Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a divisional application of application Ser. No. 10/237,367, filed on Sep. 9, 2002 now U.S. Pat. No. 6,612,552, which application is a divisional application of application Ser. No. 09/766,770, filed on Jan. 22, 2001, now U.S. Pat. No. 6,494,521, which application is a continuation-in-part of application Ser. No. 09/293,598, filed on Apr. 16, 1999, now U.S. Pat. No. 6,179,365, and a continuation-in-part of application Ser. No. 09/669,072, filed Sep. 22, 2000, which application is presently abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to automotive sun visors which are rotatively and pivotally mounted above the windshield. More particularly, the present invention relates to pivot rods upon which sun visors are pivotally mounted, wherein the pivot rod has a connection interface (conventionally including an elbow) which is rotatively connected to the roof of the vehicle. Still more particularly, the present invention relates to a head impact energy absorbing pivot rod connection interface cover. 
     2. Description of the Prior Art 
     Federal motor vehicle standards are being continuously updated. One area of current concern is occupant safety in the event of a crash. Occupants are typically violently moved in relation to the vehicle due to the inertial forces involved in a crash. Most vulnerable is the head of the occupants. Accordingly, FMVSS 201 has recently been upgraded to include a head injury criterion (HIC). In order for vehicle manufacturers to meet the HIC, additional padding of the interior trim must be provided. 
     One area of the interior of the passenger compartment of a motor vehicle that is particularly dangerous in the event of a head impact is the elbow of a sun visor pivot rod. The pivot rod elbow is quite rigid, of a small cross-section rod stock which is sometimes plastic covered, and the angle is a sharp ninety degrees. An occupant whose head untowardly strikes the pivot rod elbow is likely to be injured because the energy of the impact will be delivered to a small surface area of the skull. 
     Referring now to FIGS. 1 and 2, an example of a conventional sun visor  10  is shown. The sun visor  10  is pivotally mounted to the main portion  12   b  of a pivot rod  12 . As best shown at FIG. 2, the pivot rod  12  includes a connection interface that conventionally has ninety degree elbow  14 , wherein an end portion  12   a  of the pivot rod  12  is rotatably mounted to the metallic roof  16  via a cap  18  which is fastened by screws  20 . As an example of mounting, the end portion  12   a  of the pivot rod  12  is rotatably attached to a cap  18  in a spring loaded manner via a compression spring  22 . The spring  22  provides frictional resistance as the elbow  14  is rotated with respect to the cap  18 . There is a sun visor mounted, as described, at each of the left and right sides of the windshield  24  (only the driver-side sun visor being shown for simplification). 
     As can be seen at FIG. 1, the pivot rod enables an occupant of the front seat to pivot the sun visor  10  to a storage location A adjacent the headliner  28  to a deployed location B so as to selectively occlude the windshield  24  along arrow P, which pivoting may well exceed ninety degrees. Further, the rotation afforded the elbow  14  allows the pivot rod  12  with its associated sun visor  10  to be rotated from a location adjacent the windshield  24  to an auxiliary location C adjacent the adjoining side door window  26  via a rotation along arrow R, a rotation which may exceed ninety degrees. 
     Accordingly, what is needed in the art is coverage of the pivot rod connection interface which will protect occupants from head impact injury in the event of a crash, yet allows the sun visor to both pivot and rotate in a fully normal and familiar manner. 
     SUMMARY OF THE INVENTION 
     The present invention is a pivot rod connection interface cover for covering the connection interface (ie., the elbow) of a sun visor pivot rod with respect to a vehicle roof so as to protect occupants from head impact injury in the event of a crash, and yet allow the sun visor to both pivot and rotate in a fully normal and familiar manner. 
     The pivot rod connection interface cover according to the present invention is composed of a base member and a cover member. The base member is affixed to the roof of the vehicle and preferably serves as a pivot rod support which allows rotation of the pivot rod with respect to the roof. The cover member snappingly engages the base member so as to be rotatable therewith and receives therewithin the pivot rod connection interface with the vehicle roof. The cover member has an exterior surface which provides head impact energy absorbance over an area much larger than that which would otherwise be the case with respect to a conventionally exposed pivot rod elbow. 
