Patent Publication Number: US-2004051337-A1

Title: Visor assembly having electronics package

Description:
BACKGROUND OF THE DISCLOSURE  
       [0001] Most automotive vehicles include sun visors coupled on or near the interior roof of the vehicle. A typical sun visor includes two substantially flat surfaces and a hinged connection to the roof of the vehicle, such that the sun visor can be moved to a deployed position to shade light exterior to the vehicle from a front seat occupant&#39;s view and to a stowed-away position wherein the occupant&#39;s view is not shielded.  
       [0002] The trend in the automotive industry has been to incorporate more and more electronic devices within the vehicle interior to provide further comfort and convenience features to occupants of the vehicle. One convenient place for locating such electronic features is the visor. In one system, a visor includes a radio frequency garage door opening transmitter and a thin foil strip extending along the longitudinal length of the visor to act as an antenna.  
       [0003] However, packaging electronics components in a visor reduces the amount of space available for a mirror. Furthermore, locating electronics components at different places on the visor can increase clutter and can require multiple wiring harnesses, which results in a more costly and labor-intensive assembly process.  
       [0004] Accordingly, there is a need for an improved visor assembly for use in a vehicle which optimizes the packaging space for electronic content and a mirror. Further, there is a need for a visor assembly having electronics and a mirror which allows for quick port installs of different product versions. Further still, there is a need for additional package space in a visor assembly to accommodate radio frequency-based electrical components. Further still, there is a need for a visor assembly having reduced clutter and a more cost-effective assembly process. The teachings hereinbelow extend to those embodiments which fall within the scope of the appended claims, regardless of whether they accomplish one or more of the above-mentioned needs.  
       SUMMARY OF EXEMPLARY EMBODIMENTS  
       [0005] According to one exemplary embodiment, a visor assembly for use in a vehicle comprises a visor having first and second surfaces, a package coupled to the visor, and a mirror coupled to the package and viewable along with the first surface of the visor. The visor assembly further comprises an electronic device coupled to the package and a user interface coupled to the electronic device and viewable along with the second surface of the visor.  
       [0006] According to another exemplary embodiment, a vanity pack comprises a package having first and second surfaces opposite one another and an enclosure disposed between the first and second surfaces configured to house an electronic circuit board. The vanity pack further comprises a mirror coupled to the first surface, and at least one user input surface disposed on the second surface configured for user interface.  
       [0007] According to another exemplary embodiment, a visor assembly for a vehicle comprises a substantially flat visor element having first and second opposite surfaces and a means for enclosing an electronic device and for providing a mirror at the first surface and an operator input device at the second surface.  
       [0008] According to yet another exemplary embodiment, a visor assembly comprises an elongated shield having first and second sides and a package integral with the elongated shield comprising a means for mirroring an image on the first side of the shield and a means for housing a user interface accessible via the second side of the shield. 
     
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
     [0009] The invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings, wherein like reference numerals refer to like parts, and in which:  
     [0010]FIG. 1. is a diagram of a first surface of a visor assembly, according to an exemplary embodiment;  
     [0011]FIG. 2 is a diagram of a second surface of a visor assembly, according to an exemplary embodiment;  
     [0012]FIG. 3 is a diagram of a visor assembly having a vanity mirror, according to an exemplary embodiment;  
     [0013]FIG. 4 is a perspective view of a method of making a visor assembly, according to an exemplary embodiment;  
     [0014]FIG. 5 is an exploded view of the visor assembly of FIG. 4, according to an exemplary embodiment; and  
     [0015]FIG. 6 is a cross-sectional view of the visor assembly of FIG. 4, according to an exemplary embodiment. 
