Process for making a sun visor by molding a pair of shells and bonding them together

A process for manufacturing a sun visor having a pair of shells bonded to each other, comprising the steps of:

• providing a first female die member and a first male die member adapted to form a forming cavity corresponding to the configuration of a first shell therebetween;
• positioning between said first female and first male die members a first sheet material for forming a first sheet member and a resin material for forming a first dish-like base member having a first annular end surface;
• closing said first female and first male die members to form said first sheet member and said first base member, thereby forming said first shell composed of said first base member and said first sheet member adhered to the outer surface of said first base member;
• folding the end portion of said first sheet member along said first annular end surface of said first base member to form a folded portion extending therealong, thereby forming a first mating surface composed of said first annular end surface of said first base member and the outer surface of said folded portion of said first sheet member;
• providing a second female die member and a second male die member adapted to form a forming cavity corresponding to the configuration of a second shell therebetween;
• positioning between said second female and second male die members a second sheet material for forming a second sheet member and a resin material for forming a second dish-like base member having a second annular end surface;
• closing said second female and second male die members to form said second sheet member and said second base member, thereby forming said second shell composed of said second base member and said second sheet member adhered to the outer surface of said second base member;
• folding the end portion of said second sheet member along said second annular end surface of said second base member to form a folded portion extending therealong, thereby forming a second mating surface composed of said second annular end surface of said second base member and the outer surface of said folded portion of said second sheet member;
• mating said first mating surface of said first shell and said second mating surface of said second shell;
• and
• melting said first annular end surface of said first base member and said second annular end surface of said second base member to bond said first and second mating surfaces.