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WO2003033286A1 - Melt compression molding visor assembly - Google Patents

Melt compression molding visor assembly Download PDF

Info

Publication number
WO2003033286A1
WO2003033286A1 PCT/US2002/032744 US0232744W WO03033286A1 WO 2003033286 A1 WO2003033286 A1 WO 2003033286A1 US 0232744 W US0232744 W US 0232744W WO 03033286 A1 WO03033286 A1 WO 03033286A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
panels
set forth
visor assembly
panel
Prior art date
Application number
PCT/US2002/032744
Other languages
French (fr)
Inventor
Thomas G. Bailey
Timothy F. O'brien
Original Assignee
Magna International Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Magna International Inc. filed Critical Magna International Inc.
Publication of WO2003033286A1 publication Critical patent/WO2003033286A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/58—Snap connection
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/549—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles said hollow-preforms being interconnected during their moulding process, e.g. by a hinge
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60J—WINDOWS, WINDSCREENS, NON-FIXED ROOFS, DOORS, OR SIMILAR DEVICES FOR VEHICLES; REMOVABLE EXTERNAL PROTECTIVE COVERINGS SPECIALLY ADAPTED FOR VEHICLES
    • B60J3/00—Antiglare equipment associated with windows or windscreens; Sun visors for vehicles
    • B60J3/02—Antiglare equipment associated with windows or windscreens; Sun visors for vehicles adjustable in position
    • B60J3/0204—Sun visors
    • B60J3/0278—Sun visors structure of the body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B29C2043/3433—Feeding the material to the mould or the compression means using dispensing heads, e.g. extruders, placed over or apart from the moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B29C43/183—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles the preformed layer being a lining, e.g. shaped in the mould before compression moulding, or a preformed shell adapted to the shape of the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B29C63/04—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material by folding, winding, bending or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/22—Hinges, pivots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3035—Sun visors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005—Body finishings
    • B29L2031/3041—Trim panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/772—Articles characterised by their shape and not otherwise provided for

Definitions

  • This invention relates to a visor assembly for a motor vehicle. More particularly, the invention relates to a visor assembly having a uniform look and a method for manufacturing the visor assembly to consistently have the uniform look.
  • Visor assemblies for motor vehicles provide comfort for occupants thereof by blocking unwanted light, such as sunlight, from entering a passenger compartment.
  • a visor assembly is mounted to a headliner within the passenger compartment.
  • the visor assembly will have a finish that complements other finished surfaces within the passenger compartment to provide an aesthetically pleasing appearance.
  • the finish is in the form of a covering that is applied over a visor core.
  • the covering is commonly formed from cloth, vinyl, or leather.
  • the manufacture of the visor assemblies is labor intensive because the covering therefor must be folded or wrapped around the visor core.
  • the folding or wrapping of the covering around the visor core is typically accomplished manually. Manual assembly results, however, in increased cycle times and inconsistencies among assembled visor assemblies.
  • United States Patent 4,570,990 to Flowerday discloses a visor including a visor core having symmetrical core halves, and an upholstery material surrounding the visor core.
  • the upholstery material is cut to a shape similar to that of the visor core but with excess material extending around peripheral edges of the visor core.
  • the excess material is folded over the peripheral edges of the visor core and bonded to an inside surface thereof by a bonding adhesive. Selected areas of a mating surface on both the core halves are heated to melt a visor core material.
  • the core halves are then closed around a hinge to clamp the excess material of the upholstery material within the peripheral edges.
  • the core halves are held together with sufficient pressure and for a period of time to allow the visor core material to cool, allowing fusion of the core halves with the upholstery material securely held within the peripheral edges.
  • the resulting visor has a seamless front appearance around its peripheral edge.
  • a visor assembly includes a first panel defining a first longitudinal side.
  • a hinge is fixedly secured to and extends along the first longitudinal side.
