Patent Publication Number: US-2009218845-A1

Title: Visor and method of making a visor

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application claims the benefit of U.S. Provisional Application No. 60/756,987, filed Jan. 6, 2006, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     The present invention relates generally to the field of visors for use in vehicles and methods for making such visors. More specifically, the present invention relates to visors for vehicles (or other applications) having two core pieces, where one of the core pieces may be adapted to additionally function as a bezel for a vanity mirror and a lens for a vanity lamp. Additionally, the present invention relates to the use of a metalized polyfilm as a vanity mirror and as a reflector for a vanity lamp. 
     Visors to use in vehicles to shield occupants from sunlight are generally known. Such visors often have a “butterfly” or “clamshell” type core portion made from a material such as cardboard or polypropylene with generally symmetrical halves that connect together to form a joint or seam about a perimeter edge of the visor. Alternatively, the halves may be two separate core elements that are fastened together during assembly of the visor. The visors may be at least partially covered by a cover material such as a fabric. 
     Visors may include components such as a vanity mirror and a vanity lamp or light. These components are often integrated within a housing that is then assembled into a recess located in one or more core portions of the visor assembly. After creating the recess, the vanity housing, having the mirror and/or lamp components installed, is attached to the visor. 
     A vanity housing described above, having both a mirror and lamp, typically comprises several components. These components include a cover or lid for the vanity, a mirror, a bezel, housing, or frame to hold the mirror in place, a light or bulb for the lamp, and reflector and lens components for the lamp. The various components are mounted within the vanity housing, which is in turn mounted to the visor. Various hardware, adhesive materials, or other fastening devices may be required to assemble the various components into the vanity housing and in turn into the visor assembly. 
     One challenge associated with traditional visors is minimizing the number of components involved in providing a vanity mirror and/or lamp. Ideally, the number of components required should be minimized, therefore easing the assembly process, production costs, and the overall assembly time. 
     Accordingly, it would be desirable to provide a visor assembly having a film that could be tensioned and act as both a thin, lightweight, and non-distorted vanity mirror and the reflector for the vanity lamp. 
     It would also be desirable to provide a visor having a two piece core design with one core piece that could also function as a bezel for a vanity mirror, It would also be desirable to provide a visor having a core piece that could also function as a lens for a vanity lamp. It would also be desirable to provide a visor having a core piece that could also function as a housing for the wiring and/or switching components required to control and power a vanity lamp. It would also be desirable to provide a visor having a core piece that could also function as a pivot housing or socket for a vanity cover or lid. 
     Accordingly, it would be desirable to provide a visor and method for making a visor having one or more of these or other advantageous features. 
     SUMMARY 
     According to one embodiment, a visor assembly includes a first core piece having an aperture and a second core piece coupled to the first core piece. A reflective film is positioned in a tensioned state between the first core piece and the second core piece such that a first portion of the reflective film is visible through the aperture. 
     According to another embodiment, a method of making a visor includes providing a first core piece and a second core piece, positioning a reflective film between the first core piece and the second core piece, and securing the first core piece to the second core piece with the reflective film there between and tensioning the reflective film, wherein at least a first portion of the reflective film is visible through an aperture in the first core piece. 
     According to yet another embodiment, a method of making a visor includes providing a reflective film, inserting the reflective film into a mold, injecting a molten plastic into the mold to form a first core piece, and securing the first core piece to a second core piece having an aperture such that at least a portion of the reflective film is visible through the aperture. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         FIG. 1  is a perspective view of a visor assembly according to an exemplary embodiment; 
         FIG. 2  is a sectional view of the visor assembly of  FIG. 1 ; 
         FIG. 3  is a partial exploded view of the visor assembly of  FIG. 1 ; 
         FIG. 4  is a sectional view of a visor assembly according to another exemplary embodiment; 
         FIG. 5  is a partial exploded view of the visor assembly of  FIG. 4 ; 
         FIG. 6  is a partial sectional view of the visor of  FIG. 4 ; 
         FIG. 7  is an illustration of both sectional and perspective views of various configurations for a mirror to be used in a visor assembly according to various exemplary embodiments; and 
         FIG. 8  is an illustration of sectional views of various configurations for a peripheral seam for a visor assembly according to various exemplary embodiments. 
