Abstract:
The present invention provides an expanded polypropylene over-mold blade sun visor carrier assembly incorporating an electrical distribution system therein in cooperative combination with a center support assembly containing a corresponding electrical distribution system and a support shaft.

Description:
BACKGROUND OF INVENTION 
     1. Field of the Invention 
     The present invention generally relates to a sun visor for vehicles having a sun visor body supported by a sun visor shaft and a sun visor center support. More particularly the present invention relates to a sun visor for vehicles comprising a sun visor carrier containing an electric current distribution means over-molded with an expanded polypropylene plastic over-mold, sun visor body. 
     2. Description of the Related Art 
     Vehicle sun visors comprising a sun visor body or blade, a sun visor bent shaft, and a center support are well known and are described in numerous publications and have been in extensive use. Newer but also known are sun visors produced by over-molding a sun visor carrier with expanded polypropylene or similar materials. However, no such over-molded sun visors provide an integral electric current distribution system allowing for vanity lamps and the like mounted on or in such sun visors without the need for assembly line wiring of such vanity lamps and the like. 
     For example, U.S. Pat. No. 6,682,121 issued Jan. 27, 2004 to Conforti teaches a sunscreen suitable for mounting directly onto the glass surface of a side or rear vehicle window to reduce the light transmission into the vehicle passenger compartment. 
     U.S. Pat. No. 5,975,616 issued Nov. 2, 1999 to Eple et al teaches a molded sun visor which does not require a separate visor covering but which provides no means of providing electrical power for items such as vanity lights mounted on or in said sun visor. 
     U.S. Pat. No. 5,727,837 issued Mar. 17, 1998 to Viertel teaches a sun visor utilizing a carrier insert with plastic over molding without the need for a fabric cover. In one embodiment a micro-switch is taught for activating and deactivating electrical power to vanity lights. 
     U.S. Patent Application Publication 2001/0024048 published Sep. 27, 2001 to Hobson et al teaches a clamshell type sun visor body covered with a fabric. 
     European Patent Application WO 93/08038 published Sep. 29, 1993 to Industrias Techno-Matic, S.A. teaches single piece hollow bodied sun visor which may have its hollow core filled with sound insulating material. 
     DISCLOSURE OF THE INVENTION 
     The present invention provides advantages and alternatives over the prior art by providing an expanded polypropylene over-mold blade sun visor carrier assembly incorporating an electrical distribution system therein in cooperative combination with a center support assembly containing a corresponding electrical distribution system and a support shaft. 
     According to a further aspect of the present invention, provides for the pre-assembly of the electrical system necessary to provide power to vanity lamps and the like while reducing the assembly time and assembly complexity of the vehicle interior on the assembly line. 
     According to yet another aspect of the present invention provides for a sun visor having a thin profile that does not require the application of a fabric cover, and eliminates the requirement of providing a separate electrical wiring system to power vanity lamps and the like. 
     According to a yet further aspect of the present invention there is provided a sun visor carrier assembly for use as a core for an over-molded expanded polypropylene sun visor suitable for use in vehicles comprising in cooperative combination: a) a sun visor carrier body comprising; a blade section having located therein a vanity assembly mounting device, and a rod mounting section having a bore there through for mounting on a sun visor rod said bore being dimensionally maintained by a plurality of fasteners; b) a pair electrical connection wires providing electrical current to a vanity assembly; c) a detent dip attached to said sun visor carrier body with a detent dip fastener device; d) a cylindrical detent sleeve having a flat face portion, a cylindrical rod end bushing, and a cylindrical center support pin assembly comprising a body having molded therein a spaced apart pair of electrical contact surfaces, said electrical contact surfaces electrically connected said electrical connection wire of component b); all mounted within said bore of said carrier body; e) a sun visor rod support having a flat face and mounted within said cylindrical detent sleeve such that the flat faces of each are aligned, and said cylindrical rod end bushing; f) a covering tape over the assembled rod mounting section to prevent plastic migration during over-molding of the carrier body; and f) a center support assembly comprising a body having a assembly mounting bore, a pair of electrical contact clips wherein each electrical contact clip is connected to the vehicles power system by means of an electrical wire attached thereto; thereby providing a sun visor carrier body assembly with cooperating sun visor rod and sun visor center support assembly allowing for overmolding with a plastic to produce a finished sun visor having electrical provision for a vanity assembly incorporating electrical components. 
