Abstract: A method of forming a vehicle accessory embodying the present invention includes the provision of a fabric or other upholstery material in the shape of a container which when filled with an amorphous filler material defines an accessory such as a visor, introducing an amorphous material such as a mixture of expandable chemicals into the container so formed and allowing them to expand and cure while constraining the major sides of the container during curing thereby forming an accessory core and integral cover. Visors embodying a preferred embodiment of the present invention comprise an integral cover and structural core of an amorphous material introduced to fill the cover and which is bonded thereto. In a preferred embodiment, the cover is formed from a butterfly pattern which is folded and has edges joined with the exception of an opening at one corner and which is subsequently inverted to define the visor-shaped container.

Abstract: A method of forming a vehicle accessory embodying the present invention includes the provision of a fabric or other upholstery material in the shape of a container which when filled with an amorphous filler material defines an accessory such as a visor, introducing an amorphous material such as a mixture of expandable chemicals into the container so formed and allowing them to expand and cure while constraining the major sides of the container during curing thereby forming an accessory core and integral cover. Visors embodying a preferred embodiment of the present invention comprise an integral cover and structural core of an amorphous material introduced to fill the cover and which is bonded thereto. In a preferred embodiment, the cover is formed from a butterfly pattern which is folded and has edges joined with the exception of an opening at one corner and which is subsequently inverted to define the visor-shaped container.