Visor and method for making the same

Abstract: An automobile visor has a self-supporting cardboard butterfly inner support (11,13) which is covered with a decorative material (17). The butterfly is folded to form opposing edges and a urethane adhesive (27) is used to bind the sides of the butterfly together and to clamp the decorative material in place. The adhesive (27) contacts the edge of the decorative material contained within the folded butterfly and fixes it firmly in place. As the urethane resin cures, it expands to form a rigid foam member which forms a stiffening member for the visor. A torque member is attached to the visor within the folded butterfly and has a member (25) for attachment to the ceiling of an automobile. The method of making the visor is also disclosed.

Description: The visors used in automobiles to protect the eyes of the driver and of the front seat passenger from direct sunlight or glare have undergone a substantial change over the years. What appears to be a simple device is actually a complex structure having a hardboard fibreboard or moulded plastic inner core which is covered with padding and then a decorative cover. A torque or visor pivot rod mechanism is also included for holding the visor in the stored position or to allow the visor to be set at the position which provides the preferred shade for the driver's or passenger's eyes, the use position. In a typical visor, a moulded plastic or hardboard frame is used to establish the overall configuration of the visor. In many cases, paper or thin cardboard, in what is called a butterfly configuration, is then folded over the plastic frame or hardboard. Foam padding is then glued to the paper butterfly and then the entire configuration is covered with a decorative material which is sewn in place about the edge of the visor. In some constructions, the foam padding has been placed underneath the paper butterfly with the decorative material being completely glued to the paper butterfly and wrapped around the padded core of the visor. US-A-4,570,990, shows a typical prior art visor construction. The patent discloses an automobile type visor employing a moulded plastic core comprising a folded self-supporting wall member. The edge of a decorative covering material is fastened by adhesive about the edge of the moulded plastic core and then the core is folded and fused to join the core halves together to additionally secure the edge portions of the decorative material by compressing the decorative material around the periphery between the abutting peripheral edges of the core halves. Abutments extend between opposed interior faces of the wall member which give support to the wall member and by means of which the two halves of the wall member are adhered together. The preambles of the independent claims are based on US-A-4,570,990. In all of the constructions of visors seen to date, a core member of some type has been used upon which the visor is assembled. In accordance with the present invention a vehicle visor incorporates those features set out in the characterising portion of Claim 1. In the preferred embodiment, the self-supporting member is preformed from cardboard. The cardboard material is formed to raise the centre portion of each butterfly wing relative to the surrounding edge. When the wings of the butterfly are closed together, the edges abut and the raised centre portion provides thickness to the visor. Before the cardboard is folded, adhesive is applied near one edge of the interior of the cardboard member. The cardboard core is then folded, bringing one edge into contact with the other, and the edge of the covering material is folded into the space between the two abutting cardboard edges. The assembly is then held together to allow the adhesive to firmly grip both cardboard faces and the edge of the decorative material which projects into the cardboard core. The adhesive expands to form a rigid foam member which not only adheres the two cardboard surfaces together, but also adheres to and fills any crevice and opening in the edge of the decorative material to firmly hold it in place. No inner core support is used in this construction of the visor which substantially simplifies the construction of the visor and reduces the expense by eliminating the core support and all the parts associated with the core support. In the improved visor of the preferred embodiment of the present invention, the adhesive performs multiple functions. It expands to fill the portion of the cavity in the visor adjacent the abutting edges. It firmly attaches the two cardboard faces together, secures the decorative covering material in place and forms a rigid stiffening member for the edge of the visor. It also simplifies the construction