     The base member is provided, in a preferred form, with a central aperture and a plurality of mounting holes (eg., two screw holes). The base member further has a perimeter and, in a preferred form, a plurality of resilient upstanding tabs situated at the perimeter. Each tab curvably follows the curvature of the adjoining perimeter, and is characterized by a lower chamfer, and upper chamfer and a apex therebetween, wherein the apex is disposed radially outward in relation to the perimeter. 
     The cover member has, in a preferred form, an internal annular slot for receiving therein the upper and lower chamfers of the tabs, wherein the apex slidably abuts the slot sidewall. In this regard, the resiliency of the tabs, coupled with the upper chamfer allow the cover member to snap lockingly onto the tabs and the tabs to be slidingly movable all along the annular slot. 
     The cover member may be a single component or may be a plurality of components. The cover member serves to cover the pivot rod connection interface, as for example by receiving a connection interface including a pivot rod elbow of an independent pivot rod or receiving a connection interface of an integrally incorporated visor pivot rod. For example, the cover member may be composed of an inner cover component which is rotatably connected with the base member, and of an outer cover component which is connected with the inner cover component, wherein a visor pivot rod is connected integrally with the inner cover component and the outer cover component covers the connection interface of the pivot rod. 
     The cover member, in one form thereof, has an exterior surface of a generally hemispherical dome shape, having a portal which may or may not be defined by a flat-faced portal arch; and in another form thereof, has an exterior surface of a generally curvaceous shape with a flat-faced portal. Internally, the cover member has an interior hollow space defined by an interior surface. Preferably, but not necessarily, the interior surface is provided with left and right guide walls which are mutually parallel and straddlingly intersect the portal. Preferably, too, is provided a concave guide wall which extends between the left and right guide walls, and is located centrally relative to the annular slot. The left and right guide walls serve not only as an optionally included extra guidance for the pivot rod (pivot rod guidance is primarily by the portal and concave guide wall, if present), they serve as crush features which aid impact energy absorbance in cases where the impact causes deformation of the cover wall of the cover member. 
     Operation of a preferred form of the present invention for interfacing with a conventional pivot rod will now be discussed. 
     The base member is attached rotatably to the end portion of a pivot rod elbow at the central aperture, and the pivot rod is captured at the portal of the cover member. Screws then secure the base member to the roof of a vehicle. Next, the cover member is snapped onto the base member, wherein the end portion of the pivot rod elbow abuts the concave guide wall and is located centrally with respect to the annular sidewall of the cover member and the perimeter of the base member. The pivot rod side of the pivot rod elbow is guided between the left and right guide walls and exits at the portal. 
     An occupant can now pivot the sun visor on the pivot rod in the normal manner. Further, the occupant can rotate the sun visor to the adjoining side door window, in that while the base portion cannot move, the cover portion is rotatable with the pivot rod elbow as the sun visor is rotated in the normal manner. 
     In the unfortunate event of a crash, should the occupant be thrown forwardly in a collision course toward the pivot rod connection interface (ie., the elbow), the cover member will absorb the energy of the head impact over a sufficiently large area to limit the likelihood of head impact injury. In the event of the head impact that is so great as to deform or crush the cover member, the left and right guide walls will serve as crush features that absorb impact energy. 
     Accordingly, it is an object of the present invention to provide a head impact energy absorbing connection interface cover for a pivot rod of a sun visor. 
     It is a further object of the present invention to provide a head impact energy absorbing connection interface cover for a pivot rod elbow of a sun visor, wherein the sun visor is both pivotable and rotatable. 
     It is yet another object of the present invention to provide a pivot rod connection interface cover in which the pivot rod is integrated therewith. 
     These, and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a portion of an automotive interior, showing a prior art sun visor pivot rod connection interface including an elbow. 
     FIG. 2 is a partly sectional, detail side view of the prior art sun visor pivot rod connection interface. 
     FIG. 3 is a perspective view of a portion of an automotive interior, showing a sun visor pivot rod connection interface cover according to a first form of the present invention. 
     FIG. 4 is a perspective view of the pivot rod connection interface cover according to the first form of the present invention. 
     FIG. 5 is a bottom plan view of a cover member of the pivot rod connection interface cover according to the first form of the present invention. 
