WO2006031835A2

WO2006031835A2 - Extruded visor assembly

Info

Publication number: WO2006031835A2
Application number: PCT/US2005/032608
Authority: WO
Inventors: Konrad H. Marcus
Original assignee: Extol Inc.
Priority date: 2004-09-14
Filing date: 2005-09-13
Publication date: 2006-03-23
Also published as: WO2006031835A3

Abstract

A visor body is extruded from a length of polymeric material which can be cut to a desirable length to form a visor core. The core is enclosed at opposite ends with end caps. One edge of the extrusion includes a spline for receiving a pivot rod for attaching the visor to a vehicle. In one embodiment, a retractable visor panel extends from the core. In one embodiment, the retractable panel can be pivoted and moved laterally. In yet another embodiment, the visor includes an illuminated vanity mirror assembly with a first mirror with a predetermined magnification and a second mirror having a second magnification characteristic.

Description

EXTRUDED VISOR ASSEMBLY

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U. S. C. § 119(e) on U.S. Provisional

Application No. 60/609,785 entitled EXTRUDED CORE VISOR, filed on September 14, 2004, by Konrad H. Marcus, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The present invention relates to automotive vehicle visors and particularly to visors having an extruded body allowing flexibility of design for different vehicles. Vehicle visors have been molded of polymeric material, typically utilizing a butterfly hinged polypropylene core which is folded to complete the visor body. The body can be covered by an upholstery material and may include accessories, such as illuminated vanity mirrors, garage door opening transmitters, and the like.

[0003] Other visor core constructions have been proposed, such as the use of fiberboard, planar sheets of polymeric material and blow-molded polymeric cores. With molded visor cores, each vehicle or line of vehicles into which the visor must be mounted typically requires a specific visor shape and, therefore, require different molds for each style of visor core. The result is a relatively expensive overall visor cost in view of the need for multiple molds for different vehicle lines. Although various attempts have been made to develop a low cost visor, the result is either a visor body which is very thin and somewhat flimsy in appearance and operation or a visor which does not withstand wear and have the necessary durability for use over the lifespan of a vehicle.

[0004] There exists a need, therefore, for a vehicle visor which is relatively inexpensive to manufacture and yet which is of high quality construction and allows for incorporation into a variety of vehicle lines without the necessity of multiple molds or dies to form the visor bodies.

SUMMARY OF THE INVENTION

[0005] The visor of the present invention satisfies this need by providing an extrusion of polymeric material which can be cut to a desirable length to form a visor core to accommodate different vehicles. In one preferred embodiment of the invention, the extruded visor core is hollow and enclosed at opposite ends with end caps. One edge of the extrusion forming the visor core includes an integrally extruded spline for receiving a pivot rod for attaching the visor body to a vehicle utilizing a conventional pivot rod assembly. In another embodiment of the present invention, the hollow extruded body includes an open edge opposite the spline such that a retractable auxiliary visor panel can be mounted within the visor body and extended for extending the overall sun-blocking coverage of the visor assembly. Also in one embodiment of the invention, the retractable visor panel can be pivoted and moved laterally along the direction of the longitudinal axis of the visor once extended to provide adjustable sun-blocking protection.

[0006] In yet another embodiment of the present invention, the visor assembly includes an externally mounted illuminated vanity mirror assembly having a pair of panels pivotally mounted to one another. A first panel is mounted to the visor body and, when the visor is in a lowered position use position, has a first mirror with a predetermined magnification. The second panel includes a surface which, when pivoted away from said first panel, faces the vehicle occupant and includes a mirror having a second magnification characteristic. In a preferred embodiment of the mirror assembly, illumination panels are provided adjacent one or both of the mirrors. One of the mirrors has a one-to-one magnification, and a second mirror has a magnification ratio greater than one-to-one, such as three-to-one.

