Modular sun visor assembly and method of assembling a sun visor

A sun visor assembly for use in a vehicle, comprising:

• two opposing flaps folded together;
• a track disposed between said flaps and secured to at least one of said flaps, said track having a rail connected thereto, said track further having an elbow, said elbow including a rod guide;
• a hinge block slidably and nonrotatably disposed between said flaps, said hinge block including a pair of opposing arms extending therefrom, said pair of opposing arms disposed directly opposite one another and forming a clip, said clip slidably engaging said rail;
• and
• a visor support rod for attaching said sun visor to a vehicle interior member, said visor support rod slidably disposed within said rod guide, and said visor support rod connected at one end to said hinge block and slidable therewith, the other end of said visor support rod extending outwardly from said flaps, said hinge block rotatable about the longitudinal axis of said rod and said flaps rotatable therewith, whereby said sun visor is pivotable about the longitudinal axis of said rod and said rod is extendable and retractable from said sun visor.

A sun visor assembly comprising:

• a visor support rod;
• a plurality of visor core components, each of said visor core components having a core alignment element;
• and
• a folded outer covering assembly having opposing flaps with an inner folded surface and an outer folded surface, said inner folded surface comprising a plurality of covering alignment elements which mate with said core alignment elements whereby said visor core components are secured between said flaps and have exterior surfaces which are in substantial registry with said interior surface of said opposing flaps;
• said plurality of visor core components further including:
• a track non-slidingly secured to said outer covering assembly, said track having a rail extending therefrom, said track further having an elbow, said elbow including a rod guide, said visor support rod slidably disposed within said rod guide;
• and
• a sliding member having a pair of opposing arms extending therefrom, said pair of opposing arms disposed directly opposite one another and forming a clip, said clip slidingly engaging said rail.