GB1587837A - Sun visors for motor vehicles - Google Patents

Description

(54) SUN VISORS FOR MOTOR VEHICLES (71) We, AIO INDUSTRIE RIUNITE S.P.A., a joint stock Company organised under the Laws of Italy, of via S. Giacomo, 2-10092-Beinasco (Torino), Italy, (formerly ITT INDUSTRIES INC., a Corporation organised and existing under the Laws of the State of Delaware, United States of America, of 320 Park Avenue, New York 22, State of New York, United States of America,) do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates to a sun visor for motor vehicles, comprising a padded body, an internal reinforcement of metal wire, and an auxiliary support attached to the reinforcement. Sun visors of this type are supported at one end by means of a main support. comprising a support rod which penetrates longitudinally into the sun visor adjacent the upper edge of the latter and around which the sun visor can be unfolded; the auxiliary support is situated close to the other end of the sun-visor and is engageable with a coupling element (typic- ally in the form of an elastic gripper) attached to the bodywork of the vehicle, the base of the staple being aligned with the axis of the support rod.

In the sun visors presently known the auxiliary support is separately manufactured. At the end of its arms hooking elements are formed, usually in the form of a spike. For its own part, the reinforcement of metal wire is provided with a fixing unit, usually stamped out of plate and provided with hooking counter-teeth in which the arms of the staple are inserted during the assembly stage of the sun visor. This arrangement is complicated. for which reason the manufacture of the sun visor involves a notable time and cost factor of both materials and machining.

According to the present invention there is provided a sun visor, including a generally flat soft body, a metal wire reinforcement in said body, a first pivotal support in the vicinity of one end of the body and a second pivotal support in the vicinity of the other end of the body, the second support comprising a U-shaped core which is directly formed by the metal wire of the reinforcement and is covered by two half-shells moulded of plastics material and engaging each other in the plane of the U.

Preferably the two half-shells are moulded in one piece in which a weakening line (groove) is provided extending along the back of the support whereby the two half-shells are openable and closable in the manner of a hinge; thus, when being assembled the two half-shells are simply closed onto the U core projecting from the sun visor. The closing together can be made permanent by previously smearing on the mating face of at least one of the half-shells a suitable adhesive, for example, of the epoxy type. Preferably, on the matching face of one half-shell, protuberances are formed which are force-fitted into the corresponding cavities formed on the matching face of the other half-shell. In this manner one eliminates the risk that once tightened onto the core, the two half-shells could accidentally reopen before the adhesive sets sufficiently. As will be seen subsequently, these protuberances and cavities are preferably formed in those parts of the half-shells which enclose between themselves the corresponding branches of the core. The plastics material from which the half-shells are formed is preferably constituted of a polyamide resin or a co-polymer of acrylonitrile/butadiene/styrene (ABS).

In the appended drawings Figure 1 is a general view of the sun visor; Figure 2 is a view in elevation of the staple of the visor of Figure 1; Figure 3 is a transverse section according to line III-III of Figure 2; Figure 4 illustrates in perspective view the two half-shells in the open position, before being mounted on the core.

The visor 10 comprises a soft flat body formed by an envelope of two flexible sheets (for example PVC) welded together around the contour of the envelope. Between the sheets is enclosed a yieldable and elastic core, for example, of flexible polyurethane foam. At least two layers of polyurethane foam are used, between which is enclosed a stiffening reinforcement 12 made of elastically flexible wires. This reinforcement can assume the most diverse forms and can also be formed of a number of wires; Figure 1 illustrates only one convenient but many others are possible. The reinforcement comprises, in proximity to one end of the visor, a pivotal support 14 contructed of plate and adjacent to the upper edge of the sunscreen, in which is rotatably engaged (eventually snap-fitted) a support rod 16 directed in parallel to the upper edge of the visor.

The geometric axis of the rod 14 is indicated by X. The outer end of the rod is elbow bent and rotating in a support 18 fixable to the bodywork of the motor vehicle. The upper edge of the visor has close to the free end of the sun-visor, a recess 20, required for housing a second pivotal support, in such a manner that the longitudinal axis X' of the staple is aligned with the axis X of the rod 16. In these conditions, when the visor is rotated around the rod 16, the second support correspondingly rotates in a gripper element (not shown).

