DE19853246A1 - Sun visor used in motor vehicle - Google Patents

Abstract

Two half-shells are thermally bonded together, and also to an outer decorative material. Between the shells, a separate rigid interior is inserted. The half-shells comprise inner and outer shells, the outer being bonded to the covering. The shells have an integral hinge connecting them, and are made as a single component. An Independent claim is included for the corresponding method of construction. The shells are made of mixed fibers with a strong, high-melting component and a low-melting thermoplastic component. The low melting component is a thermoplastic plastics, preferably polypropylene. In thermal bonding of the components, which include fibrous mats, gas pressure is introduced between them during hot pressing. The strong fibers may be flax, hemp, sisal, jute, bast, wood fibers or their mixtures.

Description

The invention relates to a sun visor, in particular for use in motor vehicles in the area above the Windshields are movably mounted to if necessary to be folded down or swiveled and the occupants from strong or low solar radiation protect.

Conventional sun visors are predominantly composite components made of different materials with a PVC film be encased and welded. Most sun visors are essentially rectangular and have a corner point on a so-called mirror foot that goes into a drive on the tool-side ball-joint leads to a free as possible To ensure mobility of the sun visor. In the area a second corner is a so-called locking axis, which as an axis of rotation for interaction with a vehicle egg term counterpart is formed to a swivel form, which serves as the axis of rotation for the sun visor and can also be disengaged if necessary Swivel the sun visor in other directions.

The conventional sun visors have a number of after parts. So these are generally structurally complex and usually consist of several core components, which the be already mentioned PVC film is wrapped. The PVC films have the disadvantage that this is undesirable for a certain time have chemical emissions, such as Plasticizer, vinyl chloride, etc. Furthermore, the PVC film not fully connected to the internal components and can so, z. B. expand when exposed to heat and folds or Form waves. Also the welding process is both the weld seam formed is technically complex as well relatively unaesthetic in appearance. Covers with textile The surface cannot be welded and has to be complex can be sewn in, so that this is only in the high-priced range can be used.

The invention is therefore based on the object of a new one To provide a sun visor that can be used by everyone Surface materials, lowest emissions and low Has weight and enables a very simple production light.

Furthermore, a high energy consumption in an accident caused by an occupant's head as well as a high torsional stiffness desirable. After all, it should there is no noise with mechanical twisting, in particular do not give a "creak".

An embodiment of the invention is shown in FIGS. 1 to 7, a second embodiment in FIGS. 8 and 9.

The basic principle of the first embodiment provides that a collapsible or available outer shell with a De is provided in the cormantle and integrated integrally, in this outer shell inserted an inner frame and then the Outer shell folded or folded and closed becomes.

The outer shell preferably consists of a stiffener the mixed fiber molded part, which in a pressing process with the Decorative coat was provided. For this, a mixed fiber mat, which consists of a mixture of stabilizing, firm and stiff fibers and matrix fibers from a low Rig melting fabric is made with a decorative layer is pressed under elevated temperature. With this press process melt the matrix fibers and glue them together Mixed fibers and the decorative layer to form an inte grail outer shell component. The matrix fibers exist preferably made of a low-melting plastic, especially polypropylene, while for the stable fibers natural fibers are particularly preferably used.  

The mixing ratio between the stabilizing and the matrix fibers can preferably be between 30:70 and 70:30 Percent by weight.

Flax fibers are particularly suitable as natural fibers, Hemp, kenaf, sisal, bast, jute, coconut, wood fiber or mi made of it. The natural fibers show at low fro costs, light weight and ecological production high strength and later facilitate disposal the sun visors. Alternatively, though less preferred synthetic fibers can be used, such as Glass fibers, nylon fibers, polyester fibers etc.

Mixed fiber mats with a weight per unit area of 300 to 4000 g / m ² , in particular 400-600 g / m ^{2, are} typically used. The pressures used for the pressing process depend on the type of materials used, in particular the decorative layer, and are between approximately 0.2 and 30 kg / cm ² . The temperature used depends on the melting point of the matrix fibers used and is typically around 200 ° C.

The insert frame inserted in the outer shell is on most useful as an injection molded plastic part or fiber Molding manufactured separately and has a shape that in a simple process in a form-fitting manner in the outer shell can be inserted or inserted. The insert frame preferably further comprises means for entering the Sun visor integrable insert such as make-up mirror, Lighting, etc. Particularly advantageous it is when the insert frame is made of the same materials has like the matrix material of the outer shell, for example in both cases polypropylene, so that two components in a simple manner with each other thermally can be connected.

Both the outer shell and the insert frame exist preferably each in one piece and has a so-called named film hinge on, d. H. one in the direction of buckling  extending constriction along which the two halves can be folded together. Alternatively, it would be possible to form two individual components by one separate hinge are connected. It would also be conceivable that the insert frame consists of two separate components.

