Rotation system for a vehicle sun visor

A rotation system for a vehicle sun visor assembly prepared by a process comprising the steps of:

• forming a contact element, wherein the contact element comprises a flattened surface and an opening disposed on the flattened surface, wherein the opening is configured to facilitate sliding the rod into the contact element;
• disposing the contact element at least partially about a rod of the vehicle sun visor assembly, wherein the rod comprises a first material;
• overmolding the rod with a mold material;
• and
• disposing a spring box about the contact element, wherein the spring box includes a biasing element configured to urge a contact surface of the biasing element against the contact element to control rotation of a sun visor about the rod, wherein the contact element comprises a second material that is harder, more wear-resistant, or a combination thereof, when compared to the first material.

A vehicle sun visor assembly, comprising:

• a vehicle sun visor;
• a rod coupled to the vehicle sun visor, wherein the rod is configured to couple to a vehicle to support the vehicle sun visor within an interior of the vehicle, and the rod is configured to facilitate rotation of the vehicle sun visor about the rod;
• a contact element non-rotatably coupled to the rod, wherein the contact element comprises a flattened surface and an opening disposed on the flattened surface, wherein the opening is configured to:
• facilitate sliding the rod into the contact element;
• and
• be filled by a mold material when the rod and the contact element undergo a molding process;
• a biasing element configured to urge a contact surface of the biasing element against the contact element to control rotation of the vehicle sun visor about the rod;
• and
• a spring box configured to surround the contact element and the biasing element, wherein the spring box or the biasing element comprises the contact surface.