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS  
     [0016] Referring first to FIG. 1, a visor assembly  10  is illustrated. Visor assembly  10  is configured to be coupled to a vehicle interior, which can be the interior of an automobile, truck, minivan, work vehicle, or other vehicle. Visor assembly  10  comprises a visor body  12  which can be of a molded polymeric material such as polypropylene or other materials such as fiberboard which can be preformed in a butterfly shape and folded over in a clam-shell design to complete the visor body construction. Visor body  12  can be covered with a fabric, leather, or other aesthetic and tactile material. Visor body  12  is coupled to the roof of a vehicle or other vehicle interior element (e.g., pillar, door, etc.) by a coupling assembly (not shown) which can be of conventional construction. The coupling assembly can be an elbow bracket assembly and can include a pivot rod extending into visor body  12 . A torque fitting coupled to visor body  12  engages the pivot rod for allowing the visor to be held in a raised, stored position or a plurality of lowered, deployed positions, and also to allow the visor to be moved from the front windshield position to the side window position in a conventional manner. A support rod  14  is coupled to visor body  12  and is configured for a removable coupling to a support receptacle (not shown) mounted to a vehicle roof.  
     [0017] Visor body  12  includes a surface  16  which is substantially flat and opposite a surface  18  (FIG. 2). In this exemplary embodiment, surface  16  is viewable by or visible to a vehicle occupant in a first, stowed position and is concealed from a vehicle occupant in an open or deployed position. Surface  18  is viewable by or visible to a vehicle occupant in the open or deployed position and is concealed from a vehicle occupant in the first, stowed position. Such movement is provided by the above-described coupling arrangement between visor body  12  and the roof of the vehicle interior, which may include a hinge, or other coupling device.  
     [0018] Visor body  12  includes a package  20  coupled to visor body  12 . Package  20  comprises a plastic or other polymeric material in this embodiment, but may alternatively comprise other materials. Package  20  defines an enclosure therein of sufficient size and shape to house an electronic device. The electronic device may be housed or disposed at least partially, substantially (i.e., more than 50% of the electronic device) or completely within package  20 . Package  20  can comprise one molded part or a plurality of parts coupled together using a fastener, such as, glue, screws, an interference fit, etc.  
     [0019] In this exemplary embodiment, package  20  houses two electronic devices: a trainable transceiver and a memo recorder. The trainable transmitter includes a radio frequency transmitter and a radio frequency receiver coupled to a control circuit on a circuit board disposed in the enclosure defined by package  20 . The trainable transmitter is concealed by package  20  from the occupant&#39;s view. The trainable transmitter can be trained to one or more original transmitters employed for remotely controlling home, office, or vehicle accessories, such as a garage door opening mechanism, home lighting, home security, etc. In a training mode, an existing original transmitter transmits a radio frequency or other wireless signal on a carrier frequency. The trainable transmitter is configured to learn the frequency and data code from the signal and to store data representing the frequency and data code. In an operation mode, the trainable transmitter transmits the frequency and data code to the accessory to be controlled. The data code can be modulated according to a modulation scheme and can be encrypted using a rolling code algorithm or can be a fixed code.  
     [0020] The memo recorder comprises a speaker or microphone and a control circuit configured to receive audible signals at the microphone, to store the audio signals, and to replay the audio signals at the speaker.  
     [0021] Both of the electronic devices housed within package  20  include user interfaces in this exemplary embodiment. A trainable transmitter interface  22  includes three operator-actuated switches which control the operation of the trainable transceiver during learning and operating modes. For example, each of the switches can be programmed to control a different appliance. Trainable transmitter interface  22  is coupled to the trainable transmitter circuit and is also viewable or accessible by a vehicle occupant along with surface  16 .  
     [0022] A memo recorder user interface  24  includes a speaker/microphone  26 , a record button  28 , a next message button  30 , and a play button  32 . In operation, the user presses record button  28  and speaks near speaker/microphone  26 . In response, the control circuit associated with the memo recorder records the message and stores it in a memory, such as a digital memory. Multiple messages can be recorded. Play button  32  can be actuated to begin play back of a message. Next message button  30  can be used to cycle through a plurality of messages.  
     [0023] According to one advantageous feature, memo recorder user interface  24  can include a microphone, which can be coupled to an elbow bracket which acts as a movable coupling between visor body  12  and the roof of the vehicle.  