  • a second panel defines a second longitudinal side. The second panel complements the first panel and the second longitudinal side is fixedly secured to the hinge such that the second panel is folded over the first panel.
  • a sheet of material is applied over the first and second panels.
  • a layer of backing material covers all of the sheet of material to secure all of the sheet of material to all of the first and second panels and the hinge to uniformly and tightly cover the visor assembly.
  • Figure 1 is a perspective view, partially cut away, of a passenger compartment for a motor vehicle showing a visor assembly of one embodiment of the invention mounted to a headliner;
  • Figure 2 is a perspective view of one embodiment of the invention partially assembled;
  • Figure 3 is a cross-sectional view taken along lines 3-3 in Figure 2;
  • Figure 4 is an isolated view of a hinge of one embodiment of the invention;
  • Figure 5 is a side view of a press utilized in the method for manufacturing one embodiment of the invention.
  • a visor assembly is mounted to a headliner 12 of a motor vehicle 14.
  • the visor assembly 10 pivots about a rod 15 to selectively block unwanted light, such as sunlight, from entering a passenger compartment 16 of the motor vehicle 14.
  • the visor assembly 10 includes a first panel 18 defining a first longitudinal side 20, and a second panel 22 defining a second longitudinal side 24.
  • the second panel 22 mirrors the first panel 18 structurally.
  • the first 18 and second 22 panels are formed from a thermoplastic material, such as polypropylene.
  • the first 18 and second 22 panels which are shown to extend witliin the same plane in Figure 2, each include an outer side 26, 28 parallel to the respective first 20 and second 24 longitudinal sides, and connecting sides 30, 32 extending between the outer sides 26, 28 and the respective first 20 and second 24 longitudinal sides.
  • the first 18 and second 22 panels each include an outer panel surface 34, 36 and an inner panel surface 38, 40 opposite thereto, as is best seen in Figure 4.
  • a visor component 35 may be secured to the inner panel surface 38, 40 of one of the first
  • visor component 35 examples include, but are not limited to, mirror subassemblies, light subsystems, remote controls, information displays, and article holding devices. While only one visor component 35 is shown in the Figures, it will be appreciated that the visor assembly 10 may include more than one visor component 35.
  • Each of the outer sides 26, 28 includes a flange 42, 44 extending upwardly therefrom.
  • the flange 42, 44 includes a top portion 46, 48.
  • a plurality of locking tabs 50, 52 extends upwardly from each of the flanges 42, 44.
  • the plurality of locking tabs 50 on the first panel 18 lockingly engages the plurality of locking tabs 52 on the second panel 22 to hold the panels 18, 22 together after the first panel 18 is folded over the second panel 22.
  • the locking tabs 50, 52 could engage the flange 42, 44 opposite thereto. In this embodiment, the locking tabs 50 on the one flange 42 would not be aligned with the locking tabs 52 on the other flange 44.
  • a hinge 54 includes a base 56 defining first 60 and second 62 hinge sides and a hinge channel 63 disposed therebetween.
  • the first hinge side 60 is fixedly secured to the first longitudinal side 20, and the second hinge side 62 is fixedly secured to the second longitudinal side 24 so that the hinge 54 interconnects the first 18 and second 22 panels.
  • the hinge 54 which extends outside of the plane of the first 18 and second 22 panels, allows the first panel 18 to be folded over the second panel 22 to produce the visor assembly 10 in its fully assembled form. Similar to the first 18 and second 22 panels, the hinge 54 is formed from a thermoplastic material, such as polypropylene.
  • a sheet of material 64 is applied over the first 18 and second 22 panels to provide a finished appearance thereto that is complementary to the rest of the passenger compartment 16.
  • the sheet of material 64 may be cloth, fabric, or a similar decorative covering material.
  • the sheet of material 64 is secured to the outer panel surface 34, 36 by a layer of backing material 66.
  • the layer of backing covers all of the sheet of material 64 to secure all of the sheet of material 64 to all of the first 18 and second 22 panels and the hinge 54.