     
    
    
     DETAILED DESCRIPTION  
     Referring to  FIG. 1 , a visor  10  includes a first or top core piece  12 , a second or bottom core piece  14 , and a vanity mirror  16 . Top core piece  12  has an aperture  20  configured to allow an occupant of a vehicle to view vanity mirror  16  located between top core piece  12  and bottom core piece  14  according to an exemplary embodiment. As discussed in more detail below, top core piece  12  may also function as one or both of a vanity mirror bezel and a vanity lamp lens. 
     Referring to  FIG. 2 , top core piece  12  has an inner surface  22  and an outer surface  24 . Bottom core piece  14  similarly has an inner surface  32  and an outer surface  34 . Bottom core piece  14  is configured to have a peripheral configuration shown as substantially symmetrical to the peripheral configuration of top core piece  12 , so that core pieces  12 ,  14  form a peripheral seam or joint  26  when assembled. As shown in  FIG. 8 , peripheral seam  26  may comprise various configurations for top and bottom core pieces  12 ,  14  at the interface for peripheral seam  26 . 
     Referring to  FIGS. 2 and 3 , inner surface  32  may have a raised region  30  (e.g., base, platform, etc.) that is proximate aperture  20  in top core piece  12  when visor  10  is assembled. Raised region  30  provides a surface on which mirror  16  (e.g., a metalized, reflective film) may be mounted and may act as a backing surface or structure for the mirror material. In an alternative embodiment, raised region  30  may extend beyond aperture  20  in top core piece  12  when visor  10  is assembled to assist in positioning and securing mirror  16  in place (e.g., by an interference fit of the top and bottom core pieces  12 ,  14 ). 
     According to one embodiment, mirror  16  may be made from a film or polyfilm  40  (see  FIG. 3 ). Film  40  may be metalized on at least one surface so as to be reflective and suitable for use as mirror  16 . To avoid distortion of film  40 , film  40  may be tensioned or stretched as it is assembled into visor  10 . Referring to  FIGS. 2 and 3 , film  40  is positioned above inner surface  32  of bottom core piece  14  so that the reflective surface of film  40  is facing inner surface  22  of top core piece  12  when visor  10  is assembled. If bottom core piece  14  includes raised region  30 , film  40  may be preferably positioned so as to cover the entire surface of raised region  30  that would otherwise be visible through aperture  20  in top core piece  12  when visor  10  is assembled. In use, visor  10  is rotated down from a stowed position, and film  40  is visible through aperture  20  in top core piece  12  by an occupant of a vehicle. 
     Referring again to  FIG. 2 , top core piece  12 , bottom core piece  14 , and film  40  may be configured in various ways. In order to hold film  40  in a tensioned position, film  40  may be provided with an adhesive backing, or be configured to be heat sealed, thermal-welded, ultrasonically welded, or captured between top and bottom core pieces  12 ,  14  in an interference, snap, or compression type fit. For example, as shown in  FIG. 2 , top and bottom core pieces  12 ,  14  may have one or more ridges or projections  46  configured to secure top core piece  12 , film  40 , and bottom core piece  14  together and maintain tension in film  40 . A plurality of projections such as ridges  46  (or other suitable structure) may be used and located on either or both of top or bottom core pieces  12 ,  14 . In addition to securing film  40 , ridge or ridges  46  may also act to help secure top and bottom core pieces  12 ,  14  together through heat sealing, thermal or ultrasonic welding, a snap or interference fit, or any other suitable means. Further, projections or ridges  46  may be used to provide tension in film  40  when visor  10  is assembled, e.g., by stretching film  40  into a recess, etc. 
     As shown in  FIGS. 1-3 , top core piece  12  is constructed of a plastic material and is provided without a fabric covering according to one embodiment. Bottom core piece  14  may likewise be made of a plastic material and provided without a fabric covering. In an alternative embodiment, bottom core piece  14  may be made of plastic or any other suitable material (e.g., cardboard), and then covered by a material (e.g., fabric, vinyl, leather, etc.) in a color or material texture chosen, for example, to match or contrast with the interior of a vehicle. According to an alternative embodiment, top core piece  12  may additionally serve as a pivot housing or socket for a cover or lid for vanity mirror  16  and/or a lamp  18  (see  FIG. 4 ). The cover or lid is intended to conceal mirror  16  and/or lamp  18  from view when not in use, and be either slid or rotated open to allow viewing of mirror  16  and/or lamp  18 . Top core piece  12  may have a base for a slide cover or lid, or an integrally molded pivot housing or socket. 
