A-pillar Visor with Magnetic Tolerance Compensation
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Solution Overview
Problem
Traditional visors in vehicles with extended windshields obstruct the view when stowed, as they are typically mounted on a header that forms a visual boundary, and manufacturing and assembly tolerances can lead to insecure attachment of visors due to mismatched lengths between anchor and housing.
Innovation Solution
A visor design anchored to the A-pillar with a magnet assembly that allows for a stowed position along the A-pillar, compensating for cross-vehicle tolerances, and featuring a reciprocating magnet arrangement for secure attachment and deployment, along with adjustable blades and integrated lighting and mirror systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the visor is mounted on the header in traditional vehicles, then the visor can be stowed or deployed, but the visor obstructs the driver's view when stowed due to the extended windshield forming a partial roof
Solution Approach 1:
The visor is extracted from its traditional mounting location on the header and repositioned to the A-pillar. This relocation removes the visor from the driver's field of view when stowed, eliminating the visual obstruction problem while preserving the visor's light-blocking functionality when deployed.
2Object-affected harmful factors
If the visor is hinged to the A-pillar, then the visor can be positioned along the A-pillar without obstructing view, but manufacturing and assembly tolerances cause mismatched lengths between anchor and housing leading to insecure attachment
Solution Approach 1:
The attachment system uses a magnet assembly with adjustable parameters. The magnet can be positioned at different distances from the housing, allowing the system to accommodate variations in component lengths caused by manufacturing tolerances. This parameter adjustment ensures secure attachment across different vehicles despite tolerance stack-up.
Solution Approach 2:
The magnet assembly incorporates a spring mechanism that allows dynamic adjustment of the magnet's position. The spring enables the magnet to move toward or away from the housing, providing adaptability to tolerance variations and ensuring reliable engagement between the visor and the vehicle structure.
3Device complexity
If a fixed magnet arrangement is used for visor attachment, then the structure is simple, but the attachment is insecure due to manufacturing and assembly tolerances
Solution Approach 1:
The magnet assembly transforms a static, fixed magnet arrangement into a dynamic system with adjustment capability. The spring-loaded mechanism allows the magnet to move and adapt its position, providing tolerance compensation while maintaining relatively simple overall structure.
Solution Approach 2:
The system changes the fixed parameter of magnet position into a variable parameter that can adjust within a range. This parameter change enables the magnet to accommodate tolerance variations in component lengths, ensuring secure attachment without significantly increasing device complexity.
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
Enhances visibility by keeping the visor out of the driver's field of view when stowed and ensures secure attachment by accommodating manufacturing and assembly tolerances, while providing adjustable lighting and mirror functionality.
Implementation Method 1
a magnet assembly that allows for a stowed position along the A-pillar, compensating for cross-vehicle tolerances, and featuring a reciprocating magnet arrangement for secure attachment and deployment
Data Source
AI summary
A vehicle includes: a front windshield that continuously extends along an A-pillar so as to form a partial roof of the vehicle above a driver area; a visor having a proximate end hinged to the A-pillar so as to assume a stowed position along the A-pillar; and on the front windshield, an attachment configured to selectively engage a distal end of the visor in a deployed position.