  • the layer of backing material 66 may be a cloth backing or a film backing, both of which are known to those skilled in the art.
  • a layer of adhesive material 68 is applied along an interior surface 70 of the sheet of material 64 to secure the layer of backing material 66 thereto.
  • the sheet of material 64 Prior to folding of the first 18 and second 22 panels, the sheet of material 64 has an outer periphery that is greater than that of the first 18 and second 22 panels combined.
  • the sheet of material 64 includes sheet ends 72 that extend beyond the outer sides 26, 28 after the sheet of material 64 is secured to the first 18 and second 22 panels.
  • the sheet ends 72 are wrapped around the top portion 46, 48 of the flange 42, 44 so that the sheet ends 72 abut the inner panel surface 38, 40.
  • a portion 73 of the sheet of material 64 is bonded to the flange 42, 44 by a bonding agent 61, which is applied to the top portion 46, 48 of the flange 42, 44.
  • the sheet of material 64 includes a plurality of slits 74 so that as the sheet of material 64 is wrapped around the top portion 46, 48 of the flange 42, 44, the plurality of locking tabs 50, 52 extending from the flange 42, 44 extends through the plurality of slits 62. Thus, the sheet of material 64 fits over the plurality of locking tabs 50, 52, and is attached to the flange 42, 44 by the bonding agent 61 on the top portion 46, 48 of the flange 42, 44.
  • the sheet of material 64 will not define the plurality of slits 74, in which case the plurality of locking tabs 50, 52 will pierce the sheet of material 64 to allow the sheet of material 64 to fit over the plurality of locking tabs 50, 52 and bond to the flanges 42, 44.
  • the combination of the sheet of material 64 being adhered all along the first 18 and second 22 panels, and the sheet ends 72 of the sheet of material 64 being bonded to the top portions 46, 48 of the flanges 42, 44 results in the sheet of material 64 tightly and uniformly covering the visor assembly 10.
  • the first step is securing the sheet of material 64 in a cavity 76 of a press 78.
  • the cavity 76 is an upper cavity half 77 and a lower cavity half 84.
  • the sheet of material 64 is positioned within the cavity 76 such that an exterior surface 80 of the sheet of material 64 abuts the upper cavity half 77 and the sheet of material 64 extends across all of the cavity 76.
  • the adhesive material 68 is layered onto the interior surface 70 of the sheet of material 64 prior to applying the layer of backing material 66 thereto.
  • the layer of backing material 66 is applied to the sheet of material 64. This is done prior to the closing of the press 78.
  • a molten thermoplastic material 82 is introduced or injected to a lower cavity half 84 of the press 78 by a nozzle 86.
  • the nozzle 86 is located such that the sheet of material 64 extends between the nozzle 86 and the upper cavity half 77.
  • the molten thermoplastic material 82 is cured to secure the sheet of material 64 thereto and to form the first 18 and second 22 panels and the hinge 54.
  • a chemical and/or mechanical bond is created between the molten thermoplastic material 82 and, depending upon the embodiment, either the sheet of material 64 or the layer of backing material 66.
  • the sheet of material 64 is secured to first 18 and second 22 panels and the hinge 54.
  • the press 78 is then opened by moving the upper cavity half 76 away from the lower cavity half 84.
  • the sheet ends 72 which are cut to a close proximity of the cavity edges by the cavity halves 77, 84, extend beyond the outer side 26, 28 are wrapped around the top portion 46, 48 of the flange 42, 44 so that a segment of the sheet ends 72 is bonded to the flange 42, 44 by the bonding agent 61, which is coated along top portion 46, 48.
  • the sheet ends 72 can be coated with the bonding agent 61.
  • the portion 73 of the sheet ends 72 that extend over the flange 42, 44 and into the inner panel surface 38, 40 may be further trimmed.
  • the visor component 35 and rod 15 are mounted within the inner panel surface 38, 40.
