Flush mounted visor light

A truck mounted visor (1) containing a plurality of illumination sources (7, 8, 9, 11, 12). The illumination sources are flush mounted within the visor leading edge (6). Each light (7, 8, 9, 11, 12) is mounted within a cavity (26), and includes a bulb (13), socket (14) and mounting bracket (15).

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to an improved method and apparatus 
for providing a source of illumination used in conjunction with a vehicle 
mounted visor. In particular, the present invention includes a flush 
mounted light mounted within the visor. 
2. Description of Related Technology 
The use of windshield visors for trucks and other motor vehicles is well 
known. An illustrative embodiment of such a device is shown, for example, 
in U.S. Pat. No. 288,309, which discloses a visor which is mounted on the 
roof of a motor vehicle, preferably near the forward portion of the roof. 
The visor typically extends beyond the forward edge of the roof line, 
thereby extending above and beyond the plane of the windshield. Such a 
visor offers numerous advantages, including protection of the windshield 
from sun and rain, thereby improving visibility through the windshield for 
occupants of vehicle. Depending on the design of the visor, other benefits 
may include providing a mounting surface for vehicle accessories, such as 
a horn or a light. 
An example of a windshield visor including means for illumination is 
disclosed in U.S. Pat. No. 273,672. Previous visors that include lights 
have suffered from numerous problems, including a failure to direct 
substantially all of the light in a forward direction, promoting increased 
aerodynamic drag, and being located behind the visor leading edge, thereby 
preventing illumination of the area immediately in front of the visor. An 
example of a commercially available visor, which includes lights mounted 
on the leading edge of the visor, is the "suncap sunvisor", manufactured 
by the Deflecta-Shield Corporation of Corydon, Iowa. 
SUMMARY OF THE INVENTION 
The present invention addresses some of the shortcomings of prior art 
devices by providing a source of illumination that is countersunk or flush 
mounted with the leading edge of the visor, the lights thereby 
substantially conforming to the original shape of the visor such that 
there is no additional contribution to aerodynamic drag. Accordingly, a 
visor is provided with a substantially continuous leading edge in which 
appropriate orifices or indentations have been provided in which a lens, 
or transparent or translucent pane, may be placed, behind which is mounted 
a light. Several such lights may be mounted on a single visor, the light 
itself being recessed within the visor such that substantially all of the 
light is projected in a forward direction and illuminates the area 
immediately in front of the visor and beyond. Additional advantages 
include a smooth surface which is much easier to clean, particularly in an 
automated car wash in which any sort of appendage is subject to damage. 
Being recessed, the lights are less vulnerable to breakage from any 
source, and the visor itself is easier to manufacture since it is formed 
substantially as a single piece. By coating the interior of the recessed 
light structure with a suitable reflective material, more efficient light 
transmission is promoted since substantially all of the light is projected 
forwardly. The resulting visor has greater structural integrity since it 
is formed as a single piece in which the light structure tends to stiffen, 
rather than weaken the visor. Additionally, the visor produces less wind 
noise when the vehicle is in motion since the protruding lights do not 
generate turbulent vortices in their wake, insofar as they are recessed 
and do not increase the visor's total wetted area.