of the visor and eliminates the need for a heavy inner core which was previously used to clamp the decorative material in place on the outer surface of the visor. According to another aspect of the invention a method for making a vehicle visor comprises: those features set out in the characterising portion of Claim 23. The following description of an exemplary embodiment is made with reference to the accompanying drawings, in which:- Fig. 1 is an elevational view of an open visor assembly showing the butterfly core, the decorative fabric and adhesive in place along one edge of the core; Fig. 2 is an elevational view of the visor of Fig. 1 now closed; Fig. 3 is an enlarged partial sectional view taken along the line III-III of Fig. 2; Fig. 4 is a perspective view showing the visor in place in an automobile and with a vanity mirror installed and open in the visor. Referring to Fig. 1, the visor assembly is indicated generally by the number 10. The visor has an inner core made of the walls 11 and 13 preferably formed in one butterfly-like piece of a thin self-supporting material. The walls or wings 11 and 13 can be prepared by a die cutting or stamping procedure, or by moulding depending upon the material. The walls or wings 11 and 13 are intended to be folded, as shown by the directional arrow, about the crease lines indicated generally by the number 15. The crease lines provide a living hinge for the butterfly. Although within the narrowest aspect of this invention a paper derivative material is the preferred material from which the walls 11 and 13 are formed. Any compression formed composite natural or synthetic material can be used. The walls can be approximately 0.040 inch to 0.100 inch (1.02 to 2.54 mm) in thickness. The thin wall material is supported by the adhesive while thicker materials are unnecessary and thereby add expense. The preferred wall material is a cardboard formed of laminate of kraft paper 0.080 inch (2.03 mm) in thickness and having a thin sheet of plastic film under each outer layer of paper to provide wet strength. The material is sold under the trademark VALDOR by Fiber Converters of Three Rivers, Michigan. Similar materials are also available from other suppliers. The most important requirement for the wall material is that it be capable of being formed, be self-supporting and be compatible with the adhesive used, that is, nonreactive and capable of being wet or adhered to by the adhesive. In addition to cardboard and composite materials, plastic materials meeting these physical requirements can also be used as suitable wall materials for the visor. The outer surface of the visor 10 is covered with a decorative material 17 which completely covers the outer or exposed surface of the visor. The decorative material 17 can be cloth, leather, or preferably a vinyl or fabric outer sheet integrally bonded to a polymeric foam backing material. Within the broadest aspect of this invention it is conceivable that the outer surfaces of the walls 11 and 13 would have decorative surfaces or a flock coating applied thereto before or after being secured together, thus eliminating the need for a separate decorative material. Also, within the broadest aspect of this invention, a material formed into a sleeve can be slipped over the body formed by the two halves. The butterfly-like wing 11 has an opening 19 which is bounded by the edges 21. The butterfly-like wing 13 has a row of perforations 23 which are used to support a spring and detent member (not shown) which is used to hold the visor 10 on a pivot rod assembly 25 (Fig. 4). A suitable visor pivot rod assembly is disclosed in U.S. patent application Serial No. 413,235, filed September 27, 1989, in the name of M.Lanser et al. As shown in Fig. 1, the decorative material 17 covers the free edges of the butterfly wings 11 and 13. The material 17 is held in place on the cardboard core during the visor assembly process. Before the core is folded closed, a layer of adhesive 27 is applied adjacent the edge of the butterfly wing 13 in contact with the edge of the fabric material 17 which is turned inward over the edge of the butterfly wing. The adhesive 27 contacts the cardboard core and the edge of the decorative material. Since the butterfly is substantially symmetrical, when wing 11 is folded over wing 13 the adhesive 27 will contact the inner surface of the butterfly-like wing 11 and the edge of the decorative material covering the edge of the butterfly wing 11. It is only necessary to apply the adhesive to one wing of the butterfly in view of the substantially symmetrical construction. Upon folding of the butterfly, the adhesive will be applied to the closed (Fig. 2) wing where it will contact the cardboard core and the edges of the decorative