     FIG. 6 is a top plan view of a base member of the pivot rod connection interface cover according to the first form of the present invention. 
     FIG. 7 a  is a partly sectional view of the cover member, seen along line  7   a — 7   a  in FIG.  5 . 
     FIG. 7 b  is a partly sectional side view of the base member, seen along line  7   b — 7   b  in FIG.  6 . 
     FIG. 8 is a partly sectional, detail side view of the pivot rod connection interface cover according to the first form of the present invention, shown in operation mounting a sun visor pivot rod to the roof of an automobile. 
     FIG. 9 is a detail, partly sectional view of a snapping interface between the base member and the cover member, as seen at circle  9  of FIG.  8 . 
     FIG. 10 a  is a partly sectional top view of the pivot rod connection interface cover according to the first form of the present invention, shown in operation with a pivot rod, wherein a portion of the cover member is cut-away, and wherein the pivot rod is at a first location. 
     FIG. 10 b  is a partly sectional top view of the pivot rod connection interface cover shown in operation with a pivot rod, wherein a portion of the cover member is cut-away, and wherein the pivot rod is now rotated to a second location. 
     FIG. 11 is a perspective view of a portion of an automotive interior, showing the sun visor pivot rod connection interface cover according to a second form of the present invention, wherein the sun visor is at its storage location. 
     FIG. 12 is a perspective view of a portion of an automotive interior as in FIG. 11, now showing the sun visor pivoted to its deployed location adjacent the windshield. 
     FIG. 13 is a perspective view of a portion of an automotive interior as in FIG. 11, now showing the sun visor pivoted to its auxiliary location adjacent the adjoining side door window. 
     FIGS. 14 a  and  14   b  are perspective views of the pivot rod connection interface cover according to the second form of the present invention. 
     FIG. 15 is a bottom plan view of a cover member of the pivot rod connection interface cover according to the second form of the present invention. 
     FIG. 16 is a bottom plan view of a cover member of the pivot rod connection interface cover according to an alternative aspect of the present invention. 
     FIG. 17 is a partly sectional, detail side view of the pivot rod connection interface cover according to the alternative aspect of the present invention, shown in operation mounting a sun visor pivot rod to the roof of an automobile. 
     FIG. 18 is another bottom plan view of a cover member of the pivot rod connection interface cover according to the alternative aspect of the present invention. 
     FIG. 19 is an exploded perspective view of a pivot rod connection interface cover according to a third form of the present invention. 
     FIG. 20 is a top plan view of the pivot rod connection interface cover according to the third form of the present invention. 
     FIG. 21 is a sectional side view of the pivot rod connection interface cover according to the third form of the present invention. 
     FIG. 21A is a broken-away detail sectional view of component interaction between the base member and the cover member of the pivot rod connection interface cover according to the third form of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIGS. 3 through 18, the pivot rod connection interface cover according to the present invention will be described, wherein FIGS. 3 through 10 b  depict a first form of the pivot rod connection interface cover  100 , FIGS. 11 through 15 depict a second form of the pivot rod connection interface cover  100 ′, FIGS. 16 through 18 show an alternative aspect of the pivot rod connection interface cover, and FIGS. 19 through 21A depict a third form of the pivot rod connection interface cover  100 ′″. 
     As can be understood by simultaneous reference to FIGS. 3 and 4, the pivot rod connection interface cover  100  includes a cover member  102  having, preferably, a generally hemispherical dome shape. The pivot rod connection interface cover  100  receives the conventional elbow  14  of a conventional pivot rod  12  of a conventional sun visor  10 . In this regard, the sun visor  10  is conventionally pivotally mounted on the main portion  12   b  of the pivot rod  12 , so as to be conventionally pivotal from adjacent the headliner  28  (at location A) to adjacent the windshield  24  (at location B, shown in phantom) along arrow P. Further in this regard, the pivot rod connection interface cover  100  is structured to enable rotation of the elbow  14  so that the pivot rod  12  and its associated sun visor  10  are conventionally rotatable from adjacent the windshield  24  to adjacent the adjoining side door window  26  (at auxiliary location C, shown in phantom) along arrow R. 