[0007] These and other features, objects and advantages of the present invention will become apparent upon reading the following description thereof together with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Fig. 1 is a fragmentary perspective view of a vehicle incorporating a visor embodying the present invention;

[0009] Fig. 2 is an enlarged perspective view of the visor shown in Fig. 1, shown in an open use position with the vanity mirror assembly in a lowered use position;

[0010] Fig. 3 is an exploded perspective view of the components of the visor assembly shown in Figs. 1 and 2;

[0011] Fig. 4 is a perspective view of an extrusion which can be employed for manufacturing visor bodies of different configurations; [0012] Figs. 5A-5C are a perspective, a side view, and a top view, respectively, of the left end cap for one configuration of the visor assembly shown in Figs. 1-3;

[0013] Figs. 6A-6C are a perspective, a side view, and a top view, respectively, of the right end cap for the visor assembly shown in Figs. 1-3;

[0014] Figs. 7A-7C are vertical cross-sectional views of different cross-sectional extrusions which can be employed for different visor bodies;

[0015] Fig. 8 is a cross-sectional view of the visor assembly shown in Figs. 1-3, taken along section lines VIII-VIII of Fig. 2;

[0016] Fig. 9 is a left side elevational view of the visor shown in Figs. 1-3, illustrating the operation of the retractable panel;

[0017] Fig. 10 is a front elevational view, partly in phantom form, of the retractable panel assembly, shown in a retracted position; and

[0018] Fig. 11 is a front elevational view, partly in phantom form, of the retractable panel assembly, shown in an extended position, illustrating the adjustability of the panel once extended.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0019] Referring initially to Fig. 1, there is shown a vehicle 10, such as an automobile, sport utility vehicle, truck, or the like, which includes a roof 12, typically covered by a headliner 13, to which there may be mounted an overhead console 14 including a variety of electronic components, such as a compass, garage door opener, overhead lights, and the like. The vehicle 10 includes a windshield 15 to which there typically is mounted a rearview mirror 16. An A-pillar 18 supports roof 12 adjacent a side window 19. Mounted to roof 12 of the vehicle 10 is a visor assembly 20 embodying the present invention.

[0020] Visor assembly 20 may be mounted utilizing a pivot rod 22 (Fig. 2) which extends from the body of the visor, as described below, and is mounted to the vehicle at one end by a conventional pivot mounting bracket 24, which can be of the type which includes an elbow and socket which are coupled to rod 22 and secure to the vehicle roof 12 such that the visor can be lowered and pivoted from the front windshield position to the side window position in a conventional manner. The opposite end of pivot rod 22 may be releasably snap-fitted to the vehicle roof 12 by means of a conventional snap-in socket 26 for releasing the end of the passenger side visor shown to allow it to pivot to the side window when in a lowered position.

[0021] Visor assembly 20 shown in Figs. 1-3 includes a variety of features which may or may not be used for particular visors. In particular, visor assembly 20 as shown in Figs. 1-3 includes a retractable auxiliary pivotable and slidable visor panel assembly 80, as well as an illuminated vanity mirror assembly 60. Other visor assemblies 20 may not include these additional features.

[0022] The visor assembly 20 includes an extruded polymeric core 30 which is best seen in Figs. 3, 4, and Ik-IC. Each of the embodiments of the core 30 include a spline 32 at an upper edge which includes a longitudinally extending aperture 31 for receiving visor pivot rod 22 therein to allow the pivot mounting of the visor to the vehicle between a raised stored position, as illustrated in Fig. 1, to a lowered use position, as seen in Figs. 2, 10, and 11. Visor rod 22 may be a polymeric rod or, in some embodiments, a hollow metallic rod for receiving electrical conductors extending through pivot rod mounting bracket 24 for providing electrical power to an illuminated vanity mirror package 60. Further, the pivot rod 22 may comprise a pair of stub axles which extend from opposite ends of the visor assembly as opposed to a continuous, elongated rod. In any event, whatever pivot rod mechanism is employed, they will be supported by the spline 32 of visor core 30 and fit within aperture 31 of the extruded visor core 30.

[0023] The core 30 includes downwardly extending first and second spaced-apart walls

34 and 36 which may be integrally joined at an end 35 opposite the spline 32, as seen in the embodiment of Figs. 7A-7C, or may include an open slot 37, as seen in Figs. 3 and 8 for receiving the retractable auxiliary visor panel 80. In all embodiments, the visor core 30 is hollow, including an open volume 33 to provide a lighter weight visor and one which requires less material to manufacture. The visor core 30 may include reinforcing ribs, such as ribs 38 (Figs. 7A-7C), and walls 34 and 36 may be straight or have a variety of curved shapes depending upon the design of the line of vehicles into which the visor is to be installed.