     [0024] The trainable transmitter and memo disclosed herein are exemplary electronic devices which may be housed within package  20 . Other electronic devices can be housed in package  20  individually or in combination with other electronic devices. Accordingly to one exemplary embodiment, the electronic devices housed in package  20  are configured to perform occupant convenience functions, such as, wirelessly controlling accessories remote to the vehicle, wirelessly or controlling via wire accessories coupled to the vehicle, controlling a vehicle anti-theft device, generating and displaying compass heading or temperature information to an occupant, providing a memo recorder for a vehicle occupant, providing access to a nearby wireless phone via a Bluetooth communications protocol or other wireless communications protocol, etc. Further, the electronic device or devices disposed within package  20  can be a portion or component of an electronic system configured to provide an occupant convenience function or to provide some other vehicle-related function. The electronic device or devices disposed within package  20  can include one or more control circuits (e.g., analog and/or digital circuit components, a microprocessor, a microcontroller, etc.), frequency or infrared communication devices, user interface components (e.g., buttons, switches, a display, which can include an icon, a light-emitting diode, a reconfigurable display, such as, a vacuum fluorescent display, liquid crystal display, etc.).  
     [0025] Referring now to FIG. 2, one advantageous aspect of this exemplary embodiment is disclosed. Package  20  includes a vanity mirror portion  34  extending from surface  18  of visor body  12 . As shown in FIG. 1, package  20  includes a user interface portion  36  extending from surface  16  of visor assembly  10 . Vanity mirror portion  34  and user interface portion  36  of package  20  define an outer surface of package  20 , a first portion of which extends from and is viewable with surface  16  of visor body  12  and a second portion of which extends from and is viewable with surface  18  of visor body  12 . The two portions are spatially aligned on visor body  12  such that at least a portion of each of the two portions overlaps spatially.  
     [0026] Referring to FIG. 3, vanity mirror portion  34  of package  20  defines a recess  38  in which a mirror  40  is disposed. Mirror  40  can be coupled to package  20  and/or visor body  12  using any of a plurality of fasteners, such as, glue, screws, an interference or friction fit, etc. In this embodiment, mirror  40  is coupled to vanity mirror portion  34 . Cover  42  is coupled via a hinge  44  or other movable coupling to vanity mirror portion  34  of package  20 . Cover  42  is movable between a closed position (FIG. 2) in which cover  42  conceals at least a portion of mirror  40 , and preferably all of mirror  40 , and an open position (FIG. 3) in which the portion or entire mirror  40  is not concealed, from the point of view of a vehicle occupant seated in the vehicle. In this embodiment, light sources  46  and  48  are coupled to electronic circuitry disposed within package  20 , which circuitry is configured to detect the position of cover  42  and to illuminate light sources  46  and  48  (e.g., incandescent light bulbs, fluorescent light bulbs, light-emitting diodes, etc.) when cover  42  is open and to turn light sources  46  and  48  off when cover  42  is closed.  
     [0027] According to one advantageous aspect, package  20  is configured to house an electronic device which includes a circuit board, which device is disposed between mirror  40  and at least one of user interfaces  22  and  24  (FIG. 1). According to a further feature, the circuit board is sandwiched, or inserted or enclosed between mirror  40  and user interfaces  22 ,  24 . In alternative embodiments, one or more portions of the circuit board may be disposed outside of the area between mirror  40  and at least one of user interfaces  22 ,  24 .  
     [0028] According to another exemplary embodiment, a vanity pack comprises package  20  having a surface associated with user interface portion  36  and a surface associated with vanity mirror portion  34 , which surfaces are disposed opposite one another. Package  20  defines an enclosure disposed between the first and second surfaces of package  20 , the enclosure configured of suitable size and shape to house an electronic circuit board. The vanity pack further includes mirror  40  coupled to the first surface and at least one user input surface configured to receive user input devices disposed on the second surface. The user input surface can be an aperture configured to receive a button or switch. In this manner, the second surface is configured for receiving user input devices to act as a user interface to the electronic circuit board. The vanity pack can further include the electronic device disposed in the enclosure and a user interface coupled to the second surface and configured to provide operator inputs to the electronic device. The vanity pack can further include one or more of the features described hereinabove with reference to FIGS.  1 - 3 .  
