Visor Assembly Inner Shield Spacer Design
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Solution Overview
Problem
The manufacture of inner shields in visor assemblies is complex and time-consuming due to the need for a silicone layer that requires precise application and curing, which can be contaminated by dust and dirt, leading to incorrect assembly and difficulties in recycling.
Innovation Solution
The inner shield features a protrusion along its periphery that forms the spacer, eliminating the need for a separate silicone layer and allowing for mechanical attachment and easy deformation for manufacturing, enabling simpler production and recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a silicone layer is used as a spacer between the inner shield and outer shield, then the insulation layer is created and the inner shield can distort relative to the outer shield, but the manufacture becomes complex and time-consuming due to adhesion and curing requirements
Solution Approach 1:
The spacer function is merged with the inner shield itself by forming a protrusion directly on the inner shield periphery. This eliminates the separate silicone layer and its associated adhesion and curing processes, while maintaining the insulation layer and distortion capability.
Solution Approach 2:
The silicone layer is extracted/removed from the system. The spacer function that was previously performed by the silicone layer is now performed by a protrusion formed from the inner shield material itself, eliminating the need for adhesion and curing processes.
2Adaptability or versatility
If a silicone layer is used as a spacer, then the inner shield can be positioned in replaceable manner, but the process is susceptible to contamination by dust and dirt during adhesion and curing
Solution Approach 1:
The silicone layer is removed from the system, eliminating the adhesion and curing processes that are susceptible to contamination. The protrusion is formed directly on the inner shield through mechanical deformation, which can be performed in a controlled manner without exposure to contaminants.
3Reliability
If a silicone layer is adhered to the inner shield, then the spacer function is achieved, but recycling of the inner shield becomes difficult
Solution Approach 1:
The silicone layer is removed from the system. The spacer function is now performed by a protrusion formed from the inner shield material itself, which can be easily separated and recycled without the complications of adhered silicone material.
4Ease of manufacture
If the inner shield is made with constant thickness, then simple manufacture from sheet material is enabled, but distortion relative to the outer shield is limited
Solution Approach 1:
The spacer function is merged with the inner shield by forming a protrusion. The inner shield maintains constant thickness for simple manufacture, while the protrusion provides the necessary spacing that enables distortion capability without compromising the constant thickness advantage.
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
This design simplifies the manufacturing process, reduces the risk of contamination, allows for distortion without internal stresses due to temperature differences, and facilitates easier recycling by integrating the spacer with the inner shield material, improving assembly and performance in extreme conditions.
Implementation Method 1
The distance between inner shield and outer shield is found in practice to be an advantage because it creates an insulation layer between inside and outside
Implementation Method 2
The protrusion is preferably arranged in the inner shield by mechanical deformation of the inner shield
Data Source
AI summary
Visor assembly (1) comprising an outer shield (2) and an inner shield (6) which is arranged at a distance therefrom and lies within the periphery of the outer shield, wherein a spacer (7) extending along the periphery of the inner shield is provided in order to hold the inner shield at a predetermined distance from the outer shield, wherein mechanical fixing means (10, 12) are arranged between the two shields for mutual fixation thereof, wherein the inner shield is formed at the position of its periphery such that a protrusion (7) from the inner shield is obtained, this protrusion forming the spacer.