[0024] Visor core 30, as seen in Fig. 4, can be extruded from a blank 39 of polymeric material, such as polypropylene, polyvinyl chloride, ABS, polycarbonate, or any other suitable polymeric material. The extrusion can be made utilizing any conventional, commercially available extrusion machines and formed in lengths of up to ten or more feet. Extrusion 39 can be cut, for example, at lines 40, 41, or 42, as seen in Fig. 4, to provide different lengths of visors depending upon the size of the vehicle into which the visor made from the visor core is to be mounted. The configuration of the cross section of the visor core, as seen in Figs. 3 and 7A-7C, can be varied as desired for a given planar or curvilinear shape for the cross section of the visor body. Extrusion or blank 39 forming the visor core 30 may also include additional reinforcing ribs, such as ribs 44 and 45 shown in the embodiment of Fig. 7C.

[0025] The wall thicknesses of walls 34, 36 of the visor core 30 can also be varied depending upon the length of the visor being manufactured and/or its cross-sectional configuration and whether or not interior support ribs, such as 44 and 45, are employed. Typically, the material will be as thin as reasonably possible to reduce the cost of the overall visor manufactured while maintaining its strength. The extrusion 39 can be textured by rollers mounted at the end of the extrusion machine while the material is still relatively warm and plastic to form a textured surface directly on the outer surface 46 (Fig. 4) of the extrusion to provide a textured appearance, as illustrated at a graphic 47 in Fig. 4. The visor core 30, once end caps 50 and 55 (Figs. 5A-5C and 6A-6C) have been mounted to the extruded core 30, can be upholstered with various fabrics 49 (Fig. 2) or vinyl material to conform the visor to that of the headliner material 13 of a given vehicle.

[0026] The visor core 30 is completed to form the body of the visor 20 by the mounting of left end cap 50 and right end cap 55 to the visor, as seen in Figs. 1-3, to enclose the open ends of the extrusion 39 and provide additional support for the walls 34 and 36. End caps 50, 55 are shaped to conform to a given visor extrusion 39 with end caps 50, 55 being shown to conform to that visor shape shown in Figs. 1-4. End cap 50 includes an outer wall 52 and an inner projection 54, which extends within the hollow space 33 of the core 30 and can be adhesively bonded to the left end of the visor or ultrasonically welded to the core. Typically, end caps 50, 55 will be made of the same material as the extrusion and will include an aperture 51 which aligns with aperture 31 of the visor core to provide additional support for the visor rod 22 regardless of the configuration of the visor rod. Similarly, right end cap 55 will have an outer wall 56 and an insert plug 58 which is inserted in the right end of the extrusion 39 forming the visor core 30 and also adhesively or ultrasonically bonded to the extruded core with an aperture 57 aligned with aperture 31 in the core for receiving the pivot rod. The end caps can be molded utilizing an injection molding machine and textured to match the texture 47 of the visor core or upholstered utilizing conventional upholstering techniques. Alternatively, the visor core 30 itself can be upholstered and the end caps 50, 55 textured for providing a decorative polymeric trim appearance to the visor.

[0027] As seen in Figs. 5A-5C and 6A-6C, the end caps can have a different or the same shape as one another, depending upon a particular visor, to provide the desired finished appearance to the visor 20 into which the end caps are installed. The visor described thus far is a plain visor with no auxiliary features, such as the illuminated vanity mirror assembly 60 shown in Figs. 2 and 3 or the auxiliary pull-out and sliding panel as illustrated in Figs. 3 and 8-11. These additional supplemental features can be incorporated onto the extrusion 39 forming the visor body or core 30, either individually or conjunctively, to provide a deluxe, higher featured visor. In addition, the hollow space 31 of the visor body can accommodate other auxiliary features, such as electronic packages including compasses, garage door openers, and the like. Two auxiliary features including a vanity mirror and retractable auxiliary panel, however, will now be described in conjunction with the basic visor.