     According to still another aspect of the present invention there is presented a sun visor carrier assembly for use as a core for an over-molded expanded polypropylene sun visor suitable for use in vehicles comprising in cooperative combination: a) a sun visor carrier body comprising; a blade section having located therein a vanity assembly mounting device, and a rod mounting section having a bore there through for mounting on a sun visor rod said bore being dimensionally maintained by a plurality of fasteners; b) an electrical connection wire providing electrical current to a vanity assembly; c) a detent clip attached to said sun visor carrier body with a detent clip fastener device; d) a cylindrical detent sleeve having a flat face portion, a cylindrical rod end bushing, and a cylindrical center support pin assembly comprising a body having molded therein a spaced apart pair of electrical contact surfaces, one electrical contact surface electrically connected said electrical connection wire of component b) and the other electrical contact surface connected to carrier body, all mounted within said bore of said carrier body; e) a sun visor rod support having a flat face and mounted within said cylindrical detent sleeve such that the flat faces of each are aligned, and said cylindrical rod end bushing; f) a covering tape over the assembled rod mounting section to prevent plastic migration during over-molding of the carrier body; and f) a center support assembly comprising a body having a assembly mounting bore, a pair of electrical contact clips wherein each electrical contact clip is connected to the vehicles power system by means of an electrical wire attached thereto; thereby providing a sun visor carrier body assembly with cooperating sun visor rod and sun visor center support assembly allowing for overmolding with a plastic to produce a finished sun visor having electrical provision for a vanity assembly incorporating electrical components. 
     The present invention thus advantageously provides a low cost, attractive sun visor assembly that reduces the cost of final assembly in the vehicle. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  shows an exploded perspective view of one preferred embodiment of the present invention including the sun visor carrier assembly having a plurality of fastening devices, the support shaft, and the center support assembly. 
         FIG. 2  shows a perspective view with a partial section of the center support assembly of the present invention shown in  FIG. 1 . 
         FIG. 3  shows a perspective view with a partial section of the center support pin assembly of the present invention shown in  FIG. 1 . 
         FIG. 4  shows an exploded perspective view of a second preferred embodiment of the present invention including the sun visor carrier assembly having a welded fastening, the support shaft, and the center support assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made to the drawings, wherein to the extent possible like reference numerals are utilized to designate like components throughout the various views. Referring to  FIG. 1 , there is presented a perspective exploded view of a preferred embodiment of the present invention comprising a sun visor carrier or support body  1  preferably comprising formed sheet metal having a blade section  2  and a rod mounting section  3 . The blade section  2  having located therein a vanity assembly attachment device  6  adapted to mount a vanity assembly  21  therein, as well as an electrical connection wire  14  which connects to one of electrical wires  30  ( FIG. 3 ), and optionally openings  22  to reduce the weight of the carrier body  1 . The mounting section  3  having a bore  4  there through for mounting an elbow rod assembly comprising an elbow rod  7 , having a flat face  71 , and also having mounted thereon a detent sleeve  8 , a rod end bushing  9  to provide stability for elbow rod  7 , and a center support pin assembly  15 . The center support pin assembly  15  being fixedly mounted within bore  4 , and having located on a portion of its outer surface a pair of electrical contact surfaces  16  connected to a pair of electrical wires  30  ( FIG. 3 ), one of said pair of electrical wires  30  being connected as the hot lead to electrical wire  14  and the other being connected as a ground to blade section  2 . A plurality of staples  5 , or other suitable fasteners, is used to provide a desired dimensional diameter of bore  4  and to retain the center support pin assembly  15  within said bore  4 . The rod mounting section  3  may have the end mounting the center support pin assembly  15  crimped to assist fixedly securing said center support pin assembly  15  within bore  4 . Detent sleeve  8  having a flat surface  81  thereon. The flat surfaces  81  and  71  providing both rotational and detent features to the sun visor rod  7 . A detent clip  12  is fastened to support  1  with a rivet fastening device  13 . It is to be understood that fastening devices  5  and  13  may be selected from any of the well-known fastening devices suitable for these purposes. The vanity assembly  21  is adapted to mount in mount  6  of blade section  2  of sun visor carrier body  1  and electrically connect to a vehicle&#39;s power supply via electrical wire  14 , center support pin assembly  15 , and center support assembly  17 . 