     As can be understood from FIG. 4, the large diameter of the cover member  102 , on the order for example of about 2 and one-half inches, affords a radius of curvature of the exterior surface  132   a  thereof which is much larger than that of a naked pivot rod elbow  14 . Accordingly, in the event of a crash, an occupant whose head H is propelled forcibly in a direction F against the pivot rod connection interface cover  100 , would be far less likely to be injured because of the large contact area of the exterior surface  132   a , as compared to a naked pivot rod elbow  14 , which has a small contact area because of its much smaller radius of curvature, as well as the compounded danger associated with its rather sharply defined ninety degree bend. 
     Referring now additionally to FIGS. 5 through 10 b , the structure and function of the pivot rod connection interface cover  100  will be further detailed, wherein it will be noted that the pivot rod connection interface cover further includes a base member  104 . 
     The base member  104  has a central aperture  106  and a pair of mounting holes  108 . The base member  104  has a circular perimeter  110 . A plurality of resilient upstanding tabs  112  are located at the perimeter  110 , three tabs being shown by way of preference. Each tab  112  curvably follows the circular curvature of the adjoining perimeter  110 . Each tab  112  has a lower chamfer  114 , an upper chamfer  116  and an apex  118  situated therebetween, wherein the apex is disposed radially outward in relation to the perimeter  110 . The interface of each tab  112  with the base member provides a resiliency such that each tab may be moved radially inwardly when exposed to a firmly applied force, and will thereafter return to its original shape. A preferred material of composition of the base member is plastic, but a metal or another structurally strong material may be substituted. 
     The cover member  102  is preferably composed of plastic, which may be decorated to match the color and look of the passenger compartment interior decor, and although the aforesaid hemispherical dome shape is preferred, this may be modified by bevels or other pleasingly fanciful shapes provided no sharp corners are created which would raise head impact injury concerns. 
     Adjacent the equatorial terminus  120  of the cover member  102 , an internal annular slot  122  is formed for receiving therein the upper and lower chamfers  116 ,  114  of the tabs  112 , wherein the apex  118  slidably abuts the slot sidewall  124 . In this regard, when the base member  104  is aligned with the equitorial terminus  120  and then pushed into the cover member  102 , the resiliency of the tabs  112 , coupled with the upper chamfer  116  provide snap lockingly of the tabs into the annular slot  122 , wherein the base member is rotatable with respect to the cover member as the tabs slide along the annular slot. The resiliency of the tabs  112 , coupled with the lower chamfer  114  provide snap unlockingly of the tabs out of the annular slot  122 , which allows for easy disassembly. 
     The nature of a preferred interface of the tabs  112  in the annular slot  122  is shown at FIG.  9 . It will be noted that the annular slot  122  is recessed from the equitorial terminus  120  so that the base member  104  is flush with the equitorial terminus when the tabs  112  are received into the annular slot  122 . A preferred form of the annular slot  112  includes a stair-step  126  which abuts the upper chamfer  116 . As was earlier noted, the apex  118  abuts the slot sidewall  124 . Further the lower chamfer  114  abuts the slot corner  128 . Additionally, it will be noted that there is a small spacing (to facilitate relative rotation without binding) between the perimeter  110  of the base member  104  and the inner periphery  130  of the cover member  102  at the equitorial terminus  120 . 
     The interior surface  132   b  of the cover wall  132  of the cover member  102  is a concave reciprocal of the convex hemispherical dome shape of the exterior surface  132   a . A portal  134  is formed through the cover wall  132 . The portal  134  may be defined by a flat-faced portal arch  136 , as shown, or by another configuration, such as for a preferably example, a shape which more smoothly merges to the convexity of the hemispherical dome shape. The portal  134  may be circular or, as shown, may be elongated to universally accommodate variously elongated pivot rod end portions  12   a.    
     Internally to the cover member  102 , mutually parallel left and right guide walls  138 ,  140  are connected at both ends thereof to opposing locations of the interior surface  132   b , wherein the center of the inner periphery  130  is located equidistantly therebetween and the left and right guide walls are aligned directly with the portal in straddling relation thereto. A concave guide wall  142  extends between the left and right guide walls  138 ,  140 , and the curvature thereof is located concentrically relative to the inner periphery  130 . The left and right guide walls  138 ,  140  serve not only as an optionally included extra guidance for the pivot rod (pivot rod guidance occurs between the concave guide wall  142  and the portal  134 ), they serve as crush features which aid impact energy absorbance in cases where the impact causes deformation of the cover wall  132  of the cover member  102 . 