In Figure 2, it is seen how a section of the wire 12' of the reinforcement 12 projects from the bottom of the recess 20 and comprises two branches 12A interconnected by a base 12B to form a U configuration.

The base 12B is straight; the branches 12A are perpendicular to the base 12B but this is not essential.

The base 12B and the branches 12A, forming the core of the support, indicated by P in Figure 1, are covered by the two half-shells 22A. 22B moulded of synthetic thermoplastic material in an injection moulding press.

Each of the half-shells presents a general U-shaped form, with a flat face 24A, 24B respectively, matching with the other shell.

In the said flat face there is provided a groove 26A, 26B respectively, of semicircular section and of U-shape corresponding to that of the core. When the two half-shells are applied to the core their faces 24A, 24B mate relatively to each other (as shown by the join line 26 in Figure 3) and the join is made permanent by means of a suitable adhesive as already stated hereabove. The external cross member T of each half-shell is of essentially semi-circular profile, so that in the assembled condition (Figure 3) the external surfaces of the cross members conjointly form a cylindrical surface C at least approximately circular, coaxial with the axis X'. It is not important if whether the base 12B of the core of the support lies on the axis X'; in particular, the latter can be off-centre relatively to the inside of the U, as in the case illustrated, but parallel to the axis X'.

With advantage, the two half-shells are moulded in one piece, in which these are connected to each other back to back, as can be seen from Figure 4. Along the connection ridge zone there is provided, preferably from the inside, a groove 28 for the purpose of reducing the thickness of material in this area. In this manner, the two half-shells can be closed on the core 12A, 12B. Furthermore, it is advantageous to mould on the matching face 24A of the half-shell 22A, close to the end of the branches, projecting cylindrical pins 30, whilst in the matching face 24B of the half-shell 22B cylindrical seats 32 are provided in the positions corresponding to the small pins. The diameter of the pins is of some hundredths of a millimeter greater than that of the seats, so that, when closing the half-shells onto the core the pins 30 are force-fitted in the respective seats 32 and keep them closed until the setting of the adhesive which joins together the faces 24A, 24B.

By producing the pins 30 and the seats 32 with sufficient accuracy and by using for the half-shells 22A, 22B a thermoplastic material of high elasticity, such as, for example nylon, it is possible to achieve a sufficiently strong engagement of the pins in the seats to render superfluous the application of the adhesive; or, alternatively, it is sufficient to slightly spread adhesive only on the wire core 12A, 12B.

It is clear that the joining of the two half-shells onto the core of the staple can also be achieved by other means. For example, by using instead of the pins 30 only small conical projections and doing without the seats 32 the joining of the two half-shells can be easily achieved by means of ultrasonics.

WHAT WE CLAIM IS: 1. A sun visor, including a generally flat soft body, a metal wire reinforcement in said body, a first pivotal support in the vicinity of one end of the body and a second pivotal support in the vicinity of the other end of the body, the second support comprising a U-shaped core which is directly formed by the metal wire of the reinforcement and is covered by two half-shells moulded of plastics material and engaging each other in the plane of the U.

2. A sun visor according to claim 1, in

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (5)

