Abstract:
A mounting assembly is disclosed for mounting a sun visor to a vehicle panel having opposing faces and an aperture therethrough. The mounting assembly includes a mounting component mountable to the vehicle panel. The mounting component includes a first side having a number of spaced apart retaining members extending therefrom and a second side including at least one catch projecting therefrom. The opposing faces of the panel are gripped between the second surface and the catch to retain said mounting component against the vehicle panel. The mounting assembly also includes a bezel component moveably connected to the mounting component by the retaining members.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to interior components for vehicles and, more particularly, to a mounting assembly suitable for mounting a sun visor in a vehicle interior.  
         [0003]     2. Description of the Related Art  
         [0004]     Sun visors are typically mounted in a vehicle in a manner that allows a visor blade to pivot between a “stored” position adjacent an interior headliner and a “use” position adjacent a vehicle windshield. Since the sun may enter a side window of a vehicle, most sun visors are allowed to pivot between the windshield and the side window in the “use” position.  
         [0005]     A number of methods have been proposed for moveably mounting a sun visor to a vehicle interior. One known method is a snap-in type mount. This type of mount is generally the easiest and most cost effective to install, since a mounting member simply snaps into a hole in an interior panel of a vehicle. A pivot rod supported visor blade is then moveably attached to the mounting member to complete the installation of the sun visor.  
         [0006]     It has become increasingly more popular for vehicle manufacturers, particularly in the automotive industry, to require vehicle component suppliers to supply integrated vehicle systems. One such integrated system is a vehicle headliner assembly that includes, among other components, a vehicle headliner, a driver sun visor and a passenger sun visor. Conventional sun visor mounts are typically configured for use with a single headliner configuration. However, the ability to use a single mount with multiple headliner configurations would allow a supplier to streamline their product portfolio and reduce the various costs associated with providing multiple mount configurations. Accordingly, a need exists for a modular mount suitable for use with different headliner configurations.  
       SUMMARY OF THE INVENTION  
       [0007]     In accordance with an embodiment of the invention, a mounting assembly is disclosed for mounting a sun visor to a vehicle panel having opposing faces and an aperture therethrough. The mounting assembly includes a mounting component mountable to the vehicle panel. The mounting component includes a first side having a number of spaced apart retaining members extending therefrom and a second side including at least one catch projecting therefrom. The opposing faces of the panel are gripped between the second surface and the catch to retain the mounting component against the vehicle panel. The mounting assembly also includes a bezel component moveably connected to the mounting component by the retaining members. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description:  
         [0009]      FIG. 1  is a fragmentary perspective view of a sun visor assembly installed in a vehicle;  
         [0010]      FIG. 2  is a perspective view of a mounting assembly according to an embodiment of the invention, pre-installed in a vehicle headliner;  
         [0011]      FIG. 3  is an exploded view of the mounting assembly and headliner of  FIG. 2 ;  
         [0012]      FIG. 4  is a top view of a mounting component according to an embodiment of the invention;  
         [0013]      FIG. 5  is a cross-sectional view of the mounting component of  FIG. 4  taken along line  5 - 5 ;  
         [0014]      FIG. 6  is a bottom view of the mounting component of  FIG. 4  according to an embodiment of the invention;  
         [0015]      FIG. 7  is an exterior view of a bezel component according to an embodiment of the invention;  
         [0016]      FIG. 8  is a cross sectional view of the bezel component of  FIG. 7  taken along line  8 - 8 ;  
         [0017]      FIG. 9  is an interior view of the bezel component of  FIG. 7  according to an embodiment of the invention;  
         [0018]      FIG. 10  is a detailed cross-sectional view showing a bezel component secured to a mounting component and sandwiching a headliner of first thickness “A” therebetween;  
         [0019]      FIG. 11  is a detailed cross-sectional view showing a bezel component secured to a mounting component, and sandwiching a headliner of second thickness “B” therebetween;  
         [0020]      FIG. 12  is the detailed cross-sectional view of  FIG. 10  showing a fastener securing the mounting assembly to a vehicle panel; and  
         [0021]      FIG. 13  is a partial cross-sectional view of a bezel component according to an embodiment of the invention, showing an elbow secured to a bearing portion of the bezel component. 
     
    
     DETAILED DESCRIPTION  
       [0022]     Referring now to the drawings, the preferred illustrative embodiments of the present invention are shown in detail. Although the drawings represent some preferred embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.  
         [0023]     Referring to  FIG. 1 , a vehicle  20  is shown that includes a windshield  22  and a hidden sheet metal panel  24  that functions as a backing plate of limited size for attaching a sun visor  26  or as a larger sheet metal panel that defines the interior roof of vehicle  20 . Panel  24  is covered by a headliner  30 , such AS a cushioned fabric material, which may be colored to complement the decor of the vehicle interior. A layer of energy-absorbing material (not shown), such as foam and the like, may be disposed between panel  24  and headliner  30  to absorb the energy of an impact by the vehicle occupants during an accident.  