     Operation will now be described with particular attention being directed to FIG.  8 . 
     The base member  104  is attached rotatably to the end portion of a pivot rod elbow  14  at the central aperture  106 . By way of exemplification, the end portion  12   a  of the pivot rod  12  has a slot and trapped washer  146  at one side of the central aperture, and a spring loaded washer  148  at the other side of the central aperture, wherein spring pressure generates a desired degree of resistance to rotation of the pivot rod elbow in relation to the base member. Other structural interfaces of the base member  104  with respect to the roof and the pivot rod may be utilized, depending on the application involved. Indeed, the pivot rod may be rotatably attached to the roof via an appropriately configured bracket, and the base member may be connected to the bracket. The pivot rod  12  is captured at the portal  134  of the cover member  102 . 
     Screws  144  then secure the base member to the roof  16  of a vehicle, squeezing any intervening headliner  28 . Next, the cover member is snapped onto the base member, wherein the tabs  112  resiliently snap into the annular slot  122 , as described hereinabove. Now, the end portion  12   a  of the pivot rod  12  abuts the concave guide wall and is axially positioned centrally with respect to the inner periphery of the cover member and the perimeter of the base member. The main portion  12   b  of the pivot rod is guided between the left and right guide walls and exits the cover member through the portal. 
     As shown at FIGS. 10 a  and  10   b , the cover member  102  may now rotate with the pivot rod  12 , yet the base member  104  remains stationary. 
     As shown at FIG. 3, an occupant can now pivot the sun visor on the pivot rod in the normal manner. Further, the occupant can rotate the sun visor to the adjoining side door window, in that while the base portion cannot move, the cover portion is rotatable with the pivot rod elbow as the sun visor is rotated in the normal manner. 
     As mentioned, in the unfortunate event of a crash, should the occupant be thrown forwardly in a collision course toward the pivot rod elbow, the exterior surface  132   a  of the cover member will distribute the energy of the head impact over a sufficiently large area to limit the likelihood of head impact injury; and, in the event of the head impact being is so great as to deform or crush the cover member, the left and right guide walls will serve as crush features that absorb impact energy. 
     Referring now to FIGS. 11 through 15, the pivot rod connection interface cover  100 ′ according to the present invention will be described, wherein like numerals to those previously used for FIGS. 1 through 10 b  will indicate like structural designations in FIGS. 11 through 15. 
     The pivot rod connection interface cover  100 ′ includes the base member  104  as was described hereinabove, and shown at FIGS. 6 and 7 b . As can best be seen by FIGS. 14 a  and  14   b , the pivot rod connection interface cover  100 ′ further includes a cover member  102 ′ having a generally curvaceous shape. The preferred generally curvaceous shape includes a rounded nose portion  150  and a flat-faced portion  152  at the portal  134 ′. The portal  134 ′ is open at the equitorial terminus  120 ′, thereby allowing the cover member  102 ′ to be detached fully from the pivot rod  12  when snapped off from the base member  104 . The generally curvaceous shape of the cover member  102 ′ as shown at FIGS. 11 through 15 is believed to be the most preferred cover member shape. 
     Referring now to FIGS. 11 through 13, it is to be understood that the pivot rod connection interface cover  100 ′ receives the conventional elbow  14  of the conventional pivot rod  12  of the conventional sun visor  10 . In this regard, the sun visor  10  is conventionally pivotally mounted on the main portion  12   b  of the pivot rod  12 , so as to be conventionally pivotal from adjacent the headliner  28 , at storage location A to adjacent the windshield  24 , at deployed location B. Further in this regard, the pivot rod connection interface cover  100  is structured to enable rotation of the elbow  14  so that the pivot rod  12  and its associated sun visor  10  are conventionally rotatable from adjacent the windshield  24  to adjacent the adjoining side door window  26 , at auxiliary location C. By reference to FIGS. 11 through 13, it will be noted that the sun visor  10  may be configured to recessively fit with respect to the pivot rod connection interface cover  100 ′ in a most aesthetically pleasing manner. 
