GB2108451A - Improvements in sun visor assemblies - Google Patents

Abstract

The frame wires (1, 2) of a sun visor body are sandwiched between the parts (17) of a plug assembly (16). The plug assembly (16) is received within a housing (6) for a pair of leaf springs (15) which bear on a support shaft (4) provided with opposed flats (36) for cooperation with the leaf springs to hold the visor in two stable positions. The leaf springs are each supported at their opposite ends, and an intermediate portion (38) of each spring is resiliently deflected on relative rotation of the housing (6) and shaft (4) from the stable positions. The plug parts (17) are each provided with an integral bridge piece (23) to enable the leaf springs to be assembled into position on the plug parts (17) prior to insertion of the plug assembly (16) into the housing (6). <IMAGE>

Description

SPECIFICATION Improvements in sun visor assemblies This invention is concerned with improvements in sun-visor assemblies for motor vehicles and is especially concerned with an improved arrangement for pivotally mounted a visor body on a support shaft to provide for at least one stable position of the body relative to the shaft.

Visor assemblies providing such a facility are known and comprise a visor body, which is normally a padded or covered frame, a mounting assembly which pivotally mounts the body on the support shaft and a spring device, forming part of the mounting assembly, which bears on flat portions on the shaft to provide the means to hold the body in the desired stable position.

Such known visor assemblies operate satisfactorily but have a number of undesirable characteristics.

Usually the mounting assembly comprises a metal hinge plate into which the support shaft extends and a metal spring which engages the support shaft for the purpose already mentioned. These metal parts frequently have very sharp edges and although covered by a skin or padding are nevertheless a safety hazard if the vehicle is involved in a collision.

According to the invention a sun-visor assembly comprises a visor body, a support shaft for the body, and a mounting assembly, the visor body being pivotally mounted on the support shaft by means of the mounting assembly, the mounting assembly housing a leaf spring which is arranged with its ends supported bythe mounting assembly and with an intermediate portion of the spring capable of move menttransversely of the length of the spring, the arrangement being such that in one angular position of the visor relative to the shaft the intermediate portion of the spring bears on a substantially flat face of the shaft to provide frictional stabilityforthe visor in that position.

On relative pivotal movement of the visor body and shaft from said angular position the intermediate portion of the spring will be resiliently deflected transversely of the length of the spring.

Preferably the leaf spring is substantially flat when in face contact with the flat face of the shaft, the spring bowing on relative pivotal movement of the visor body and shaft from said angular position.

The portion of the shaft provided with the flat face is preferably positioned substantially closer to one of said spring ends than to the other end, in order to provide a substantial spring force resisting pivotal movement of the visor body from said angular position, since transverse deflection of the intermediate portion of the spring when the intermediate portion is relatively close to said one end requires substantial bowing of the spring as compared with the bowing that would be produced if the shaft were to be located midway between the spring ends.

The mounting assembly preferably comprises a housing for the leaf spring, the housing devoid of sharp external edges to provide a safety housing for the spring.

Preferably the mounting assembly comprises a plug which is adapted to be received substantially within a socket provided in the housing and retaining means is provided to retain the plug in its assembled position, the direction of insertion of the plug into the socket lying substantially in the plane of the spring whereby the forces exerted on the spring in use do not substantially urge the plug outwardly of the socket.

The plug is preferably provided with location means for the spring, to enable the spring to be assembled into position on the plug prior to insertion of the plug into the socket, the location means ensuring that the spring is in its correct assembled position when the plug has been inserted into the housing socket.

Preferably the retaining means comprises a snap engagement between the plug and the housing since a snap engagement can be made sufficiently strong to bear any small forces which may tend to urge the plug outwardly of the socket. This is a considerable advantage of the plug and socket arrangement as compared with a housing constructed in two halves where a snap engagement would usually be inadequate to bear the forces tending to separate the housing halves.

The spring location means preferably comprises a bridge piece on the plug, but location pips or lugs may be employed.

The plug is preferably adapted to be secured to the visor body prior to insertion of the plug into the socket, and the housing is preferably provided with one or more slots connecting with the socket to receive the connections to the visor body on insertion of the plug into the socket. Usually the connections will be constituted by portions of a wire frame of the visor body.

A further undesirable characteristic of known visor assemblies is that the spring device comprises only one spring and if this spring breaks due to fatigue the visor body drops into the operative position and it may not be possible for the driver to return it to the inoperative stable position. Also, on some visors having a spring indexing device the friction provided by a single spring is frequently too great so making rotation of the visor body unnecessarily difficult.