material 17, which covers that wing of the butterfly. A separate deposit of adhesive 28 is made near the hinge to prevent the wings of the butterfly from sliding relative to one another. While many different adhesives can be used to seal the butterfly wings together to form the visor core, suitable adhesives are preferably applied as a viscous liquid and form a rigid member when cured or reacted; are compatible with the core and decorative cover material; and are able to withstand temperatures encountered by the interior of an automobile (220½ F. or 104°C). Moisture cured polyurethane resins and hot melt polyamid resins are suitable for use. The preferred adhesive is a rigid urethane foam similar to the type used for insulation purposes. The foam can be either a single urethane resin or, by way of example and not limitation, a two part mixture of a urethane resin and an isocyanate resin. Suitable urethane resins are available from Dow Chemical, Mobay, Tanner Chemical and BASF. The preferred material from BASF is a "TF" foam adhesive which is a mixture of a urethane and an isocyanate resin. The resin includes a hallogenated hydrocarbon blowing agent to cause the material to foam. A foam adhesive is preferred since the foam cuts down on the amount of adhesive material used, and the weight of the adhesive. Adhesive 27 can be applied from a dispenser having a nozzle which will lay down a bead of the adhesive along the edge of the cardboard butterfly in contact with the edge of the decorative material. The butterfly is closed after application of the adhesive and the urethane resin reacts quickly to foam and form a rigid member which firmly seals the two wings of the butterfly together and firmly attaches and holds the decorative material in place. The decorative material is only loosely held by the edges of the visor core. Now referring to Fig. 3, it can be seen that the adhesive 27 expands and becomes a rigid foam-like material. The expansion of the adhesive fills the portion of the cavity within the visor adjacent the abutting edges and any recess or cavities in the decorative cover material to securely adhere the cover to the core. The visor has a smooth leading edge 14 (Fig. 2) caused by the gradual bending of the cardboard butterfly core material about the series of crease lines 15. The crease lines 15 are a series of parallel relief cuts in the surface of the cardboard material which form a living hinge and facilitate the smooth bending of the cardboard core. At the opposite edge of the visor, the decorative material 17 is turned in between the edges of the wings 11 and 13 and forms a smooth trailing edge 16 on the visor with the decorative material being held tightly in place by the adhesive. No stitching is required to hold the decorative material in place. Also, the cardboard core is not intended to clamp the material in place as is the usual practice with polymeric cores, the construction here being much simpler than that with polymeric butterfly cores which rely on a high clamping pressure between the opposed edges of the folded butterfly polymeric material to hold the decorative material in place. If desired, a vanity mirror 31 can be placed into the open area 19 in the face of the visor, as shown in Fig. 4. The vanity mirror can be glued to the back of the visor 13 with the same adhesive. The back of the mirror should have a safety coating thereon to prevent glass fragments from escaping in the event of an accident. A layer of tape can be used for the safety coating. In Fig. 4, the visor 10 is shown lowered covering a portion of the windshield 35. The adhesive material 27 cures to become a rigid foam reinforcing member about the edge of the visor (Fig. 2). The cured adhesive gives the visor substantial torsional strength so that it can be manipulated by the driver or passenger in the vehicle without distortion or damage. In the past, the visor had to rely on an internal reinforcing member which added cost and complexity to the visor. From the above description, it can be seen that a substantially improved automobile visor has been developed using a cardboard or cardboard-like material as a self-supporting, rigid core member. No additional internal structure is needed to support the visor other than the cardboard and the adhesive material which performs multiple functions. The adhesive adheres two wings of the butterfly core together, secures the decorative material in place, and provides a reinforcing member for the edges of the visor. Though the invention has been described with respect to a specific preferred embodiment thereof, many variations and modifications will become apparent to those skilled in the art, provided they remain within the scope of the invention as defined by the claims.