     The cover member  102 ′ is preferably composed of plastic, which may be decorated to match the color and look of the passenger compartment interior decor, and has a generally curvaceous shape without sharp corners which would raise head impact injury concerns. 
     Adjacent the equatorial terminus  120 ′ of the cover member  102 ′, at the inner periphery  130 ′ is the aforementioned annular slot  122 ′. The annular slot  122 ′ is, as described above, formed for receiving therein the upper and lower chamfers  116 ,  114  of the tabs  112 , wherein the apex  118  slidably abuts the slot sidewall. In this regard, when the base member  104  is aligned with the equitorial terminus  120 ′ and then pushed into the cover member  102 ′, the resiliency of the tabs  112 , coupled with the upper chamfer  116  provide snap lockingly of the tabs into the annular slot  122 ′, wherein the base member is rotatable with respect to the cover member as the tabs slide along the annular slot. The resiliency of the tabs  112 , coupled with the lower chamfer  114  provide snap unlockingly of the tabs out of the annular slot  122 ′, which allows for easy disassembly. 
     The nature of a preferred interface of the tabs  112  in the annular slot  122  was described hereinabove and is as generally shown at FIG.  9 . 
     The interior surface  132   b ′ of the cover wall  132 ′ of the cover member  102 ′ is of a generally concave shape. The portal  134 ′ is formed through the cover wall  132 ′ at the flat faced portion  152 . The portal  134 ′ is preferably elongated in a direction normal to the plane defined by the equitorial terminus  120 ′ and is preferably open thereat. 
     Internally to the cover member  102 ′, mutually parallel left and right guide walls  138 ′,  140 ′ are connected at both ends thereof to opposing locations of the interior surface  132   b ′, wherein the center of the inner periphery  130 ′ is located equidistantly therebetween and the left and right guide walls are aligned directly with the portal  134 ′ in straddling relation thereto. A concave guide wall  142 ′ extends between the left and right guide walls  138 ′,  140 ′, and the curvature thereof is located concentrically relative to the inner periphery  130 ′. The left and right guide walls  138 ′,  140 ′ serve not only as an optionally included extra guidance for the pivot rod (pivot rod guidance is primarily between the concave guide wall  142 ′ and the portal  134 ′), they serve as crush features which aid impact energy absorbance in cases where the impact causes deformation of the cover wall  132 ′ of the cover member  102 ′. 
     Operation will now be described for the pivot rod connection interface cover  100 ′. 
     The base member  104  is attached rotatably to the end portion of a pivot rod elbow  14  at the central aperture  106  (as was described with respect to the pivot rod connection interface cover  100 ). Next, the pivot rod  12  is passed into the portal  134 ′ between the left and right guide walls  138 ′,  140 ′, against the concave guide wall  142 ′ and then snapped onto the base member, wherein the tabs  112  resiliently snap into the annular slot  122 , as described hereinabove. Now, the end portion of the pivot rod  12  abuts the concave guide wall and is axially positioned centrally with respect to the inner periphery of the cover member and the perimeter of the base member. The main portion of the pivot rod is guided between the left and right guide walls and exits the cover member through the portal. The cover member  102 ′ is now able to rotate with the pivot rod  12 , while the base member remains positionally affixed with respect to the roof. Accordingly, an occupant can now pivot the sun visor on the pivot rod in the normal manner. Further, the occupant can rotate the sun visor to the adjoining side door window, in that while the base portion cannot move, the cover portion is rotatable with the pivot rod elbow as the sun visor is rotated in the normal manner. 
     As mentioned, in the unfortunate event of a crash, should the occupant be thrown forwardly in a collision course toward the pivot rod elbow, the exterior surface  132   a ′ of the cover member  102 ′ will distribute the energy of the head impact over a sufficiently large area to limit the likelihood of head impact injury; and, in the event of the head impact being is so great as to deform or crush the cover member, the left and right guide walls will serve as crush features that absorb impact energy. 