According to a preferred feature of the invention there are two such leaf springs each supported at its ends and each capable independently of retaining the visor in the stable position by engagement with respective flat faces on the shaft.

Preferably the flats are provided on opposite sides of the shaft, and the arrangement may then provide two stable positions for the visor, 180 apart.

Preferably the leaf springs are arranged in positions facing each other on opposite sides of the shaft.

When a plug is employed with two leaf springs, the plug is preferably formed as two plug portions which are each provided with location means for a respective one of the springs, the plug portions being arranged to retain between them the connections to the visor body.

The plug portions are preferably each provided with one or more integral projecting tongues which are received within complementary recesses in the other plug portion when the plug portions are assembled together.

Preferably tongues and recesses are offset from a central axis of the plug portion which axis is parallel to the direction of insertion of the plug into the socket, and the plug portions are thereby enabled to be identical to avoid the need for handing.

Instead of employing a plug the housing may be formed in two halvs to enable insertion of the spring, the housing halves then being secured together in use by any convenient means such as screws, rivets or clamps.

The support shaft is preferably made of metal but may be of plastics and include means for retaining the shaft in the mounting member when assembled.

The shaft may have an angled end portion adapted to be connected directly to the vehicle structure, or a separate mounting bracket may be provided.

The mounting assembly and shaft may include electrical contacts and connections to provide for the operation of an illuminated vanity mirror mounted on the visor body, such means functioning to illuminate the mirror in one position of use of the visor and automatically switching of the light when the visor is moved to the inoperative position. Any convenient form of electrical pick-up may be provided for this purpose. When the mounting assembly is made of plastics the electrical contacts and/or connections may be embedded in the mounting assembly. Preferably, the pick-up comprises one fixed and one rotatable sleeve mounted on the shaft.

Avisor assembly in accordance with the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure I is a front view of the mounting assembly secured on the visor frame and with the assembled shaft; Figure 2 is a cross-section of the line 2-2 of Figure 1 with the visor being shown in its parked or inoperative position relative to the shaft; Figure 3 is a side elevation of one end portion of the shaft; Figure 4 is a side view of the housing of the mounting assembly; Figure 5 is an under plan view of the housing; Figure 6and 7are front and rear views respectively of one plug part; Figure 8 is a side elevation of a plug part; and Figures 9 and 10 are plan and under-plan views respectively of a plug part.

With reference to Figures 1 to 3, the visor assembly comprises a visor body comprising parallel visor frame wires 1 and 2 which are connected to one end portion 3 of a support shaft 4 by a mounting assembly 5. the visor body further comprises padding which surrounds the visor frame and mounting assembly 5 in the usual way. The support shaft 4 extends pivotallythrough the mounting assembly and thereby enables the visor body with the mounting assembly 5 to be pivoted in use from a parked or inoperative position to an operative position.

The mounting assembly 5 comprises a moulded plastics housing 6, shown in Figure 4 and 5, in the general form of an envelope or sleeve having an open lower end or mouth 7 and rectangular windows 8 and 9 in its identical front and rear walls 10.

The identical side walls of the housing are each provided with a circular hole 12, to allow passage of the shaft 4, and a vertical slot 13 extending from the lower end of the housing and having a rounded upper end 14 which in the assembled device is engaged by the frame wire 2.

A pair of identical flat leaf-springs 15 are housed in the mounting assembly 5. The springs 15 are oblong-rectangular pieces of spring steel which are flat on assembly into the mounting assembly. The springs 15 are located in position in the housing 6 by a plug assembly 16 which consists of two identical moulded plastics plug parts 17 between which are sandwiched the frame wires 1 and 2 seated in semi-circular recesses 18. The housing 6 is constructed as a socket to receive the plug assembly 16 and springs 15. The plug assembly 16 is slidably received within the lower part of the housing 10, a snap engagement between the plug assembly 16 and the housing 10 being provided by chamfered elongate projections 19 on the respective plug parts 17 engaging with opposing elongate openings 20 in the respective housing walls 10.

In a modification, not shown, a single frame wire is employed instead of the two wires 1, 2 and a joggled portion of the wire is clamped between the plug parts 17.

The construction of the plug assembly 16 is such that the plug assembly may be assembled onto the frame wires 1 and 2, and the leaf springs 15 may be located in position on the plug assembly 16 priorto insertion of the plug assembly into the housing 6, and then the plug assembly is simply pushed into the housing to assemble the springs 15 into position and wires 1 and 2 into position. Assembly is completed after the addition of padding to the frame by pushing the shaft end portion 3 through holes 12.