     As further shown in  FIG. 1  is a center support assembly  17  having provided therein a pair of contact clips  18 , a pair of corresponding electrical wire leads  19  connected to said contact clips  18 , and a bore  20  for mounting said center support assembly to the vehicle by known fastening devices suitable for this purpose. Finally there is shown a portion of the tape  11  which covers the completed carrier body  1  to prevent plastic migration into the bore  4  during the over-molding of the sun visor body (shown here in phantom). 
     Referring now to  FIG. 2 , there is shown a perspective view with a partial section of the center support assembly  17  of  FIG. 1  having a mounting bore  20  and showing the pair of electrical wires  19  electrically connected to a pair of contact clips  18 . 
     Turning now to  FIG. 3 , there is shown a perspective view with a partial section of the center support pin assembly  15  of  FIG. 1  having a pair of electrical contact support surfaces  16 , each of said pair of electrical contact support surfaces  16  connected to an electrical wire  30 . 
     The OLE — LINK1 center support assembly  17  OLE — LINK1 and center support pin assembly  15  are made of electrically non-conductive material, preferably plastic, and most preferably expanded polypropylene. 
     In practice of one preferred embodiment, the carrier body  1  is formed with the appropriate vanity assembly mount  6  and optionally weight reduction openings  22  formed in blade section  2  and rod mounting section  3  is stapled with a plurality of staples  5 , detent  12  is fastened to carrier body  1  preferably using a rivet  13 , and electrical wire  14  is installed. Then detent sleeve  8 , rod end bushing  9 , and center support pin assembly  15  are mounted in bore  4  and secured in place. Electrical wire  14  is connected to one of electrical wires  30 . A piece of tape  11  is then positioned to cover the openings in the rod mounting section of carrier body  1  to prevent plastic migration during the over-molding process. Next the over-molded sun visor body of expanded polypropylene is molded over the assembled carrier body  1 . An appropriate vanity assembly  21  is then mounted in the sun visor using vanity assembly mount  6 . Finally the elbow rod  7  is mounted within the detent sleeve  8 , and rod end bushing  9 . During assembly of the sun visor in a vehicle the elbow rod  7  is mounted by known means to the vehicle roof. The center support assembly  17  is also mounted by known means in an appropriate location in the vehicle to accept the sun visor of the present invention. 
     In practice of a second preferred embodiment, the carrier body  1  is formed with the appropriate vanity assembly mount  6  and optionally weight reduction openings  22  formed in blade section  2  and rod mounting section  3  is welded as shown by weld bead  51 , detent  12  is fastened to carrier body  1  preferably using a rivet  13 , and electrical wire  14  is installed. Then detent sleeve  8 , rod end bushing  9 , and center support pin assembly  15  are mounted in bore  4  and secured in place. Electrical wire  14  is connected to one of electrical wires  30 . A piece of tape  11  is then positioned to cover the openings in the rod mounting section of carrier body  1  to prevent plastic migration during the over-molding process. Next the over-molded sun visor body of expanded polypropylene is molded over the assembled carrier body  1 . An appropriate vanity assembly  21  is then mounted in the sun visor using vanity assembly mount  6 . Finally the elbow rod  7  is mounted within the detent sleeve  8 , and rod end bushing  9 . During assembly of the sun visor in a vehicle the elbow rod  7  is mounted by known means to the vehicle roof. The center support assembly  17  is also mounted by known means in an appropriate location in the vehicle to accept the sun visor of the present invention. 
     It is presently preferred to use heat welding to secure rod mounting section  3  when carrier  2  comprises plastic, it is to be further understood that the weld may be a single continuous weld or a plurality of spot welds. In another presently preferred embodiment it is preferred to use a plurality of staples  5  to secure rod mounting section  3  when carrier  2  comprises metal. 
     Although the preferred embodiments of the present invention has been disclosed, various changes and modifications may be made without departing from the scope of the invention as set forth in the appended claims.