**WARNING** start of CLMS field may overlap end of DESC **. Figure 3 is a transverse section according to line III-III of Figure 2; Figure 4 illustrates in perspective view the two half-shells in the open position, before being mounted on the core. The visor 10 comprises a soft flat body formed by an envelope of two flexible sheets (for example PVC) welded together around the contour of the envelope. Between the sheets is enclosed a yieldable and elastic core, for example, of flexible polyurethane foam. At least two layers of polyurethane foam are used, between which is enclosed a stiffening reinforcement 12 made of elastically flexible wires. This reinforcement can assume the most diverse forms and can also be formed of a number of wires; Figure 1 illustrates only one convenient but many others are possible. The reinforcement comprises, in proximity to one end of the visor, a pivotal support 14 contructed of plate and adjacent to the upper edge of the sunscreen, in which is rotatably engaged (eventually snap-fitted) a support rod 16 directed in parallel to the upper edge of the visor. The geometric axis of the rod 14 is indicated by X. The outer end of the rod is elbow bent and rotating in a support 18 fixable to the bodywork of the motor vehicle. The upper edge of the visor has close to the free end of the sun-visor, a recess 20, required for housing a second pivotal support, in such a manner that the longitudinal axis X' of the staple is aligned with the axis X of the rod 16. In these conditions, when the visor is rotated around the rod 16, the second support correspondingly rotates in a gripper element (not shown). In Figure 2, it is seen how a section of the wire 12' of the reinforcement 12 projects from the bottom of the recess 20 and comprises two branches 12A interconnected by a base 12B to form a U configuration. The base 12B is straight; the branches 12A are perpendicular to the base 12B but this is not essential. The base 12B and the branches 12A, forming the core of the support, indicated by P in Figure 1, are covered by the two half-shells 22A. 22B moulded of synthetic thermoplastic material in an injection moulding press. Each of the half-shells presents a general U-shaped form, with a flat face 24A, 24B respectively, matching with the other shell. In the said flat face there is provided a groove 26A, 26B respectively, of semicircular section and of U-shape corresponding to that of the core. When the two half-shells are applied to the core their faces 24A, 24B mate relatively to each other (as shown by the join line 26 in Figure 3) and the join is made permanent by means of a suitable adhesive as already stated hereabove. The external cross member T of each half-shell is of essentially semi-circular profile, so that in the assembled condition (Figure 3) the external surfaces of the cross members conjointly form a cylindrical surface C at least approximately circular, coaxial with the axis X'. It is not important if whether the base 12B of the core of the support lies on the axis X'; in particular, the latter can be off-centre relatively to the inside of the U, as in the case illustrated, but parallel to the axis X'. With advantage, the two half-shells are moulded in one piece, in which these are connected to each other back to back, as can be seen from Figure 4. Along the connection ridge zone there is provided, preferably from the inside, a groove 28 for the purpose of reducing the thickness of material in this area. In this manner, the two half-shells can be closed on the core 12A, 12B. Furthermore, it is advantageous to mould on the matching face 24A of the half-shell 22A, close to the end of the branches, projecting cylindrical pins 30, whilst in the matching face 24B of the half-shell 22B cylindrical seats 32 are provided in the positions corresponding to the small pins. The diameter of the pins is of some hundredths of a millimeter greater than that of the seats, so that, when closing the half-shells onto the core the pins 30 are force-fitted in the respective seats 32 and keep them closed until the setting of the adhesive which joins together the faces 24A, 24B. By producing the pins 30 and the seats 32 with sufficient accuracy and by using for the half-shells 22A, 22B a thermoplastic material of high elasticity, such as, for example nylon, it is possible to achieve a sufficiently strong engagement of the pins in the seats to render superfluous the application of the adhesive; or, alternatively, it is sufficient to slightly spread adhesive only on the wire core 12A, 12B. It is clear that the joining of the two half-shells onto the core of the staple can also be achieved by other means. For example, by using instead of the pins 30 only small conical projections and doing without the seats 32 the joining of the two half-shells can be easily achieved by means of ultrasonics. WHAT WE CLAIM IS:

1. A sun visor, including a generally flat soft body, a metal wire reinforcement in said body, a first pivotal support in the vicinity of one end of the body and a second pivotal support in the vicinity of the other end of the body, the second support comprising a U-shaped core which is directly formed by the metal wire of the reinforcement and is covered by two half-shells moulded of plastics material and engaging each other in the plane of the U.

2. A sun visor according to claim 1, in

which the two half-shells are moulded in one piece in which is provided a line of weakness extending along the back of the staple, whereby the two half-shells are openable and closable like a hinge.

3. A sun visor according to claim 1 or 2, in which protuberances are formed on the engagement face of one half-shell and make a force fit in corresponding cavities in the engagement face of the other half-shell.

4. A sun visor according to claim 1, 2 or 3, in which the plastics material is a polyamide resin or an acrylonitrile/butadiene/styrene (ABS) copolymer.

5. A sun visor substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.