  • the first panel 18 is then folded over the second panel 22 about the hinge 54.
  • the plurality of locking tabs 50 extending from the flange 42 of the first panel 18 lockingly engages the plurality of locking tabs 52 extending from the flange 44 on the second panel 22 to hold the first 18 and second 22 panels together.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Abstract

A visor assembly (10) includes a first panel (18) defining a first longitudinal side (20) and a second panel (22) defining a second longitudinal side (24). A hinge (54) is fixedly secured to and extends along the first longitudinal side (20). The second panel (22) complements the first panel (18) and the second longitudinal side (24) is fixedly secured to the hinge (54) such that second panel (22) is folded over the first panel (18). A sheet of material (64) is applied over the first and second panels (18, 22). A layer of backing material (66) covers all of the sheet of material (64) to secure all of the sheet of material (64) to all of the first and second panels (18, 22) and hinge (54) to uniformly and tightly cover the visor assembly (10).

Description

MELT COMPRESSION MOLDING VISOR ASSEMBLY
Backgroun of the Invention
1. Field of the Invention
• This invention relates to a visor assembly for a motor vehicle. More particularly, the invention relates to a visor assembly having a uniform look and a method for manufacturing the visor assembly to consistently have the uniform look.
2. Description of the Related Art
Visor assemblies for motor vehicles provide comfort for occupants thereof by blocking unwanted light, such as sunlight, from entering a passenger compartment. A visor assembly is mounted to a headliner within the passenger compartment. Typically, the visor assembly will have a finish that complements other finished surfaces within the passenger compartment to provide an aesthetically pleasing appearance. The finish is in the form of a covering that is applied over a visor core. The covering is commonly formed from cloth, vinyl, or leather.
The manufacture of the visor assemblies is labor intensive because the covering therefor must be folded or wrapped around the visor core. The folding or wrapping of the covering around the visor core is typically accomplished manually. Manual assembly results, however, in increased cycle times and inconsistencies among assembled visor assemblies.
Numerous attempts have been made to manufacture a visor assembly having a covering that is securely bound to the visor core in such a way that the assembled visor assemblies have a consistent finished appearance! For example, United States Patent 4,570,990 to Flowerday discloses a visor including a visor core having symmetrical core halves, and an upholstery material surrounding the visor core. The upholstery material is cut to a shape similar to that of the visor core but with excess material extending around peripheral edges of the visor core. The excess material is folded over the peripheral edges of the visor core and bonded to an inside surface thereof by a bonding adhesive. Selected areas of a mating surface on both the core halves are heated to melt a visor core material. The core halves are then closed around a hinge to clamp the excess material of the upholstery material within the peripheral edges. The core halves are held together with sufficient pressure and for a period of time to allow the visor core material to cool, allowing fusion of the core halves with the upholstery material securely held within the peripheral edges. The resulting visor has a seamless front appearance around its peripheral edge.
Summary of the Invention
A visor assembly includes a first panel defining a first longitudinal side. A hinge is fixedly secured to and extends along the first longitudinal side. A second panel defines a second longitudinal side. The second panel complements the first panel and the second longitudinal side is fixedly secured to the hinge such that the second panel is folded over the first panel. A sheet of material is applied over the first and second panels. A layer of backing material covers all of the sheet of material to secure all of the sheet of material to all of the first and second panels and the hinge to uniformly and tightly cover the visor assembly.
Brief Description of the Drawings Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
Figure 1 is a perspective view, partially cut away, of a passenger compartment for a motor vehicle showing a visor assembly of one embodiment of the invention mounted to a headliner;
Figure 2 is a perspective view of one embodiment of the invention partially assembled; Figure 3 is a cross-sectional view taken along lines 3-3 in Figure 2; Figure 4 is an isolated view of a hinge of one embodiment of the invention; and Figure 5 is a side view of a press utilized in the method for manufacturing one embodiment of the invention.
