assembly complexity increase
Solution Approach 1:
The patent integrates the mounting function directly into the visor body structure itself, merging the support and retention functions with the main visor construction. This eliminates the need for separate mounting pieces and journals, maintaining structural strength while dramatically reducing assembly steps and manufacturing time.
Solution Approach 2:
The visor body is designed to serve multiple functions simultaneously: it provides the primary structural support, contains the lighting components, and integrates the mounting mechanism. This multi-functionality reduces the total number of components needed while maintaining overall structural integrity.
3Reliability
If the number of components such as slides, journals, and retainers is increased, then the visor durability and retention are improved, but the weight and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functional components into the visor body structure itself. The mounting features, support structures, and retention mechanisms are integrated directly into the visor housing, eliminating the need for separate slides, journals, and retainers. This reduces overall weight while maintaining durability through thoughtful structural integration.
4Ease of manufacture
If LED technology is implemented in the visor, then the energy efficiency and manufacturing simplicity are improved, but the aesthetic appearance and consumer acceptance may be compromised
Solution Approach 1:
The patent carefully selects LED parameters including color temperature and placement to match consumer expectations. By adjusting these parameters, the LED light achieves both energy efficiency and aesthetic appeal, resolving the contradiction between manufacturing simplicity and visual quality.
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 lightweight, cost-effective, and durable visor with improved manufacturing efficiency, reliable LED lighting, and an aesthetically pleasing illumination system that is easier to manufacture and more robust than prior art visors.
Implementation Method 1
a vanity having a light emitting diode (LED) to provide light therefore
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.