Claims: A vehicle visor comprising a self-supporting wall member (11,13) which is folded to form a core of the visor, the core having abutting edge portions; a decorative material (17) covering the outside of the core and having an edge portion turned over the edges of the core into the interior of the core; characterised by a layer of adhesive (27) which adheres to the opposite inside surfaces of the wall member adjacent the abutting edge and thus attaches the two sides of the wall member, and which adheres to the decorative material along said abutting edges. A visor as claimed in Claim 1 wherein the core is in a butterfly-like configuration which is folded about a centre hinge portion (15). A visor as claimed in Claim 1 or Claim 2 wherein the decorative material (17) has an edge portion which extends beyond the edge of the folded core, the edge portion being turned into the folded core to cover the abutting edges of the core. A visor as claimed in any one of the preceding claims wherein the layer of adhesive (27) is in the form of an expanded bead, preferably a rigid expanded bead. A visor as claimed in any one of the preceding claims wherein the adhesive (27) contacts the edge portion of the decorative material (17) and secures the decorative material in place on the core. A visor as claimed in any one of the preceding claim wherein the adhesive (27) is a rigid form. A visor as claimed in Claim 6 wherein the adhesive (27) is a polyurethane resin which hardens to the rigid foam. A visor as claimed in Claim 6 wherein the adhesive (27) is a mixture of a urethane resin and an isocyanate resin which hardens to the rigid foam. A visor as claimed in anyone of the preceding claims including a torque member attached within the core, the torque member having means (25) for attaching the torque member to a vehicle preferably comprising an extending member. A visor as claimed in any one of the preceding claims wherein the core is made of cardboard which is preferably preformed. A visor as claimed in any one of the preceding claims wherein the layer of adhesive (27) fills a portion of the space adjacent the bordering edges of the folded wall member (11,13), firmly attaches the two sides of the wall member together, attaches the edge of the decorative material (17) to the inside of the core, and forms a rigid stiffening member for the edge of the visor. A visor as claimed in any one of the preceding claims wherein the adhesive (27) fills any crevices in the material. A visor as claimed in any one of the preceding claims wherein the core is preformed so that, when folded, the sides of the core away from the abutting edges are spaced apart. A visor as claimed in Claim 10 or any claim dependent thereon wherein the cardboard core is made of laminated layers of kraft paper. A visor as claimed in Claim 14 wherein the core has a layer of plastic film for providing wet strength. A visor as claimed in any one of the preceding claims including a vanity mirror (31) secured by means of an adhesive. A visor as claimed in Claim 16 wherein the vanity mirror has a safety coating on the back and is secured by a layer of adhesive on the safety coating. A visor as claimed in Claim 17 wherein the safety coating is a layer of tape. A visor as claimed in any one of the preceding claims wherein the core has an integral living hinge. A visor as claimed in Claim 19 wherein the core is symmetrical and is folded about the integral hinge to form the said abutting edges. A visor as claimed in Claim 19 or Claim 20, when dependent on Claim 10, in which the living hinge is formed by spaced parallel crease lines (15) in the cardboard. A visor as claimed in any one of Claims 19 to 21 wherein the visor is folded with a curved leading edge by a gradual fold at each crease line (15) of the living hinge. A method for making a vehicle visor according to any of the preceding claims comprising: folding a wall member and a decorative cover member (17)on one side thereof to form abutting edge portions with the edges of the decorative cover being folded over and covering the abutting edges of the wall member; characterised by the step of applying a bead of adhesive (27) adjacent one edge of the wall member prior to folding, such that after folding, the adhesive adheres to the opposite inside surfaces of the wall member; then curing the adhesive to join together the edges of the wall member and to fasten the edge of the decorative cover between the walls of the wall member. A method of making a visor as claimed in Claim 23 including fastening a torque member to the wall member before the wall member is folded. A method of making a visor as claimed in Claim 23 or Claim 24 wherein the adhesive (27) expands on curing to fill a portion of the space between the walls adjacent the abutting edges of the folded wall member, attaches the two edges of the wall member together, attaches the edges of the decorative cover material between the walls of the wall member, and forms a rigid stiffening member for the edge of the visor. A method of making a visor as claimed in Claim 23 including preforming the wall member so that when folded the edges of the preformed wall member will abut while the side portions of the wall member will be spaced from each other. A method of making a visor as claimed in any one of Claims 23 to 26 characterised in that the two halves of the wall member (11,13) on each side of the fold are substantially identical and in that the adhesive (27) comprises foaming resin, the resin expanding to fill the inner portion of the visor adjacent the abutting edge portions to give rigidity to the edges. A method as claimed in any one of Claims 23 to 27 in which the wall member is folded along a crease (15).

Inventors: BINISH PATRICK WILLIAM, BINISH, PATRICK WILLIAM
Applicants: PRINCE CORP, PRINCE CORPORATION
Application year: 1990
Main classification: B60J3
IPC codes: B60J3, A47G1