Visor and method of manufacturing

A vehicle visor having upper and lower elongated sides with spaced ends intersecting said sides to provide upper corners at the intersections of said upper elongated side and said ends comprising:

• a flexible container shaped to define the outer surface of a visor, said container formed of a pattern of superimposed flexible material;
• said pattern when superimposed including a substantially straight folded edge forming said upper side;
• said superimposed material having peripheral engaging edges with a sealed portion extending along substantially the entire length of said peripheral edges except for an unsealed edge portion at one of said corners thereof thereby forming a relatively small opening at said corner, said container having been formed by drawing the flexible material through said opening to turn said superimposed flexible material inside out to form a container with said sealed portion of said peripheral engaging edges of said material extending into the interior of said container;
• said container having an amorphous filling material therein introduced in a flowable form into said container through said opening to expand said container to the shape of a visor with the sealed peripheral edges of said material covered by said amorphous filling material inside said container;
• a pivot rod extending adjacent and along said straight edge and embedded in said amorphous filling;
• and
• said amorphous filling being cured to provide a rigid visor having said pivot rod extending outwardly through said opening for supporting said visor in a vehicle.