Abstract: A light projector including a light source coupled to a base and a lens assembly. A sheath can be overmolded over the base and can form a locator sleeve. An aperture can be overmolded over the light source. The locator sleeve can fix the spatial relationship between the light source and the lens assembly. The lens assembly can include a spacer to fix the spatial relationship between two or more lenses in the lens assembly. A thermal management system can be coupled to the sheath to help reduce the temperature of the light projector.

Abstract: The specification discloses a vehicle visor including a vanity light assembly and an actuator assembly. The visor vanity additionally includes a mirror and a movable mirror cover. The light assembly includes a light source and a light pipe for conveying light from the light source to two or more diffusers, for example, on opposite ends of the mirror. The actuator assembly includes a switching arrangement for switching the light source on and off without flicker or noise in response to the opening and closing of the mirror cover.

Abstract: An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.

Abstract: An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.

Abstract: An electrical device such as an LED light assembly includes a conductive circuit and one or more electrical components connected to the circuit. The electrical components and the circuit are at least partially overmolded with a thermoplastic polymer material to encapsulate the components. The material utilized to cover the circuit and/or electrical components may also be utilized to form a housing or other structure of a finished part.

Abstract: A composite material comprises a particulate material generated as a waste by-product of an industrial process, and a binder for binding the particulate material into a uniform mass. The particulate material and binder are combined in preselected proportions and compressed to form a counterweight having a preselected density and a fixed configuration. A counterweight is manufactured by selecting a first proportion of a particulate material generated as a waste by-product of an industrial process, selecting a second proportion of a binder for binding the particulate material into a uniform mass, combining the first proportion of the particulate material with the second proportion of the binder into a uniform mass, forming the counterweight from the uniform mass, and incorporating the counterweight into a finished product.

Abstract: A method for making visor cores is disclosed. The method includes sequentially molding visor cores, and interconnecting the visor cores as they are molded to form a chain of visor cores. The visor cores remain oriented relative to one another, and the visor cores can be sequentially positioned in a cooling fixture and a flexing fixture. The chain of visors can be wound on a spool or the like for transport.

Abstract: A light assembly for interiors of motor vehicles and the like includes a three-way sliding switch having a switch member that is movable to at least three positions corresponding to operating states of the switch. The switch includes an electrically conductive movable contact member that selectively engages conductive members to provide the different electrical states of the switch. The movable contact member also engages a detent structure and forms a three-position detent tending to retain the switch member in the selected position. Thus, the electrically conductive material of the movable contact member provides an electrical function and a mechanical detent function to thereby reduce the complexity and associated cost of the switch.

Abstract: A composite material comprises a particulate material generated as a waste by-product of an industrial process, and a binder for binding the particulate material into a uniform mass. The particulate material and binder are combined in preselected proportions and compressed to form a counterweight having a preselected density and a fixed configuration. A counterweight is manufactured by selecting a first proportion of a particulate material generated as a waste by-product of an industrial process, selecting a second proportion of a binder for binding the particulate material into a uniform mass, combining the first proportion of the particulate material with the second proportion of the binder into a uniform mass, forming the counterweight from the uniform mass, and incorporating the counterweight into a finished product.

Abstract: A visor for vehicles includes a shell made of a material such as paper, vinyl, or the like. The visor includes first and second halves joined by a hinge. The first and second halves are folded about the hinge and bonded together to define a cavity. A rigid foam core fills at least a substantial portion of the cavity, and the foam core is bonded to the shell to provide support. The visor includes a structural mounting member extending from the shell for mounting the visor to the roof of a vehicle.

Abstract: A light assembly for interiors of motor vehicles and the like includes a three-way sliding switch having a switch member that is movable to at least three positions corresponding to operating states of the switch. The switch includes an electrically conductive movable contact member that selectively engages conductive members to provide the different electrical states of the switch. The movable contact member also engages a detent structure and forms a three-position detent tending to retain the switch member in the selected position. Thus, the electrically conductive material of the movable contact member provides an electrical function and a mechanical detent function to thereby reduce the complexity and associated cost of the switch.