DETAILED DESCRIPTION OF THE INVENTION 
Referring generally to FIGS. 1 and 2, a first preferred embodiment of a 
visor 1 constructed in accordance with the principles of the present 
invention is shown. The visor 1 may be constructed of any of a variety of 
suitable materials, such as metals or composites. In the preferred 
embodiment, the visor is typically formed of a molded fiber glass 
material. The visor may be attached to a vehicle roof 60 by means of 
mounting holes 2, 3, 4, 27, 28, 41, 51 and 52 suitably located around the 
visor perimeter. The visor trailing edge 5 typically resides above the 
vehicle roof 60, with leading edge 6 protruding some distance beyond the 
vehicle roof so as to overhang the vehicle windshield 62, as shown in FIG. 
1. A series of lights 7, 8, 9, 11 and 12 are mounted within leading edge 6 
of the visor 1. 
As can be seen in FIGS. 2 and 3, the lights 7, 8, 9, 11 and 12 are mounted 
so as to be substantially flush with leading edge 6. In other words, the 
lights 7, 8, 9, 11 and 12 have a surface that conforms to the contour of 
leading edge 6 so as to cause a minimal discontinuity between the leading 
edge 6 and the lights themselves. This is in contrast to the light 29 
depicted in FIG. 7, which is typical of prior art mounting arrangements. 
As seen in FIG. 7, the light 29 is mounted in leading edge surface 30 of 
visor 31, but protrudes some distance 32 beyond leading edge 30. 
Referring now to FIGS. 8, 9 and 10, the specific mounting arrangement of 
the lights to the visor 1 will be discussed. A bulb 13 resides within a 
socket 14. A C-shaped clip 15 is provided to mount the bulb 13 and socket 
14 to the visor 1. The clip 15 is positioned to partially surround a 
portion of socket 14. Once the clip 15 is positioned around socket 14, 
movement of the socket 14 relative to clip 15 is restrained in a direction 
transverse to a plane formed by the clip 15. A shoulder portion 55 on the 
socket 14 and a stop 56 on the socket portion 14 engage the clip 15 to 
prevent the bulb 13 and 14 from moving transversely to the clip 15. A 
second stop 56 may be provided on socket 14 on a side opposite to the 
first stop 56 to permit the socket 14 to engage the clip 15 in a plurality 
of orientations. A mounting hole 16 is drilled or punched through clip 15 
to facilitate mounting of the clip 15 to the visor 1. 
A light housing 17 is mounted within visor 1, being either integrally 
formed with or mounted on the rear surface 33 of leading edge 6 and the 
bottom surface 18 of visor top 19. The housing 17 can be formed as part of 
the reinforced fiber glass structure of visor 1, or may be a separate 
metal or plastic enclosure subsequently attached to the visor. The housing 
17 is of a generally rectangular shape, with a bulb opening 20 residing in 
the rear housing wall 21. A suitable mounting hole 22 is also placed in 
rear housing wall 21 to facilitate mounting of clip 15. In a preferred 
embodiment, clip 15 is aligned with light housing 17 such that bulb 13 may 
pass through bulb opening 20 as mounting hole 16 aligns with mounting hole 
22. A gasket 23, with its own bulb opening 24 and mounting hole 25, is 
placed between clip 15 and housing rear wall 21 to prevent moisture and 
contaminant from entering bulb cavity 26. The clip 15, and gasket 23, are 
secured to housing 17 by means of self tapping screw 34. 
A pair of wires 35, 36 exits the rear 37 of socket 14, being eventually 
routed through race or channel 38 to a suitable source (not shown) of 
electrical power. As shown in FIG. 10, the channel 38 is located beneath 
light 12. It should be noted that one alternative location for the channel 
38 is adjacent the bottom surface 18 of the visor top 19 wherein the 
channel is above the lights. Channel 138 and wires 135 and 136, all shown 
in dashed lines in FIG. 10, illustrate this alternative location. 
The bulb cavity 26 is itself defined and sealed along the leading edge 6 of 
visor 1 by means of lens 39, which is contoured to substantially match the 
shape of leading edge 6. A gasket 40 is placed between lens 39 and leading 
edge 6 to provide protection from moisture and contaminants within bulb 
cavity 26. The lens 39 is secured by means of self tapping screws 42,43 
passing through mounting holes 44,45 within the lens 39, which are 
ultimately anchored to leading edge mounting holes 46, 47. The mounting 
holes 46, 47 reside within a recessed shelf region 48 which is offset from 
leading edge surface 6 by a distance substantially equal to the thickness 
of lens 39. 
Referring now to FIG. 11, a second preferred embodiment of a visor is shown 
having slightly different structure for mounting the lights to the visor. 
Instead of a clip 15 for mounting the bulb 13 and socket 14, a socket 
bracket 115 is provided. The socket 14 is permanently attached by means 
of, for example, an adhesive or a rivet, to socket bracket 115. Socket 
bracket 115 has at least one mounting hole 116 which has been formed, 
drilled or punched through the bracket 115. As in the first preferred 
embodiment shown in FIGS. 1-10, the socket bracket 115 of the second 
preferred embodiment, along with gasket 23, are secured to housing 17 by 
means of a self-tapping screw 34. 
The above description is of the preferred embodiments of the invention, but 
it will be apparent that many modifications and variations could be 
achieved by one skilled in the art without departing from the spirit or 
scope of the novel concepts of the invention. The scope of the invention 
should be determined by the appended claims only.