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 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 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 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 push lens is integrated with a bezel and connected to the bezel by an integrally formed hinge to allow the lens to deflect for actuating a switch.

Abstract: A push lens is integrated with a bezel and connected to the bezel by an integrally formed hinge to allow the lens to deflect for actuating a switch.

Abstract: A stamped reinforced visor elbow having a metal reinforcing member that holds electrical conductors encased in a molded polymeric material. The reinforcing member is generally U-shaped in cross section and can be formed by stamping. The reinforcing member provides support for the visor elbow while providing a channel for electrical conductors. The reinforced visor elbow is made by forming a metal reinforcing member through a stamping die, placing one or more conductors into a recess created in the reinforcing member and the steps of molding a polymeric material over the reinforcing member while holding the wires to form the reinforced visor elbow.

Abstract: A stamped reinforced visor elbow having a metal reinforcing member that holds electrical conductors encased in a molded polymeric material. The reinforcing member is generally U-shaped in cross section and can be formed by stamping. The reinforcing member provides support for the visor elbow while providing a channel for electrical conductors. The reinforced visor elbow is made by forming a metal reinforcing member through a stamping die, placing one or more conductors into a recess created in the reinforcing member and the steps of molding a polymeric material over the reinforcing member while holding the wires to form the reinforced visor elbow.