[0028] Referring to Figs. 2 and 3, a vanity mirror assembly 60 is shown and includes a first panel 62 which includes a curved lip 64, which extends over the top edge 32 of visor body 30. Panel 62 has a first face 63 (Fig. 3) which faces the surface 49 of visor body 30 and an opposite face 65 to which a first vanity mirror 66 is secured. Mirror 66 has a first magnification characteristic such as a 1: 1 magnification and is spanned on opposite sides by illumination panels 67 and 68, which can be electroluminescent panels provided power through a pair of wires extending through a hollow pivot rod 22 and pivot rod mounting bracket 24 to the vehicle's electrical system. When the second panel 70, which is pivotally mounted to the lower edge of panel 62 by pivot pins 71 and 73, is lowered to expose mirror 66, power is applied to electroluminescent panels 67 and 68 to provide illumination for the mirror 66 and a second mirror 76 mounted to the second panel during low ambient light conditions. A conventional switch extending between panels 62 and 70 can be activated when panel 70 is pivoted to the position as seen in Fig. 2 for applying power to illumination means 67 and 68 which, instead of electroluminescent panels, can be other light sources, such as lamps or LEDs. The second panel 70 includes an outer surface 72 which is exposed to the interior of the vehicle when the visor is in a lowered use position and an opposite inner surface 74 to which mirror 76 is mounted. Mirror 76 has a magnification ratio different than mirror 66 and preferably is about a 3: 1 magnification to provide ease of use with, for example, makeup.

[0029] Mirror assembly 60 includes a tab 77 (Fig. 3) for releasing a catch 78 (Fig. 2) which snap-locks the second panel 70 to the first panel 62 for closing and opening the vanity mirror assembly 60 for use. Assembly 60 can be an entirely separate assembly which is injection molded of a suitable polymeric material which is the same as or blends with that of visor core 30 and can be attached to visor 20 utilizing a suitable adhesive material or ultrasonic bonding or by snap-fitting the visor utilizing the curved edge 64 and a similar curved edge (not shown) on the opposite edge of panel 62, such that the mirror package 60 snap-fits over the visor body. The vanity mirror package 60 may or may not include the supplemental lighting panels 67 and 68 but preferably includes the dual magnification mirrors 66 and 76.

[0030] The visor 20, as described above, may also include a retractable auxiliary panel assembly 80, as seen in Figs. 3 and 8-11. If the visor is to include such a feature, the extrusion 39 will include an elongated socket 81 (Figs. 3 and 8) below spline 32 for receiving an upper or first mounting bracket 82 of the auxiliary retractable panel assembly 80. Bracket 82 can be extruded of metal or polymeric material which has a cross-sectional configuration, as seen in Figs. 3 and 8, to fit within aperture 81 and pivotally receives a pair of pivot arms 84 and 86 which are pivotally mounted at their upper ends to bracket 82 by means of pivot pins 85 and 87 (Figs. 10 and 11). The opposite lower ends of pivot arms 84 and 86 are pivotally mounted by pivot pins 88 and 89 to a second bracket 90 in a parallelogram configuration, such that bracket 90 to which an auxiliary panel 100 is pivotally and slidably mounted can be moved between a retracted position, as shown in Figs. 1, 2, 8, and 10, to an extended position, as shown in Figs. 3, 9, and 11. [0031] Bracket 90 includes a catch 92 which can be a magnetic catch or can engage a socket (not shown) in bracket 82 for holding the retractable panel 100 in a retracted position, as seen in Fig. 10. Bracket 90 also includes a pair of downwardly extending mounting bosses 94 and 96 which receive a pivot rod 98 therebetween for pivotally and slidably receiving panel 100. Panel 100 can also be molded of a polymeric material and may include a reinforcing edge 102, as well as a pull tab 104, for extending the panel in a direction indicated by arrow A in Fig. 10 from the visor core 30. Panel 100 can be made of an opaque material, a semi translucent or transparent material tinted as desired or may be made of micro louver material for selectively blocking light therefrom. Further, the material can be a Polaroid material for preventing glare. In some embodiments, it may be made of electrochromic glass, which may include a sensor for sensing incoming light and changing the opacity of the panel for changing its light transmissive characteristics as desired to provide light blocking for the auxiliary panel 100. Panel 100 includes a socket 106 which extends over pivot rod 98 to allow the panel 100 to pivot in the direction indicated by arrow B in Fig. 9 forwardly and rearwardly, as well as slide laterally as indicated by arrow C in Fig. 11 laterally from side to side when panel 100 has been extended from the core 30 of visor 20. Bracket 90 can be manufactured of a molded polymeric material or formed of a cast metal, if desired, as can pivot rod 98. As seen in Figs. 3 and 11, the lower mounting bracket 90 for auxiliary light shield panel 100 includes mounting bosses 99 and 99 ' for receiving pivot arms 84, 86 and pivot pins 88, 89, respectively.