     Referring now to  FIG. 4 , film  40  may be adapted to be used as a reflector material  38  for vanity lamp  18  in a visor  110 . A top core piece  112  may be configured to house a light source, shown as lamp  18 , and the associated wires and/or switching components to power and control lamp  18 . For example, visor  110  shown in  FIG. 4  has lamps  18  located on each side of mirror  116 . Each lamp  18  includes reflector element  38 , a light or bulb  44  (e.g., an illumination source or element), a lens element  28  (shown, for example, as part of top core piece  112 ), and any wiring or switching components (not shown) that may be housed within visor  110 . Lens  28  allows light to pass through itself when lamp  18  is in use. Bulb  44  provides the light for lamp  18  and is located between lens  28  and reflector element  38 . Reflector element  38  reflects the light emitted from bulb  44  back through lens  28 . 
     According to one embodiment, as shown in  FIG. 4 , film  40  acts as reflector  38  and may be held in position between top core piece  112  and a bottom core piece  114  using any suitable method such as adhesives, heat sealing, or any other suitable fastening device. Film  40  may be sized so as to extend beyond the perimeter of an aperture  120  in top core piece  112  and beneath the light elements or bulbs  44  of lamps  18  on either side of mirror  116 . As shown in  FIG. 4 , one or more projections or ridges  146  may be positioned, for example, between mirror  116  and lamp  18  to secure film  40  in position. Ridges  146  may be configured so as to provide contact between film  40  and ridge  146  across substantially all or a portion of a transverse portion of film  40  orientated along a longitudinal direction of visor  110 . A number of other suitable means of fastening film  40  in place may alternatively be used. In an exemplary embodiment, film  40  may be held in position in a tensioned state. The tension in film  40  is intended to ensure a good reflective surface, enabling film  40  to act as vanity mirror  116 , and to eliminate distortion of film  40  that might occur if film  40  were installed in an untensioned state or injection molded in place. 
     As shown in  FIGS. 5 and 6 , film  40  may also be installed so as to substantially conform to a concave contour  36  of inner surface  132  of bottom core piece  114  in the areas proximate the vanity bulb  44 . Projections or ribs  150  in top core piece  112  are configured to match contour  36  of bottom core piece  114  and hold film  40  in a position conforming to contour  36  in bottom core piece  114 . Although  FIGS. 5 and 6  show film  40  acting as reflector  38 , film  40  may similarly conform to a contour in bottom core  114  piece when acting as mirror  116  (e.g., to provide a magnification area of the mirror) as shown in  FIG. 7 . As shown in  FIG. 7 , film  40  may be used without a curved surface, with a relatively small contoured or curved surface  52 , or with a relatively large contoured or curved surface  54 . When acting as mirror  116  with a contour, similar mounting features may be used as those used to secure film  40  as reflector  38 . 
     Referring back to  FIG. 4 , according to yet another embodiment, visor  110  is made at least partially from a transparent or translucent material (e.g., injection molded plastic, etc.) and includes aperture  120 , a bezel portion  56 , and lens portion  28 . Integrating lens  28  and the bezel  56  into top core piece  112  is intended to minimize the number of components required as a part of visor  110 . Additionally, top core piece  112  may also function as a housing or frame for the wiring and switching components associated with lamp  18 . Top core piece  112  may be textured so that in areas outside lens portion  28 , top core piece  112  does not allow visibility to other components secured within top core piece  112 . Additionally, top core piece  112  could be painted, have graphics applied (e.g., screen printing, etc.) or have a “smoke” tint. 
     Bezel portion  56  of top core piece  112  acts as a bezel for mirror  116 , being located in the area proximate the perimeter of aperture  120 , and securing mirror  116  in place without the need for a separate bezel element. As shown in  FIG. 4 , bezel portion  56  has an outer surface  58  (i.e., the surface visible to a passenger in a vehicle) and an inner surface  60  (i.e., the surface opposite the outer surface). Outer surface  58  of bezel portion  56  generally follows the contour of top core piece  112  and curves toward the surface of mirror  116 . Inner surface  60  of bezel portion  56  may be configured so that as top and bottom core pieces  112 ,  114  are assembled, bezel portion  56  is biased toward bottom core piece  114 , thereby helping to secure mirror  116  in place. Inner surface  60  of bezel portion  56  may alternatively be contoured to receive one or more of the peripheral edges of a mirror. 