Detailed Description of the Preferred Embodiment
Referring to Figure 1, a visor assembly, generally indicated at 10, is mounted to a headliner 12 of a motor vehicle 14. The visor assembly 10 pivots about a rod 15 to selectively block unwanted light, such as sunlight, from entering a passenger compartment 16 of the motor vehicle 14. Referring to Figure 2, the visor assembly 10 includes a first panel 18 defining a first longitudinal side 20, and a second panel 22 defining a second longitudinal side 24. The second panel 22 mirrors the first panel 18 structurally. The first 18 and second 22 panels are formed from a thermoplastic material, such as polypropylene. The first 18 and second 22 panels, which are shown to extend witliin the same plane in Figure 2, each include an outer side 26, 28 parallel to the respective first 20 and second 24 longitudinal sides, and connecting sides 30, 32 extending between the outer sides 26, 28 and the respective first 20 and second 24 longitudinal sides. In addition, the first 18 and second 22 panels each include an outer panel surface 34, 36 and an inner panel surface 38, 40 opposite thereto, as is best seen in Figure 4. A visor component 35 may be secured to the inner panel surface 38, 40 of one of the first
18 and second 22 panels. Examples of the visor component 35 include, but are not limited to, mirror subassemblies, light subsystems, remote controls, information displays, and article holding devices. While only one visor component 35 is shown in the Figures, it will be appreciated that the visor assembly 10 may include more than one visor component 35. Each of the outer sides 26, 28 includes a flange 42, 44 extending upwardly therefrom.
The flange 42, 44 includes a top portion 46, 48. A plurality of locking tabs 50, 52 extends upwardly from each of the flanges 42, 44. The plurality of locking tabs 50 on the first panel 18 lockingly engages the plurality of locking tabs 52 on the second panel 22 to hold the panels 18, 22 together after the first panel 18 is folded over the second panel 22. In an alternative embodiment, the locking tabs 50, 52 could engage the flange 42, 44 opposite thereto. In this embodiment, the locking tabs 50 on the one flange 42 would not be aligned with the locking tabs 52 on the other flange 44.
Referring again to Figure 4, a hinge 54 includes a base 56 defining first 60 and second 62 hinge sides and a hinge channel 63 disposed therebetween. The first hinge side 60 is fixedly secured to the first longitudinal side 20, and the second hinge side 62 is fixedly secured to the second longitudinal side 24 so that the hinge 54 interconnects the first 18 and second 22 panels. The hinge 54, which extends outside of the plane of the first 18 and second 22 panels, allows the first panel 18 to be folded over the second panel 22 to produce the visor assembly 10 in its fully assembled form. Similar to the first 18 and second 22 panels, the hinge 54 is formed from a thermoplastic material, such as polypropylene. A sheet of material 64 is applied over the first 18 and second 22 panels to provide a finished appearance thereto that is complementary to the rest of the passenger compartment 16. The sheet of material 64 may be cloth, fabric, or a similar decorative covering material. The sheet of material 64 is secured to the outer panel surface 34, 36 by a layer of backing material 66. The layer of backing covers all of the sheet of material 64 to secure all of the sheet of material 64 to all of the first 18 and second 22 panels and the hinge 54. The layer of backing material 66 may be a cloth backing or a film backing, both of which are known to those skilled in the art. A layer of adhesive material 68 is applied along an interior surface 70 of the sheet of material 64 to secure the layer of backing material 66 thereto. Prior to folding of the first 18 and second 22 panels, the sheet of material 64 has an outer periphery that is greater than that of the first 18 and second 22 panels combined. Thus, the sheet of material 64 includes sheet ends 72 that extend beyond the outer sides 26, 28 after the sheet of material 64 is secured to the first 18 and second 22 panels. The sheet ends 72 are wrapped around the top portion 46, 48 of the flange 42, 44 so that the sheet ends 72 abut the inner panel surface 38, 40. At the same time, a portion 73 of the sheet of material 64 is bonded to the flange 42, 44 by a bonding agent 61, which is applied to the top portion 46, 48 of the flange 42, 44.