The construction of the identical plug parts is shown in Figures 6 to 10.

Each plug part 17 is essentially of the form of an oblong-rectangular slab having a flat front surface 21 interrupted by recesses 18 and by an oblongrectangular recess 22 extending rearwardly through the part 17 as far as a transversely extending bridge piece 23 forming part of the rear of the part 17. The upper edge 24 of the bridge piece 23 is defined by the lower extremity of a shallow recess 25 in the rear of the part 17, the recess 25 being open at its upper end 26. The depth of recess 25, in the direction normal to face 21 is such that an upper slot 27 is defined between bridge piece 23 and the face 28 defining the base of recess 25, the slot 27 having a thickness in the horizontal plane of Figure 2 to receive snugly the respective spring 17.

In order to define a lower slot 29 adjacent to the lower edge of the bridge piece 23, a transversely extending slot 30, of depth equal to that of recess 25 is provided adjacent to the bridge piece, but extending fully across the rear face of the plug part 17.

Since the recesses 25 and 30 may be provided by projections on one moulding tool, and the recess 22 by a projection on an opposing tool, this arrangement of recesses enables a two-part tool assembly without cores to be employed to mould the part 17 whilst producing slots 22 and 29 which act as vertical slots to receive the vertical spring 15.

An oblong-rectangular tab 31 projects forwardly from the upper end of part 17, one edge of the tab being located on the vertical centre-line of the part 17, the upper end of the part 17 being provided on the other side of the centre-line with a shallow slot 32 of shape complementary to that of tab 31 to receive the corresponding tab 31 of the other part 17.

A similar tab 33 and corresponding recess 34, a blind recess rather than a through-slot in this case, are provided at the lower end of part 17.

It will be appreciated that the off-setting of the tabs 31,33 from the vertical centre-line of the part 17 enables identical parts 17to be employed to make up ofthe plug assembly 16.

The function of the tabs 31,33 is to ensure accurate registration of the two plug parts 17 when they are assembled together prior to the insertion of the plug assembly 16 into the housing 6.

In order to assist in guiding the plug assembly 16 into its assembled position in housing 6 each plug part 17 is provided adjacent to its lower end with a pair of guide lugs 35 which are received in respective guide slots 36, Figure 5, provided in the mouth of the housing.

The plug parts 17 are adapted to act as carriers for the respective leaf springs 15 on assembly of the plug assembly 16 to the housing 6. As will be apparent from Figure 2 the leaf springs 15 can be assembled into their positions of use on the plug parts 17, prior to insertion of the plug assembly 16 into the housing, simply by inserting them downwardly through respective slots 22 and 29 until they abut the lower wall of the respective recess 18.

With frame wires 1 and 2 sandwiched between the plug parts 17 and with the leaf springs 15 located in the plug parts 17 it is simply necessary to push the plug assembly 16 into the mouth of housing 6 until the projections 19 snap into respective recesses 20 to hold the plug assembly in the assembled position shown in Figure 2.

Shaft 4 is provided at end portion 3 with opposed flats 36 for cooperation with the respective leaf springs, and the shaft4 may be assembled into housing 6 simply by pushing end portion 3 through holes 12. Suitable means may be provided to prevent lateral movement of the shaft 4 with respect to the housing 6.

As shown in Figure 2, the upper ends 37 of the respective springs 15 abut respective opposed platform faces 38' of the housing and with the shaft oriented as shown the undeflected spring leaves 15 abut the respective flats 36 in positions closely adjacent to the upper end 37 of the spring, but downwardly displaced therefrom. On relative rotation of the shaft 4 and mounting assembly 5 the intermediate portions 38 of the respective springs are resiliently deflected towards the respective windows 8,9 to bow the springs. The windows 8 and 9 are provided to accommodate the respecive bowed spings, and thereby enable the use of a slim housing 6. The lower end portions 39 of the respective springs are firmly clamped against transverse movement by the respective bridge pieces 23 in conjunction with abutment of the spring lower ends with the base 40 of respective recess 30.

The internal surfaces of the housing are provided with chamfers 41 to accommodate the displacement of intermediate portion 38 of the respective springs 15.

One stable position of the mounting assembly 5 relative to shaft 4 is shown in Figure 2 with the flats 36 in face contact with springs 15, but it will be appreciated that a further stable position will be when the shaft has been turned through 180 when again the flats 36 will each engage with a respective spring. In one stable position the visor will be retained in an inoperative position 'up' close to the vehicle roof and in the other it will be in an operative 'down' position.

