Abstract:
Sun visor for a motor vehicle has a nail substantially parallel a longitudinal edge of a clamshell visor half and driving the nail through a clip rod positioned in a clip rod recess. The nail is driven by sliding a visor pivot rod or attached slider against one end thereof, driving the nail through the clip rod and securing the same in the recess.

Description:
TECHNICAL FIELD 
   The present invention relates generally to adjustable sun visors for use in motor vehicles, and relates more particularly to a method and design for a visor wherein during assembly a nail member is driven across a recess in a body of the visor and longitudinally through a clip rod to secure the clip rod in the recess. 
   BACKGROUND OF THE INVENTION 
   Sun visors are well known and widely used, and a great many designs have been successfully employed in vehicles over the years. Engineers have developed a variety of ways by which visor bodies and other interior components may be constructed and mounted in a vehicle to enhance functionality or aesthetic appeal. Advances in design, however, can often add complexity to the manufacturing process for interior components. There has been and continues to be a premium in the automotive industry on cost savings, and improvements in the efficiency and speed of manufacturing processes are often welcomed by the industry. An area of particular focus in automobile technology has been reducing the number and complexity of steps required to assemble interior components such as visors. 
   Many visors are constructed with a “clamshell” type design, involving the molding of two plastic shell pieces or clamshell halves which are joined to form the visor body. Upholstery coverings are then typically mounted over the visor body. The clamshell design allows the visor body to be constructed relatively quickly and easily, however, the various components attached to the visor clamshell halves must in some cases be incorporated with several assembly steps prior to securing the clamshell halves together. For example, several known designs require multiple mounting or securing steps to position and retain the visor clip rod in a recess in the visor body. The construction of visors having such a design is relatively time intensive. Eliminating parts and steps in assembly can reduce the expense of manufacturing and constructing the visor. It is thus desirable to provide a design wherein a component such as the visor clip rod can be secured relatively quickly and easily during manufacturing. 
   SUMMARY OF THE INVENTION 
   In one aspect, the present invention provides a clamshell visor including first and second visor shells, and a clip rod. During assembly a nail member is driven across a recess and through the clip rod, securing it in position. The nail is preferably driven with a slider mechanism attached to the visor pivot rod, or with the pivot rod itself. 
   In another aspect, the present invention provides a method of manufacturing a sun visor for a motor vehicle. The method includes the steps of positioning a nail substantially parallel a longitudinal edge of a visor shell, and driving the nail through a clip rod positioned in a clip rod recess in the visor shell. The nail is preferably driven by sliding a visor pivot rod or an attached member against one end thereof, thereby driving the nail through the clip rod and securing the same in the recess. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  illustrates a visor shell having a nail positioned therein in a pre-installed position prior to driving the nail through a clip rod, in accordance with a preferred embodiment of the present invention; 
       FIG. 2  is a sectioned side view taken along line A—A of  FIG. 1 ; 
       FIG. 3  illustrates a visor shell having a nail positioned therein in an installed position; 
       FIG. 4  is a sectioned side view taken along line A—A of  FIG. 3 ; 
       FIG. 5  is a perspective view of a visor according to a preferred embodiment of the present invention; 
       FIG. 6  is an exploded view of a slider, nail and clip rod according to a preferred embodiment of the present invention. 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   Referring to  FIGS. 1 and 2  there is shown a visor  10  according to a preferred embodiment of the present invention. Visor  10  includes a visor body  12 , with a nail member  20  positioned therein. Nail member  20  preferably includes an enlarged plastic head portion  22 , and a sharpened or pointed tip  24 . As illustrated in  FIG. 2 , visor body  12  preferably comprises first and second visor shell halves  12   a  and  12   b . Visor halves  12   a  and  12   b  are preferably molded plastic, and are engageable to form a clamshell-type visor body. In a preferred embodiment, visor shell halves  12   a  and  12   b  define an aperture  30 , through which nail member  20  may be pushed to secure a clip rod, as described herein. In a preferred embodiment visor shell halves  12   a  and  12   b  each include a plurality of molded supporting protrusions  34 , which guide nail member  20  as it is slid through aperture  30 . A molded plastic stop  32 , in cooperation with protrusions  34 , preferably assists in properly orienting nail  20  when positioned in visor body  12 . The present invention broadly provides a method of assembling a visor wherein nail  20  is slid through aperture  30 , through a clip rod (not shown in  FIGS. 1 and 2 ), with a slider or pivot rod (also not shown in  FIGS. 1 and 2 ), thereby securing a clip rod in the visor body.  FIGS. 3 and 4  illustrate visor  10  with nail member  20  in an installed position, traversing a recess  25 . 
   Referring now to  FIG. 5 , there is shown a visor  210  with a visor nail  220  that has been pushed across a recess  212 , through a clip rod  260 , thereby securing the same in recess  212 . In the  FIG. 5  embodiment, a combination slider and detent mechanism  250  rotatably journals a visor pivot rod  240 . During assembly of visor  210 , pivot rod  240  and slider  250  are positioned within a channel  255  defined by one or both of the visor shell halves  212   a  and  212   b . To assemble the visor, first and second shell halves  212   a  and  212   b  are closed about pivot rod  240  and slider  250  with nail  220  positioned proximate clip rod recess  212 . After the shell halves  212   a  and  212   b  are engaged, slider  250  and pivot rod  240  can be slid along channel  255 , preferably defined in part by first shell half  212   a  and also in part by second shell half  212   b , bringing an end of pivot rod  240  into engagement with enlarged head  222  of nail  220 . A technician can grasp one end of pivot rod  240 , or a sleeve and mounting assembly  241 , and manually push nail  220  across recess  212 , capturing clip rod  260  therein. Prior to engaging visor shell halves  212   a  and  212   b , nail  220  is preferably positioned in visor shell half  212   a , and may be supported by supporting protrusions (not shown in  FIG. 5 ) similar to those depicted in  FIGS. 1–4 . 
   In a preferred embodiment nail  220  will be oriented substantially parallel with a longitudinal edge  213  of shell half  212   a . Similarly, clip rod  260  is preferably oriented substantially parallel longitudinal edge  213 . Thus, when an axial force is applied to pivot rod  240 , pivot rod  240  can drive nail  220  through clip rod  260 . Embodiments are contemplated wherein an inner diameter of clip rod  260  is substantially equal to an outer diameter of nail  220 , as well as embodiments wherein the inner diameter of clip rod  260  is larger than an outer diameter of nail  220  such that clip rod  260  is rotatably journaled by nail  220 . 
   Turning now to  FIG. 6 , there is shown an alternative embodiment of the present invention  310  which includes a clip rod  360 , a nail  320 , with an enlarged head  322 , and a slider  350 . In the  FIG. 6  embodiment, slider  350  includes a protruding end member  352  that can engage head  322  for pushing of nail  320  into engagement with clip rod  360 . In a preferred embodiment, a detent mechanism, for example a clip detent (not shown) may be engaged with slider  350 , to rotatably journal a pivot rod (not shown), and hold the pivot rod in alternate raised or lowered positions, in a manner well known in the art. 
   The present description is for illustrative purposes only, and should not be construed to narrow the breadth of the present invention in any way. Thus, those skilled in the art will appreciate that various modifications might be made to the presently disclosed embodiments without departing from the spirit and scope of the invention. Other aspects, features, and advantages will be apparent upon an examination of the attached drawing Figures and appended claims.