The sheet of material 64 includes a plurality of slits 74 so that as the sheet of material 64 is wrapped around the top portion 46, 48 of the flange 42, 44, the plurality of locking tabs 50, 52 extending from the flange 42, 44 extends through the plurality of slits 62. Thus, the sheet of material 64 fits over the plurality of locking tabs 50, 52, and is attached to the flange 42, 44 by the bonding agent 61 on the top portion 46, 48 of the flange 42, 44. Alternatively, the sheet of material 64 will not define the plurality of slits 74, in which case the plurality of locking tabs 50, 52 will pierce the sheet of material 64 to allow the sheet of material 64 to fit over the plurality of locking tabs 50, 52 and bond to the flanges 42, 44. The combination of the sheet of material 64 being adhered all along the first 18 and second 22 panels, and the sheet ends 72 of the sheet of material 64 being bonded to the top portions 46, 48 of the flanges 42, 44 results in the sheet of material 64 tightly and uniformly covering the visor assembly 10.
In a method for manufacturing the visor assembly 10, the first step is securing the sheet of material 64 in a cavity 76 of a press 78. In the embodiment shown, the cavity 76 is an upper cavity half 77 and a lower cavity half 84. The sheet of material 64 is positioned within the cavity 76 such that an exterior surface 80 of the sheet of material 64 abuts the upper cavity half 77 and the sheet of material 64 extends across all of the cavity 76.
Should the manufacturing process require a layer of backing material 66 due to the material used for the sheet of material 64, the adhesive material 68 is layered onto the interior surface 70 of the sheet of material 64 prior to applying the layer of backing material 66 thereto.
The layer of backing material 66 is applied to the sheet of material 64. This is done prior to the closing of the press 78.
Regardless of whether a layer of backing material 66 is used, a molten thermoplastic material 82 is introduced or injected to a lower cavity half 84 of the press 78 by a nozzle 86. The nozzle 86 is located such that the sheet of material 64 extends between the nozzle 86 and the upper cavity half 77. The molten thermoplastic material 82 is cured to secure the sheet of material 64 thereto and to form the first 18 and second 22 panels and the hinge 54. During forming of the first 18 and second 22 panels and the hinge 54, a chemical and/or mechanical bond is created between the molten thermoplastic material 82 and, depending upon the embodiment, either the sheet of material 64 or the layer of backing material 66. Thus, the sheet of material 64 is secured to first 18 and second 22 panels and the hinge 54.
The press 78 is then opened by moving the upper cavity half 76 away from the lower cavity half 84. The sheet ends 72, which are cut to a close proximity of the cavity edges by the cavity halves 77, 84, extend beyond the outer side 26, 28 are wrapped around the top portion 46, 48 of the flange 42, 44 so that a segment of the sheet ends 72 is bonded to the flange 42, 44 by the bonding agent 61, which is coated along top portion 46, 48. Alternatively, the sheet ends 72 can be coated with the bonding agent 61. The portion 73 of the sheet ends 72 that extend over the flange 42, 44 and into the inner panel surface 38, 40 may be further trimmed. The visor component 35 and rod 15 are mounted within the inner panel surface 38, 40. The first panel 18 is then folded over the second panel 22 about the hinge 54. The plurality of locking tabs 50 extending from the flange 42 of the first panel 18 lockingly engages the plurality of locking tabs 52 extending from the flange 44 on the second panel 22 to hold the first 18 and second 22 panels together.
The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

What is claimed is:
1. A visor assembly comprising: a first panel defining a first longitudinal side; a hinge fixedly secured to and extending along said first longitudinal side; a second panel defining a second longitudinal side, said second panel complementing said first panel and said second longitudinal side fixedly secured to said hinge such that said second panel is folded over said first panel; a sheet of material applied over said first and second panels; and a layer of backing material covering all of said sheet of material to secure all of said sheet of material to all of said first and second panels and hinge to uniformly and tightly cover said visor assembly.