     [0029] Referring now to FIGS.  4 - 6 , a method of making a visor assembly will be described, according to an exemplary embodiment. Referring first to FIG. 4, visor body  12  comprises a first visor body portion  50  coupled to a second visor body portion  52  via a hinge or other fastener  54 . Portions  50  and  52  are fabricated from a single plastic substrate in this embodiment via a stamping, cutting, or other process. The fabrication process comprises providing an aperture  56 ,  58  in each of portions  50  and  52 , wherein the aperture is adapted to or configured to receive package  20  therein. Accordingly, body  12  is a plastic “clam shell” substrate. A fabric or other material is provided in one or more pieces to cover first surface  16  and second surface  18  (not shown), wherein a small portion of the fabric extends around an outer edge  60  of body  12  and onto surfaces  62 ,  64 . The small portion can be approximately between one quarter and one inch, and preferably is a sufficient quantity such that, upon closure of halves  50  and  52 , the portion of fabric is captured, fixed, or fastened between surfaces  62  and  64  of portions  50  and  52 . An additional fastener, such as glue, etc. may be applied during the fabrication process.  
     [0030] Referring to FIG. 5, body  12  is shown in a closed configuration, which may be after the clam shell substrate is folded in half Thus, fabric is shown on surface  16  and surface  18 . In this embodiment, package  20  comprises a first portion  66  and a second portion  68 . In this embodiment, second portion  68  provides a user interface or electronic human interface, such as buttons, switches, displays, etc. Portion  66  is coupled to a mirror and viewable along with first surface  26 . An electronic device  70  comprising a circuit board, such as a printed circuit board, is configured to be disposed between portion  66  and  68 , and more specifically, between a recess  72  and a recess  74  defined by portions  66  and  68 . Portion  66  is provided into aperture  58  from a first direction relative to aperture  58  and portion  68  is provided into aperture  58  from a second direction relative to aperture  58 , with electronic device  70  disposed between first and second portions  66  and  68 . Portions  66  and  68  meet and are fastened together to form the visor assembly of this exemplary embodiment.  
     [0031] Referring to FIG. 6, a cross-sectional view of visor assembly  10  is shown, illustrating an exemplary fastening method and further advantages of this embodiment. First portion  66  meets second portion  68  at first and second interlocking structures  78 ,  80 . The interlocking structures can couple portions  66  and  68  by an interference fit, by ridges, by threads, by glue, screws, or any other fasteners. Portions  66  and  68  each include a flange  82 ,  84 , which may be a bezel, which covers a portion of fabric  86 . Flanges  82  and  84  are particularly advantageous when fabric  86  is a non-woven fabric, since non-woven fabric experiences problematic stretching in corners of an aperture, as shown in FIG. 5. Flanges  80  and  84  hide any problems or inconsistencies with stretching of the non-woven fabric from the viewer&#39;s perspective.  
     [0032] According to a further advantage, portions  66  and  68  and electronic device  70  are z-axis loaded. The z-axis load and flanges  82  and  84  advantageously reduce stretch problems with non-woven fabric, such as trim out (i.e., portions of fabric  86  which are removed near aperture  58 ).  
     [0033] In the plurality of embodiments disclosed with reference to FIGS.  1 - 6 , visor body  12  is substantially flat and has opposite surfaces  16  and  18 . In alternative embodiments, visors may take other shapes and may have other cross-sectional shapes, such as, a triangle, and may further have curved surfaces. As a further alternative, the visor assembly may include any elongated shield having first and second sides. The shield may be a visor or may alternatively be another component of a vehicle interior, or may further alternatively be any elongated surface configured to shield light. In this embodiment, the elongated shield can be integral with a package by coupling thereto, by being molded therewith, or otherwise, and the package includes a mirror or other reflective device on a first side of the shield and a housing configured to provide a user interface accessible to a vehicle occupant on the second side of the shield.  
     [0034] One or more embodiments described herein can provide the benefits of an ideal location for radio frequency-based electronics, a self-contained visor having electronics which allow for quick port installs of different levels of products, and/or a self-contained feature for adding electronics to a visor.  
     [0035] While the exemplary embodiments illustrated in the FIGS. and described above are presently preferred, it should be understood that these embodiments are offered by way of example only. For example, the mirror can include one or more smaller mirrors, and can include various configurations and compositions. Accordingly, the present invention is not limited to a particular embodiment, but extends to various modifications that nevertheless fall within the scope of the appended claims.