[0032] Thus, the extruded visor assembly of the present invention provide numerous options for different levels of visor construction, which can be configured with any desired cross section to fit a vehicle line and nest within the headliner in parallel relationship thereto and any desirable length by cutting an extruded length of visor core to the desired width of the visor. Various accessories can be additionally mounted to the visor, such as the illuminated vanity mirror assembly 60 as described in one embodiment of the invention, although other vanity mirror assemblies can likewise be incorporated into the visor body 30. Additionally, retractable and pivoted, slidable auxiliary visor panels can also be incorporated, such as assembly 80 of the present invention. The retractable panel, however, need not be pivoted and slidable for an embodiment but may pull out to extend the overall height of the visor without the additional features of pivoting and moving laterally. It will become apparent to those skilled in the art that these and various other modifications to the preferred embodiment of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.

Claims

The invention claimed is:

1. A vehicle visor body comprising: an extruded polymeric member having a front wall, a rear wall spaced from said front wall and an interconnecting spline to define a hollow visor body, said spline shaped for receiving a visor pivot rod for coupling the visor body to a vehicle; and a pair of end caps for enclosing opposite ends of said extruded polymeric member.

2. The visor body as defined in claim 1 and further including a panel mounted within the hollow extruded visor body and extendable therefrom for providing additional sun-blocking protection.

3. The visor body as defined in claim 2 wherein said panel is coupled to said visor body by at least one pivot member.

4. The visor body as defined in claim 2 wherein said panel is coupled to said visor body by a pair of pivot arms coupled to a bracket and said panel is pivotally coupled to said bracket for movement in a forward and rearward direction in a vehicle when extended.

5. The visor body as defined in claim 4 wherein said panel is slidably coupled to said bracket for lateral movement when extended.

6. The visor body as defined in claim 5 wherein said panel is made of one of an opaque, micro-louver, transparent, tinted, translucent, polarized, and/or electrochromic material.

7. The visor body as defined in claim 1 and further including a mirror assembly including a flat mirror and a magnifying mirror positioned in spaced relationship to each other.

8. The visor body as defined in claim 7 and further including an illumination source for said mirrors.

9. An automotive visor comprising: an extruded member having a first wall, a second wall spaced from said first wall, and an interconnecting spline along one edge, said member cut to a predetermined length for defining a visor body; end caps enclosing the opposite ends of the visor body so formed; said spline including an aperture for receiving a visor pivot rod; and a pivot rod mounted to said aperture in said spline for mounting said visor to a vehicle.

10. The visor as defined in claim 9 wherein said member is extruded of a polymeric material.

11. The visor as defined in claim 10 wherein said member has a hollow center and said visor includes a panel mounted within said hollow center for movement between a position retracted within said body to a position extended from said body.

12. The visor as defined in claim 11 wherein said panel is mounted to said spline by a pair of pivot arms.

13. The visor as defined in claim 12 wherein said panel is slidably coupled to said pivot arms for lateral movement when extended.

14. The visor as defined in claim 9 and further including a vanity mirror assembly including a first panel having a mirror with a first characteristic and a second panel pivotally mounted to said first panel and having a mirror having a second characteristic.

15. The visor as defined in claim 14 wherein said first characteristic is a magnification ratio of about 1 : 1 and said second characteristic is a magnification ratio greater than 1 : 1.

16. The visor as defined in claim 15 wherein said first panel is mounted to said body and includes said mirror with said first characteristic and said second panel has a surface facing said first panel and overlies said first panel when in a closed position, wherein said mirror having a second characteristic is mounted to said surface of said second panel to be exposed for use when said second panel is pivoted away from said first panel.

17. The visor as defined in claim 16 wherein one of said first and second panels include illumination means.

18. A method of manufacturing a visor body comprising the steps of: extruding a polymeric material to define a length of a member having a spline and first and second spaced-apart walls extending from said spline; cutting said member to a predetermined length to form a visor body; and capping the opposite ends of said body.

19. The method as defined in claim 18 and further including mounting a pivot rod to said spline.

20. The method as defined in claim 19 wherein said extruding step defines one of a generally flat and curvilinear cross section member.