2. A visor assembly as set forth in claim 1 wherein said first and second panels each include an outer side having a flange extending upwardly therefrom, each of said flanges defining a top portion.
3. A visor assembly as set forth in claim 2 including a bonding agent applied over said top portions of said flanges of each of said first and second panels.
4. A visor assembly as set forth in claim 3 wherein said sheet of material includes sheet ends extending beyond said outer sides of said first and second panels, said sheet ends wrapping around said top portions of said flanges of said first and second panels so that a portion of said sheet of material is bonded to said flanges by said bonding agent.
5. A visor assembly as set forth in claim 4 wherein said flanges of said first and second panels include a plurality of locking tabs extending therefrom for locking said first and second panels to each other.
6. A visor assembly as set forth in claim 5 wherein said layer of backing material includes a layer of adhesive material to secure said layer of backing material to said sheet of material.
7. A visor assembly as set forth in claim 6 wherein said hinge and said first and second panels are formed from a thermoplastic material.
8. A visor assembly as set forth in claim 7 wherein said sheet of material defines a plurality of slits through which said plurality of locking tabs extend as said sheet ends are wrapped around said top portions of said flanges of said first and second panels.
9. A visor assembly as set forth in claim 8 including a visor component secured to one of said first and second panels.
10. A visor assembly as set forth in claim 9 including a rod about which said visor assembly pivots.
11. A visor assembly as set forth in claim 10 wherein said layer of backing material is cloth backing.
12. A visor assembly as set forth in claim 10 wherein said layer of backing material is film backing.
13. A method for manufacturing a visor assembly including first and second panels each having an outer side and a flange defining a top portion extending from the outer sides, a plurality of locking tabs, a hinge, a sheet of material having sheet ends, a layer of backing material, an adhesive material, and a bonding agent, the method comprising the steps of: applying the layer of backing material to the sheet of material; securing the sheet of material to the first and second panels and the hinge; and folding the first and second panels about the hinge.
14. A method as set forth in claim 13 including the step of coating the top portions of the flanges with the bonding agent.
15. A method as set forth in claim 14 including the step of wrapping the sheet ends around the flanges.
16. A method as set forth in claim 15 wherein the wrapping step includes the step of bonding a portion of the sheet of material to the top portion of the flanges of the first and second panels using the bonding agent.
17. A method as set forth in claim 16 including the step of layering the sheet of material with the adhesive material prior to the applying step.
18. A method as set forth in claim 17 including the step of locking the first panel to the second panel with the plurality of locking tabs subsequent to the folding step.
19. A method as set forth in claim 18 including the step of forming the first and second panels and the hinge from a thermoplastic material.
20. A method for manufacturing a visor assembly using a sheet of material having sheet ends, a bonding agent, molten thermoplastic material, and a press having a lower cavity half and an upper cavity half, the method comprising the steps of: securing the sheet of material between the upper cavity half and the lower cavity half; injecting the molten thermoplastic material into the press; curing the molten thermoplastic material to secure the sheet of material thereto and to form first and second panels and a hinge; moving the upper cavity half away from the lower cavity half to open the press; and folding the first and second panels together about the hinge.
21. A method as set forth in claim 20 including the step of coating the sheet ends with the bonding agent.
22. A method as set forth in claim 21 including the step of wrapping the sheet ends of the sheet of material around each of the first and second panels prior to the step of folding the first and second panels.
23. A method as set forth in claim 22 including the step of locking the first panel to the second panel subsequent to the step of folding the first and second panels.