Since the shaft portion 3 is arranged closely adjacent to the restrained upper end 37 of both spring leaves 15 a substantial frictional resistance is generated by the leaves when the shaft is rotated from the stable position, since substantial bowing of each spring leaf is produced.

It will be appreciated that the upper end 37 of the respective springs 15 can pivot about respective surface 38 to accommodate bowing of the springs 15.

Since the upper ends of the leaf springs 15 are protected by the housing 6, and the lower ends by the housing and by the plug parts 17 there is no danger of the vehicle occupant being cut by a spring in the event of a crash. The rounded corners on housing 6 are also provided for safety reasons.

Since the forces exerted on the springs 15 on rotation of shaft 4 act substantially transversely of the lengths of the springs, there is substantially no force generated on the plug assembly 16 in the direction urging the plug assembly outwardly of the housing, which thereby enables the simple snap connections 19,20 to provide a reliable means retaining the parts assembled in all conditions of use.

Since the springs 15 are independently mounted in the mounting assembly 5 failure of one spring 15 would not affect the operation of the other spring 15.

By ensuring that each spring is sufficiently strong on its own to retain the visor in the inoperative stable position it is ensured that failure of one spring does not result in the visor suddenly falling which would distract a driver.

An angled end portion 42 of the shaft 4 is secured in a visor mounting bracket (not shown). The angle of the end portion to the shaft axis is predetermined according to the mounting position of the visor on the vehicle wall. Similarly, the angular disposition of the opposed flats 36 relative to the angled end portion will depend on the installation.

After assembly of the mounting assembly 5 to the frame 1, 2 the visor frame is then suitably padded and covered in known manner to finish the visor and increase the safety factor still further prior to the insertion of shaft 4. The mounting assembly 5 may be used in conjunction with other bearing or hinge members which assist in rotatably supporting the visor body on the shaft 4.

In a modified form the visor is provided with an illuminated vanity mirror. To provide for an electrical connection from the vehicle electrical system to the vanity mirror light the mounting assembly includes an annular pick-up having a contact element and this is housed within a suitable recess surrounding the shaft 4. The shaft carries an insulated sleeve having an electrical contact which registers with the element in the pick-up when the visor is lowered to the operative stable position, so completing the light circuit.

Conducting wires may conveniently be embedded in the plastics body of the housing or metal parts of the visor frame may be used as conductors.

Alternatively, the electrical pick-up means may comprise one fixed and one rotatable sleeve mount on the shaft 4 on the outside of the mounting assembly 25 with suitable electrical connections thereto.

The mounting assembly may be other than rectangular and could be shaped to blend with the visor contours as desired.

Claims (11)

1. A sun-visor assembly comprising a visor body, a support shaft for the body, and a mounting assembly, the visor body being pivotally mounted on the support shaft by means of the mounting assembly, the mounting assembly housing a leaf spring which is arranged withits ends supported by the mounting assembly and with an intermediate portion of the spring capable of movement transversely of the length of the spring, the arrangement being such that in one angular position of the visor relative to the shaft the intermediate portion of the spring bears on a substantially flat face of the shaft to provide frictional stabilility for the visor in that position.

2. An assembly as claimed in claim 1 in which the arrangement is such that the leaf spring is substantially flat when in face contact with the flat face of the shaft.

3. An assembly as claimed in claim 1 or claim 2 in which the portion of the shaft provided with the flat face is positioned substantially closerto one of said spring ends than to the other end.

4. An assembly as claimed in any of the preceeding claims in which the mounting assembly comprises a housing, a plug which is adapted to be received substantially within a socket provided in the housing and retaining means to retain the plug in its assembled position, the direction of insertion of the plug into the socket lying substantially in the plane of the spring.

5. An assembly as claimed in claim 4 in which the plug is provided with location means for the spring.

6. An assembly as claimed in claim 5 in which the spring location means comprises a bridge piece on the plug.

7. An assembly as claimed in any of claims 4 to 6 in which the retaining means comprises a snap enagement between the plug and the housing.

8. An assembly as claimed in any of the preceding claims in which there are two such leaf springs each supported at its ends and each capable independently of retaining the visor in the stable position by engagement with respective flat faces on the shaft.

9. An assembly as claimed in claim 8 as appended to claim 4 in which the plug is formed as two plug portions which are each provided with location means for a respective one of the springs, the plug portions being arranged to retain between them connections to the visor body.

10. An assembly as claimed in claim 9 in which the plug portions are each provided with one or more integral projecting tongues which are received within complementary recesses in the other plug portion when the plug portions are assembled together.

11. A sun-visor assembly substantially as described with reference to the accompanying drawings.