Abstract: A mounting arrangement for mounting a visor to a vehicle includes a bracket assembly that does not require use of threaded fasteners or the like. The bracket assembly includes a housing, a bracket member, and a foot member. The foot member includes tapered extensions that engage an upper side of the roof panel to retain the bracket assembly to the roof panel.

Abstract: A visor for vehicles includes an elbow member having an elongated portion, and a body member having an elongated slot defining a sidewall. The elongated slot extends generally parallel to the elongated portion of the elbow member. The body member is pivotably mounted to the elbow member for rotation about the elongated portion. A torque control member rotatably engages the elbow member, and has at least one finger received in the elongated slot. The finger is resiliently biased into engagement with the sidewall of the elongated slot, and frictionally engages the sidewall to provide controlled sliding movement of the body member relative to the elbow member.

Abstract: A vehicle visor having a pivot rod or a slip tube with a torque control disposed therein. The pivot rod or slip tube surface is provided with a layer of hardened material on the external surface to improve the wear and abrasion resistance of the pivot rod or slip tube surface in contact with the torque control. A preferred embodiment for the hardened material layer is a hard coat anodized surface layer on an aluminum pivot rod or slip tube.

Abstract: A light assembly comprises a fixed mounting plate on which there is positioned a variable resistor, a rotatable member including an arm engaging the variable resistor and a lamp subassembly pivotally mounted to the rotatable member and keyed to the rotatable member such when the lamp subassembly is rotated in a plane generally parallel to a lens associated with the lamp subassembly, the rotatable member moves with respect to the fixed mounting plate, thereby varying the resistance, which is coupled in series with a lamp contained within the lamp subassembly for varying the intensity of the illumination therefrom. In a preferred embodiment also, the lamp subassembly includes a lens having a knob associated therewith such that the lamp subassembly can be tilted and rotated for directing and varying the intensity of the illumination therefrom.

Abstract: A visor torque control comprises a spring steel body having a flange adapted to be mounted to the body of a visor and a semicylindrical collar for circumscribing at least a portion of a cylindrical visor rod. The end of the semicylindrical collar in one embodiment integrally includes an outwardly projecting tang which allows the torque control to be snap-fitted over the visor rod and further allows the diameter of the collar to be selectively adjusted. The interior of the spring steel member is integrally coated with a polymeric material to provide the desired frictional characteristics and operational feel of the rotation of the visor about the visor rod.

Abstract: A dimming control circuit for use in an illuminated vanity mirror includes a surface formed variable resistor on a conductive circuit substrate and wiper contacts engaging the resistor. One of the resistor and wiper contacts is movably mounted to a mirror frame with the other of the resistor and wiper contacts being stationary such that the resistance can be varied to control the light intensity.

Abstract: A shatter resistant mirror includes a frangible mirror material for reflecting an image which has a coating of an elastic adhesive material which bonds a rigid backing material to the frangible mirror body. In a preferred embodiment of the invention, the adhesive was one of a water-based synthetic polymeric material or a hot melt pressure sensitive adhesive. The rigid support member preferably is a fiberboard material. In some embodiments of the invention, the composite mirror structure includes multiple layers of composite fiberboard material to provide spacing for mounting the mirror in a particular application.

Abstract: A visor mount for mounting a visor panel to a vehicle roof includes a first member which extends from an edge of the visor panel and a second member which is secured to a roof of the vehicle. The first and second members are pivotally interfit with one another for rotational movement of the visor panel between a raised stored position against the vehicle roof and a lowered use position.

Abstract: An automotive visor includes a visor body with a slot for slidably receiving a panel which they include an illuminated vanity mirror. The panel is slidably mounted to the visor body and stabilizing structure assures that the panel moves smoothly between a stored position within the visor body and a use position extended from the visor body. In one embodiment the stabilizing structure includes cords which extend through the panel to opposite corners of the visor body. In another embodiment the stabilizing structure includes guide tracks and followers on the panel which are made of material to magnetically attract the followers to the tracks.