Expanded polypropylene sun visor assembly

#1. Field of the Invention

#The present invention generally relates to a sun visor for vehicles having a sun visor body supported by a sun visor shaft and a sun visor center support. More particularly the present invention relates to a sun visor for vehicles comprising a sun visor carrier containing an electric current distribution means over-molded with an expanded polypropylene plastic over-mold, sun visor body.

#2. Description of the Related Art

#FIG. 1 shows an exploded perspective view of one preferred embodiment of the present invention including the sun visor carrier assembly having a plurality of fastening devices, the support shaft, and the center support assembly.

#FIG. 2 shows a perspective view with a partial section of the center support assembly of the present invention shown in FIG. 1.

#FIG. 3 shows a perspective view with a partial section of the center support pin assembly of the present invention shown in FIG. 1.

#Reference will now be made to the drawings, wherein to the extent possible like reference numerals are utilized to designate like components throughout the various views. Referring to FIG. 1, there is presented a perspective exploded view of a preferred embodiment of the present invention comprising a sun visor carrier or support body 1 preferably comprising formed sheet metal having a blade section 2 and a rod mounting section 3. The blade section 2 having located therein a vanity assembly attachment device 6 adapted to mount a vanity assembly 21 therein, as well as an electrical connection wire 14 which connects to one of electrical wires 30 (FIG. 3), and optionally openings 22 to reduce the weight of the carrier body 1. The mounting section 3 having a bore 4 there through for mounting an elbow rod assembly comprising an elbow rod 7, having a flat face 71, and also having mounted thereon a detent sleeve 8, a rod end bushing 9 to provide stability for elbow rod 7, and a center support pin assembly 15. The center support pin assembly 15 being fixedly mounted within bore 4, and having located on a portion of its outer surface a pair of electrical contact surfaces 16 connected to a pair of electrical wires 30 (FIG. 3), one of said pair of electrical wires 30 being connected as the hot lead to electrical wire 14 and the other being connected as a ground to blade section 2. A plurality of staples 5, or other suitable fasteners, is used to provide a desired dimensional diameter of bore 4 and to retain the center support pin assembly 15 within said bore 4. The rod mounting section 3 may have the end mounting the center support pin assembly 15 crimped to assist fixedly securing said center support pin assembly 15 within bore 4. Detent sleeve 8 having a flat surface 81 thereon. The flat surfaces 81 and 71 providing both rotational and detent features to the sun visor rod 7. A detent clip 12 is fastened to support 1 with a rivet fastening device 13. It is to be understood that fastening devices 5 and 13 may be selected from any of the well-known fastening devices suitable for these purposes. The vanity assembly 21 is adapted to mount in mount 6 of blade section 2 of sun visor carrier body 1 and electrically connect to a vehicle's power supply via electrical wire 14, center support pin assembly 15, and center support assembly 17.

#As further shown in FIG. 1 is a center support assembly 17 having provided therein a pair of contact clips 18, a pair of corresponding electrical wire leads 19 connected to said contact clips 18, and a bore 20 for mounting said center support assembly to the vehicle by known fastening devices suitable for this purpose. Finally there is shown a portion of the tape 11 which covers the completed carrier body 1 to prevent plastic migration into the bore 4 during the over-molding of the sun visor body (shown here in phantom).

#Referring now to FIG. 2, there is shown a perspective view with a partial section of the center support assembly 17 of FIG. 1 having a mounting bore 20 and showing the pair of electrical wires 19 electrically connected to a pair of contact clips 18.