The inner frame is designed so that it is low Material use a high stability for the entire son guaranteed and aperture for the entrance mentioned mirror base, the locking axis and the other inlets contains parts such as mirrors etc.

The locking axis can either be integrated into the inner frame be or particularly useful as a separate insert be provided, which is available in various colors, so that the sun visors with mirror base and Locking axis can be generated in a desired color, without reworking in the form of overpainting or Overcoating of the latter components required becomes.

To assemble this version of the suns according to the invention the inner frame is placed in the outer shell. Around to bring about a stable connection between these two components, are preferably undercut on the outer shell areas provided under the correspondingly shaped area surface of the inner frame. Then will the mirror base, the locking axis and possibly a make-up mirror and other inserts placed.

Then the two shell halves on the for it provided connection surfaces thermally heated and thus melted, folded onto each other and thus thermally connected.

Due to the construction according to the invention, a sun visor can be manufactured with very little production effort
The use of fiber materials also results in a low weight of the sun visor, which has high rigidity. Especially when using natural fiber reinforced polypropylene for the outer shell and polypropylene for the insert frame, the component can be thermally joined together without the use of additional adhesive. The shells guarantee a high level of energy absorption and break resistance, with the inner frame serving to connect and stiffen the outer shell and to accommodate and integrate inserts.

The invention can rationally use a sun visor absolute freedom in the choice of the decor surface gefer be made with as uniform a material structure as possible, low-emission materials and absolutely tack-free connection manure technology.

As an alternative to the thermal connection of the two shells halves, it is also possible to make locking connections in the form of To provide latches etc., although with this alterna tive the stiffness and strength is not as high as in the preferred thermal connection. The usage of glue is not particularly beneficial, however not excluded.

The second embodiment of the invention stands out by from that the sun visor from an interior and a Outer shell consists of the mixture mentioned at the beginning fiber are made, while the outer the this shells is pressed with the decorative layer. Both the The inner and the outer shell consist of two shells halves as in the first embodiment.

For the pressing, two mixed fiber mats and one sided decorative layer placed in a press tool and zwi introduced the two mixed fiber mats blowing nozzles. As a result, a gas, preferably air, is between the pressurized both mats, and if sufficient high temperature the two mats as well as the decorative layer thermally connected to each other. That in this way formed part consists of the two to fold  the half-shells over the film mentioned above hinge are interconnected. With this so-called ten "one-step process" are preferably in the press Appropriate facilities integrated to the outside contour of the molded part in one operation by cutting off Bring edge strips to the correct outer contour and to make corresponding rework processes superfluous. This embodiment is particularly suitable for large areas Sun visors in commercial vehicles.

After inserting the mirror base, inserts such as mirrors etc. and the locking axis are the two shells, as with the another embodiment, thermally at the connecting surface chen softened and folded so that an inte flashy component with an outer decorative surface is formed.

The particular advantage of this embodiment is one in that no separate insert frame is manufactured must be, but that only that to be folded Component manufactured in one manufacturing process and ge is formed.

The invention is described below with reference to the accompanying Drawings explained further.

In Fig. 1, a first embodiment of the sun visor 10 a according to the invention is shown schematically, which is essentially rectangular in shape and has a mirror base 12 and a locking axis 14 for attachment to the vehicle. The mirror base 12 preferably comprises a joint for pivoting the sun visor 10 a in three degrees of rotation, that is to say a ball joint, while the latching axis 14 is part of a rotatable joint which can be disengaged. The sun visor 10 a can also have inserts, for example in the form of a make-up mirror 16 .

In Fig. 2, the outer shell 18 of the invented inventive sun visor is shown in perspective, which consists essentially of two half-shells 20 a and 20 b, which are connected to one another via a film hinge 22 . The film share nier 22 consists of a defined line-like tapering of the material thickness, so that the two half-shells 20 a and 20 b can be folded without breaking material.

In the outer shell 18 , a correspondingly shaped recess 24 is provided for inserts, in particular a mirror 16 ( Fig. 1). Along the outer edge, the outer shell 18 has fixing strips 26 , which form undercuts between them and the undersides of the half-shells 20 a, 20 b for inserting the insert frames described below.

At a suitable point, a recess 28 with Lageraus cut 30 is provided for the locking axis 14 shown in FIG. 1. Furthermore, the fixing strips 26 are formed in such a way that a certain area 32 is formed for inserting the holding part of the mirror base 12 shown in FIG. 1.