PCT/US2002/032744 2001-10-15 2002-10-15 Melt compression molding visor assembly WO2003033286A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US32939801P 2001-10-15 2001-10-15
US60/329,398 2001-10-15

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GB2397051A (en) * 2003-01-09 2004-07-14 Lear Corp Vehicle snap frame sun visor
EP1571025A1 (en) * 2004-03-02 2005-09-07 Wagon Sas Sun visor for vehicle with system for connecting an information plate and method of manufacturing the same
WO2009042822A1 (en) 2007-09-27 2009-04-02 Johnson Controls Technology Company Visor made from a vehicle panel material

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US3827748A (en) * 1970-07-24 1974-08-06 Happich Gmbh Gebr Reinforced sun visor, especially for motor vehicles
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US5056852A (en) * 1991-02-04 1991-10-15 Plasta Fiber Industries, Inc. Vehicle sunvisor including mechanism for securing covering on sunvisor and supporting sunvisor within vehicle and method of making same
US5108143A (en) * 1990-07-27 1992-04-28 Neo-Ex Lab. Inc. Sun visor and process for manufacturing the same
US5148588A (en) * 1990-05-11 1992-09-22 Rockwell Automotive Body Systems-France Process for the manufacture of a fabric-covered visor
US5695237A (en) * 1996-04-12 1997-12-09 Pince Corporation Visor and method of manufacture
US5887933A (en) * 1997-07-15 1999-03-30 Lear Corporation Sun visor

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Publication number Priority date Publication date Assignee Title
US2901038A (en) * 1955-04-04 1959-08-25 Happich Gmbh Gebr Sun visor
US3827748A (en) * 1970-07-24 1974-08-06 Happich Gmbh Gebr Reinforced sun visor, especially for motor vehicles
JPS5621914A (en) * 1979-07-25 1981-02-28 Kyowa Sangyo Kk Sun visor for car
US4458938A (en) * 1981-02-18 1984-07-10 Gebr. Happich Gmbh Attachment of covering on sun visor for vehicles
JPS6390428A (en) * 1986-10-01 1988-04-21 Kyowa Sangyo Kk Sun visor for vehicle and its manufacture
US4763946A (en) * 1987-06-08 1988-08-16 Prince Corporation Visor
US5007532A (en) * 1989-11-20 1991-04-16 Prince Corporation Visor and method for making the same
US5148588A (en) * 1990-05-11 1992-09-22 Rockwell Automotive Body Systems-France Process for the manufacture of a fabric-covered visor
US5108143A (en) * 1990-07-27 1992-04-28 Neo-Ex Lab. Inc. Sun visor and process for manufacturing the same
US5056852A (en) * 1991-02-04 1991-10-15 Plasta Fiber Industries, Inc. Vehicle sunvisor including mechanism for securing covering on sunvisor and supporting sunvisor within vehicle and method of making same
US5695237A (en) * 1996-04-12 1997-12-09 Pince Corporation Visor and method of manufacture
US5887933A (en) * 1997-07-15 1999-03-30 Lear Corporation Sun visor

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2397051A (en) * 2003-01-09 2004-07-14 Lear Corp Vehicle snap frame sun visor
GB2397051B (en) * 2003-01-09 2005-02-23 Lear Corp Snap frame visor
EP1571025A1 (en) * 2004-03-02 2005-09-07 Wagon Sas Sun visor for vehicle with system for connecting an information plate and method of manufacturing the same
FR2867108A1 (en) * 2004-03-02 2005-09-09 Wagon Automotive Snc SUN VISOR FOR MOTOR VEHICLE WITH INFORMATION PLATE SOLIDARIZATION SYSTEM, MANUFACTURING METHOD, INFORMATION PLATE AND CORRESPONDING MOTOR VEHICLE
WO2009042822A1 (en) 2007-09-27 2009-04-02 Johnson Controls Technology Company Visor made from a vehicle panel material
CN101868365B (en) * 2007-09-27 2013-07-17 约翰逊控制技术公司 Awning serving as traffic tool and method for manufacturing awning

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