         [0024]     A sun visor mounting assembly  32  secures sun visor  26  to panel  24  and/or headliner  30  and permits sun visor  26  to be pivoted about a substantially vertical axis from a position proximate windshield  22  to a position proximate a side window  34  of vehicle  20 . Sun visor  26  is rotatably supported on a visor shaft  36  extending from mounting assembly  32  and may be secured to a support hook (not illustrated) when not in use. It will be appreciated that the design of sun visor  26  is not material to the present invention and that other sun visor designs, including those that employ electrical circuitry to illuminate a lamp on the visor, may be used.  
         [0025]     Referring to  FIGS. 2 and 3 , an embodiment of mounting assembly  32  is shown that includes a mounting component  40  and a bezel component  42 . An elbow  44  is connectable with sun visor  26  via visor shaft  36 . A plurality of fasteners  45 , such as screws and the like, pass through bezel component  42  and mounting component  40  to secure components  40 ,  42  to panel  24 . Panel  24  generally includes an inner surface  46 , an outer surface  48  and an aperture  50  through which a portion of mounting component  40  is inserted to retain mounting assembly  32  against panel  24  until fasteners  45  may be installed. Mounting component  40  and bezel component  42  cooperatively engage headliner  30  to support elbow  44  and sun visor  26  during transport of headliner  30 . Mounting component  42  also temporarily secures headliner  30 , bezel component  42  and sun visor  26  to panel  24  during installation into vehicle  20  until fasteners  45  can be secured to panel  24 .  
         [0026]     Referring to  FIGS. 4-6 , mounting component  40  may be molded as a one-piece structure from a polymeric material, such as ABS and other suitable plastics. In an embodiment, mounting component  40  includes a first side  52  configured to engage bezel component  42  and a second side  54  configured to engage panel  24 . In a particular configuration, second side  54  includes a catch  56  that extends outwardly therefrom. In the illustrated configuration, catch  56  includes a pair of resilient catch members  58  and  60 , each including a tapered arm portion  62  and a ledge  64  having a surface that is generally parallel to and slightly spaced apart from second surface  54 . Tapered arm portions  62  engage panel  24  during installation, deflect inwardly as catch  56  is inserted into hole  50  in panel  24  and snap-back once fully inserted therein to grasp panel  24  between ledge  64  and second surface  54 . An aperture  66  may extend through mounting component  40  adjacent each of catch members  58 ,  60  to provide an opening though which to view the location of ledge  64  relative to panel  24 .  
         [0027]     With particular reference to  FIGS. 5 and 6 , first side  52  includes a number of spaced apart towers  68  that extend therefrom. Towers  68  each include a duct  70  that extends from a distal end  72  through second side  54 . Each duct  70  may include at least one inwardly extending catch feature  73  that engages fastener  45  as it is inserted therein. In the illustrated embodiment, catch feature  73  is a radially inwardly directed protrusion that engages one or more threads on fastener  45 . Catch features  73  temporarily retain fasteners  45  in ducts  56  so that mounting assembly  32  and fasteners  45  can be shipped as a single unit. Upon assembly into a vehicle, each fastener  45  is received in an aperture  74  (shown in  FIG. 3 ) in panel  24  to secure mounting component  40  and bezel component  42  to panel  24 . While fasteners  45  are shown in the illustrated embodiment as being screws, it is recognized that other suitable fasteners or fastening methods, such as rivets and the like, may also be employed to secure components  40 ,  42  to panel  24 .  
         [0028]     Referring still to  FIGS. 5 and 6 , mounting component  42  also includes a number of spaced apart retaining members  76  extending therefrom. In an embodiment, each retaining member  76  includes at least one leg  78  that extends downwardly from distal end  72  of towers  68 . When retaining member  76  includes more than one leg  78 , each leg  78  may be spaced apart from the other, as shown in  FIG. 6 . Legs  78  are resiliently deflectable relative to tower  68  and include a foot  80 . As will be described in detail below, feet  80  are configured to engage bezel component  42  to attach bezel component  42  to mounting component  40 .  
         [0029]     As illustrated in  FIG. 5 , mounting component  40  may also include at least one separator member  82  that extends from first side  52 . In an embodiment, mounting component  40  includes a number of separator members  82 , one or more of which are positioned between towers  68 . Separator members  82  are longer than towers  68  by a predetermined length and selectively engage bezel component  42 , as will be described below.  
         [0030]     Referring to  FIGS. 7-9 , bezel component  42  may also be molded as a one-piece structure from a polymeric material, such as ABS or other suitable plastic. In an embodiment, bezel component  42  includes a main body portion  84  and an integrally formed bearing portion  86 . The shape of body portion  84  preferably corresponds to the polygonal shape of mounting component  40 . An exposed outer surface  88  of bezel component  42  is aesthetically attractive and may be provided with a patterned texture. An interior surface  90  of bezel component  42  is hidden from view once installed in vehicle  20 . At least one opening  91  may be provided through bezel component to allow passage of electrical wires for powering a sun visor vanity mirror light (not shown).  
