Patent ID: 7152901

Claim:
A visor core for motor vehicles, comprising: a body made of a polymer material and including first and second halves interconnected by a hinge, the first and second halves together defining an internal cavity when folded together about a hinge to define a fully folded configuration in which the visor core is suitable for use in a vehicle interior; a connector including a post and a connector cavity that receives at least a portion of the post when the first and second halves are folded together to the fully folded configuration, the post defining a full insertion depth in the connector cavity when the first and second halves are in the fully folded configuration, wherein the connector cavity defines a side wall and the post has a non-circular cross-sectional shape and tightly engages the side wall of the connector cavity when the post is at the full insertion depth and securely interconnecting the first and second halves, and wherein the post frictionally engages the side wall of the connector cavity, and at least some of the post material is melted to the side wall of the connector cavity.