     Referring now to FIGS. 16 through 18, an alternative aspect of the present invention is shown, wherein absent are the left and right guide walls and the concave guide wall. FIG. 16 is like FIG. 5, with like parts having like numbers, except the cover  102 ′ now has no left and right guide walls and no concave guide wall. FIG. 17 depicts a pivot rod connection interface cover  100 ″ according to the alternative aspect of the present invention, shown in operation, as in FIG. 8, with like parts having like numbers. This alternative aspect of the present invention is applicable equally to any shaped dome, including the curvaceous shaped dome, as shown at FIG. 18, which is like FIG. 15 having a cover  102 ′″ and wherein like parts have like numbering. 
     Referring now to FIGS. 19 through 21A, the third form of pivot rod connection interface cover  100 ′″ will be detailed. 
     The pivot rod connection interface cover  100 ′″ is preferably composed of a plastic material, and includes a base member  302  and a cover member  304 , wherein the cover member is composed of an inner cover component  306  and an outer cover component  308 . A visor pivot rod  310  is integrally connected to the inner cover component  306 . 
     The inner cover component  306  includes a generally cup shaped annulus  312 , including a floor  314 , a sidewall  316 , an annular outer cover boss  318   a  and an annular inner cover boss  318   b  which are both slightly elevated relative to the floor, and a peripheral upper-shelf  320 . The visor pivot rod  310  is connected, via a connection interface  354 , with the sidewall  316  and projects from the annulus  312  in a direction parallel to the floor  314 . A pair of braces  322   a ,  322   b , which extend from the sidewall at the visor pivot rod to the floor, are preferably provided as part of the connection interface  354  for stiffening the visor pivot rod  310  relative to the annulus  312 , as well as for providing crush features for absorbing impact energy. The visor pivot rod  310  may advantageously have an axially extending interior recess  324  for receivably accepting therealong wiring for visor related electronics, such as for example a lighted vanity mirror. A cover stud  326  projects perpendicularly from the floor and has an engagement barb  328  for being secured to the base member  302 . The cover stud  326  is preferably hollow to save material and provide a passage for visor wiring. 
     The outer cover component  308  has a cover wall  308 ′ having an external surface  308 ″ shaped as generally discussed and shown hereinabove, such as for example the hemispherical dome shape or the generally curvaceous shape, including a portal  330  formed in the wall cover through which the visor pivot rod  310  projects, the cover wall defining an interior hollow  308 ′″. The outer cover component  308  snaps onto the inner cover component  306 , for example by a tab  332  of the outer cover component snapping into a slot  334  of the inner cover component and oppositionally, a pair of groves  336  of the portal  330  interferingly engaging a conforming section  338  of the visor pivot rod  310 , and/or by a plurality of tabs snapping into respective slots. 
     The base member  302  has an annular outer base boss  340  and an annular inner base boss  342  which are both elevated slightly above a base plate  344 , the base plate having attachment holes  346 . A base post  348  has a tapering bore  350 , depends from the base plate  344 , and has axial relief slots  352 . 
     In assembly, the base member  302  is screwably attached to the vehicle roof. A connection  325  is provided, as shown at FIG. 21A, wherein the cover stud  326  is thrust into the tapering bore  350  of the base post  348  until the engagement barb  328  has passed through the base post  348  (after causing the relief slots  352  to have temporarily widened), and is now in interfering abutment with the base post, as shown at FIG.  21 . The outer cover component  308  is then snapped onto the inner cover component  306 . Alternatively, the base member  302  and the inner cover component  306  may be pre-assembled so as to be either permanently or not permanently conjoined utilizing any interconnection modality which allows for mutual rotation therebetween. A sun visor  356  may be pivotally attached to the visor pivot rod  310  prior to commencement of the foregoing assembly process. 
     Upon completion of assembly, an occupant of the vehicle is protected from head impact injury relative to the connection interface  354  by the outer cover component  308  via its impact distributing shape and/or crush characteristics. Further, the cover member  304  is rotatable relative to the base member  302  in guidance by the outer and inner cover bosses  318   a ,  318   b  sliding on, respectively, the outer and inner base bosses  340 ,  342  in cooperation with the cover stud  326  relatively rotating contactably with the base post  348 . 
     To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.

Technology Category: 7