     Further referring to  FIG. 4 , lens portion  28  of top core piece  112  is located proximate bulb  44  for the vanity lamp  18  when visor  110  is assembled. Lens portion  28  may be fully transparent (i.e., tending not to diffuse the light provided by the vanity lamp bulb), or it may be translucent. The translucence may be created by using a tinted material in lens portion  28 , by applying a translucent coating to lens portion  28 , by providing a surface texture on one or both of the interior or exterior surface of lens portion  28 , or by any other suitable means. 
     Bezel portion  56  and lens portion  28  of top core piece  112  may be molded as part of a single-piece top core, or they may be molded in separate molding processes (e.g., insert molded) into top core piece  112 , thereby allowing for greater variances of color, material, surface texture, etc. Alternatively, lens portion  28  and bezel portion  56  may be molded as separate pieces and then mechanically attached (e.g., by a snap or interference fit, or with the use of traditional fasteners) to the top core piece  112 . 
     The various visor components disclosed and described herein as exemplary embodiments of the invention may be utilized in the assembly of a visor using a streamlined method of assembly that is intended to reduce the typical assembly time of visors and minimize material costs. According to an exemplary embodiment, a top core piece and bottom core piece are provided, the top core piece having an aperture configured to allow viewing of a mirror contained between the inner surfaces of the top core and the bottom core pieces. The top core and bottom core pieces may be made of any suitable material. 
     A mirror made of a metalized film is provided, having at least one reflective surface suitable for use as both a mirror and a vanity lamp reflector, and the top core and bottom core pieces are assembled together with the mirror being captured between the top and bottom core pieces such that at least a portion of the mirror is visible through the aperture in the top core piece. Additionally, the film may be tensioned during assembly so as to avoid distortion of the reflective properties of the film. 
     In another embodiment, a vanity lamp is additionally provided. The film is configured to act as a reflector for the vanity lamp. The film extends between the lamp bulb and the bottom core piece and is secured in place. Alternatively, the film may conform to a contour in the inner surface of the bottom core piece. 
     The bottom core piece and the film material may be joined together using heat sealing. The top and the bottom core pieces are joined together using any suitable means, including heat staking, interference fits, or a “shark tooth” configuration on one of the core pieces. Additionally, projections or ridges may be provided on one or both of the core pieces, as disclosed herein, to facilitate joining of the pieces. Additional means of joining the various components include thermal and ultrasonic welding. 
     In another embodiment, a mold is provided and the top core piece is made at least partially of a molded plastic material such that the top core piece may function as both a bezel for a vanity mirror and a lens for a vanity lamp. The areas of the top core piece covering the vanity light or bulb are translucent or transparent so as to allow the light from the bulb to pass through. The areas of the top core piece outside the lens portion may be textured or otherwise treated or manufactured so as to obscure visibility of any other components within the visor. The bottom core piece may be injection molded with a reflective film using an injection molding process such as insert molding or a mold-behind process. 
     According to any of these or other exemplary embodiments, other components may be attached to the visor, such as accessories and mounting devices to suit other desired applications. 
     The construction and arrangement of the elements of the visor and the methods for making a visor as shown in the illustrated and other exemplary embodiments are illustrative only. Although only a few embodiments of the present invention have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes, and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited herein (e.g., the core pieces may be formed from any suitable material and may be integrated with the other elements using any suitable process). For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied (e.g., the bezel portion and lens portions may be provided in any suitable shape, size, and location, or may be combined with one another in any suitable combination). Additionally, the film may be assembled into the visor as a mirror and/or reflector using a mold process such as an insert molding process or a partial mold behind mold process. The film may also be die cut so that it can be wrapped easily into complex shapes. In addition, the film may be used as a reflector in an overhead console or as a conversation mirror, being provided as a separate component or integrated into the overhead storage console (e.g., into a storage door or sunglass storage door). 
     It should be noted that the elements and/or assemblies of the visor may be constructed from any of a wide variety of materials that provide sufficient strength or durability, including any of a wide variety of moldable plastic materials (such as high-impact plastic), or foams, polymers, etc. and in any of a wide variety of colors, textures and combinations. The film may be made of any suitable film or polyfilm material that may act as both a mirror and a light reflector and may be attached in any suitable method, including application to a visor core piece directly or indirectly from a rolled good. The shape and size of the film may be varied to improve the appearance, formability, and assembly of the visor and the visor sub-components. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the present inventions. 
     The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments, Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present invention.