         [0031]     In an embodiment, body portion  84  includes a number of apertures  92  that correspond in number to ducts  70  in mounting component  40 . In a particular configuration, each aperture  92  is defined by a tower  94  that extends upwardly from interior surface  90 . Each tower  94  creates a recess  96  that extends away from exposed outer surface  88 . Apertures  92  are partially enclosed by a generally semi-circular flat  98 , which may be oriented such that an open portion of each aperture  92  is positioned inward of flat  98  in a direction extending from a corner  100  of bezel component  42 . The remaining circumference of aperture  92  is not covered by flat  98 , but includes a ledge  102 . The edge of aperture  92  is slightly tapered to deflect legs  78  and feet  80  as bezel component  42  is attached to mounting component  40 . As feet  80  cam over the taper to aperture  92 , legs  78  snap back allowing feet  80  to lock behind ledge  102  to attach bezel component  42  to mounting component  40  until fasteners  45  can be applied (see, e.g.,  FIGS. 10 and 11 ).  
         [0032]     Referring now to  FIGS. 10 and 11 , attachment of bezel component  42  to mounting component  40  allows headliner  30  to be sandwiched therebetween, enabling mounting assembly  32  to be transported with headliner  30 . Particularly, body portion  84  of bezel component  42  engages one side of headliner  30  and a raised peripheral edge  104  of mounting component  40  engages the other side of headliner  30 . Unlike prior art mounting assemblies, bezel component  42  is movable relative to mounting component  40  once attached thereto. Among other things, movement of bezel component  42  relative to mounting component  40  allows mounting assembly  32  to accommodate various headliner thicknesses. For example,  FIG. 10  illustrates mounting assembly  32  secured to a first headliner  30 ′ having a thickness “A”. In  FIG. 11 , mounting assembly  32  is secured to a second headliner  30 ″ having a thickness “B” that is less than thickness “A” in  FIG. 10 .  
         [0033]     Once the headliner assembly (i.e., headliner  30 , mounting assembly  32 , etc) is secured in a vehicle interior and fasteners  45  are attached to panel  24 , as in  FIG. 12 , body portion  84  of bezel component  42  is movably drawn by fasteners  45  against headliner  30 , which in turn is drawn against the raised peripheral edge  104  of mounting component  32  to tightly sandwich headliner  30  therebetween. As will be appreciated, various headliner thicknesses can be accommodated with this design by permitting movement of bezel component  42  relative to mounting component  40 . The amount of movement between bezel component  42  and mounting component  40  is limited by separator members  82  so that fasteners cannot overdraw bezel component  42 , thereby crushing or otherwise deforming headliner  30 .  
         [0034]     Referring to  FIGS. 8 and 13 , an embodiment of elbow  44  and bearing portion  86  are shown in detail. Elbow  44  is configured to be received in bearing portion  86  about a pivot axis  110 . In an embodiment, elbow  44  is retained in bearing portion  86  by two or more resilient legs  112  that are at least partially separated by a slot  114  ( FIG. 8 ). In the illustrated embodiment, a distal end  116  of elbow  44  includes a flange.  118  having a conical surface  120 , which forces expansion of legs  112  during insertion of elbow  44  into bearing portion  86 . As flange  118  moves above a distal end  122  of legs  112 , legs  112  contract and engage an underside of flange  118  to rotatably retain elbow  44  in bezel component  42 .  
         [0035]     The structure of mounting assembly  32  will be further understood in view of the following description of an embodiment of a method of installation. Mounting assembly  32  is first attached to headliner  30  as described above. Elbow  44  is secured to bezel component  42  prior to or subsequent to attachment of bezel component  42  with mounting component  40 . With headliner  30  sandwiched between bezel component  42  and mounting component  40 , fasteners  45  may then be inserted through apertures  92  in bezel component  42  into ducts  70  in mounting component  40 . Fasteners  45  are temporarily engaged and retained within ducts  70  by catch feature  73 . During installation of the headliner assembly into a vehicle interior, catch  56  on mounting component  40  is inserted into aperture  50  of panel  24  to retain mounting assembly  32  against panel  24 , as described above. Finally, fasteners  45  are attached to panel  24  to secure mounting assembly  32  to panel  24  (see  FIG. 12 ).  
         [0036]     While the present invention has been described with reference to the illustrated embodiments, it is recognized that various modifications to the embodiments of the present invention will be apparent to those skilled in the art without departing from the scope of the claimed invention. For example, those modifications include, but are not limited to, modifying the shape of bezel component  42  and mounting component  40 , modifying the degree of movement permitted between bezel component  42  and mounting component  40 , and modifying the shape, number and orientation of retaining members  76 . Moreover, the inventive mounting component  40  may also be utilized to secure other components in a vehicle, for example, to attach door panels to a vehicle door.  
         [0037]     Although certain preferred embodiments of the present invention have been described, the invention is not limited to the illustrations described and shown herein, which are deemed to be merely illustrative of the best modes of carrying out the invention. A person of ordinary skill in the art will realize that certain modifications and variations will come within the teachings of this invention and that such variations and modifications are within its spirit and the scope as defined by the claims.