In FIG. 3, the outer shell 18 shown in FIG. 2 is shown cut away along the line III-III shown in broken lines in FIG. 2, the edge region being shown enlarged in a detail. Here you can see the structure of the outer shell 18 consisting of a carrier shell 18 a, on the outside a decorative layer 18 b is brought on. The carrier shell 18 a consists of mixed fibers, which preferably consist of a portion of stable natural fibers and a portion of low-melting matrix fibers. Through the pressing process described above, the matrix fiber is melted and a thermal connection with the decorative layer 18 b is produced. In the enlarged view of Fig. 3 it can be seen that the opposing longitudinal edges 34 of the carrier shell 18 a are formed as sharp as possible, so that the decorative layer 18 b lying over it can also form the sharpest possible edge and in the folded state only a small, optically impairing longitudinal gap remains between the folded half shells.

In Fig. 4, the insert frame 36 according to the invention is Darge, which consists of two also connected to each other via a film hinge 38 generally rectangular frame halves 40 a and 40 b. On the outer periphery of the frame halves 40 a, 40 b, locking strips 42 are formed, which are designed such that they can be inserted in a form-fitting manner in the undercut space 44 under the fixing strips 26 of the outer shell 18 ( FIG. 3). The insertion frame 36 also has a receiving area 46 for the mirror base 12 ( FIG. 1) and bearings 48 for the locking axis 14 ( FIG. 1).

Furthermore, the insert frame 36 is provided with fixing devices 50 for fixing insert parts, such as, in particular, a mirror cassette 52 .

As shown in FIG. 5, the outer shell 18 and the insert frame 36 are connected to one another by kinking the latter along the film hinge 38 and inserting the insert frame into the outer shell 18 with elastic deformation of the fixing strips 26 and the locking strips 42 . This forms the molded part shown in FIG. 6, in which the outer shell 18 and the insert frame 36 are connected to one another in a preassembled manner.

In a subsequent connection process, the surfaces of the insert frame 36 , which are now exposed upwards, are first heated to such an extent that the material melts on the surface. Then the two frame halves are folded after inserting the mirror base 12 and the locking axis 14 , so that the melted connection areas 54 a and 54 b are welded together and is formed in tegral sun visor 10 a, as shown in Fig. 7.

In FIGS. 8 and 9, the second embodiment of the sun visor 10 according to the invention b, in which two mixed fiber mats 60 a and 60 b in a non dargestell tes press tool together with a sermatte below the Mischfa 60 a attached decorative sheet 62 is introduced. A gas is introduced in this tool between the two mixed fiber mats 60 a and 60 b via suitably attached blowing nozzles, so that they fit against the inner contour of the production mold and form the molded part shown in FIG. 8. As a result of the melting of the matrix fiber in the two mixed fiber mats 60, there is both an intimate connection to the decorative film 62 and, after cooling, a stable shaping of the two outer shells or mats.

After inserting inserts, such as in particular the mirror cassette 52 shown in FIG. 7, as well as the mirror base 12 and the locking axis 14 , as in the first embodiment, the exposed connection surface areas melt and the two shell halves collapse, firmly with one another are welded and in this way form the sun visor 10 b shown in FIG. 9.

Claims (10)

1. Sun visor, characterized in that it consists of two thermally connected half-shells, which are thermally connected on the outside with a decorative jacket and between the half-shells a separate stiff inner frame is inserted. 2. Sun visor, characterized in that this there are two thermally connected half-shells, each half-shell in turn from an inner and a Outer shell consists of the outer shell with the decor layer is thermally bonded. 3. Sun visor according to claim 1 or 2, characterized records that the two half-shells by a film set are connected and an integrally manufactured component form. 4. Sun visor according to one of the preceding claims, characterized in that the shells made of mixed fibers, consisting of a solid, high-melting fiber stock part and a low-melting component. 5. Sun visor according to claim 4, characterized in that the solid fiber component natural fibers, preferably Flax, hemp, kenaf, sisal, bast, jute, coconut, wood fibers or mixtures thereof. 6. Sun visor according to claim 4, characterized in that the low-melting component at least one thermoplastic, preferably polypropylene includes. 7. Sun visor according to one of the preceding claims, characterized in that this one or more of the in the description and / or the drawings Features includes.   8. A method of manufacturing the sun visor according to An saying 1, characterized in that one of two halves shell existing outer shell with thermoplastic Be components with a decorative film at an elevated temperature is pressed together, then in this outer shell separate rigid inner frame inserted and then the half shells are thermally assembled. 9. A method of manufacturing the sun visor according to An saying 2, characterized in that to form a or joint formation of both half-shells two fiber mat with thermoplastic components with a decorative film lie at elevated temperature and with simultaneous on conduct compressed gas between the two fiber mats together be pressed, and then the half-shells ther be mixed together. 10. Method of making a sun visor according to egg nem of claims 1 to 7, characterized in that the ses one or more of those in the description and / or the Drawings disclosed process features.