Abstract: A visor, according to one embodiment, comprises a closed-cell, semi-rigid urethane foam material thermoformed from sheets into a visor core construction with a reinforced backbone mounted along an edge thereof for mounting the visor to a vehicle. The visor is upholstered utilizing an adhesive and scrim laminate and is formed by heating, pressing and cutting to assure the outer upholstery material adheres smoothly to the visor core and provides a trim edge in appearance. According to another embodiment of the invention, a blend of kenaf fibers are employed as the core material, which is laminated with upholstery material as in the first embodiment to complete the visor construction. In yet another embodiment of the invention, a butterfly-type core construction is made of high density kenaf blend and upholstered in a manner employed for other butterfly visor core constructions.

Abstract: A track visor includes a visor body with a rolling guide assembly engaged with a track extending above at least a portion of the front windshield and side window of a vehicle. The track is a curved, non-planar configuration with a pair of outer-extending rails which are parallel to each other along straight sections of the track and increase in separation distance with increased curvature of the track. The guide assembly has three rolling wheels assembled to a carriage, with two of the wheels engaged to one rail and the third wheel engaged to the opposite rail. The third wheel is assembled to a pivot arm that is spring biased for compressing the wheels against the rails of the track. The visor body is pivotally connected to the carriage and, therefore, movable above selected positions of the windshield and side door window for providing incident light blocking.

Abstract: A visor molded to define a lip which surrounds a vehicle accessory for holding it in place after the molding process. The vehicle accessory may be a vanity mirror, a garage door opener transmitter or other accessory. In a preferred embodiment of the invention, the visor body is formed with a curved cross section along its minor axis to conform the visor shape to that of a curved headliner of a vehicle. The invention includes a method of manufacturing a visor by placing an accessory in a mold for a visor, shaping the mold to define a rim surrounding a portion of the accessory for holding it in place; molding the visor core to hold the accessory in place; and, in a preferred embodiment, placing an upholstery material in the mold such that the visor construction is completed upon completion of the molding process.

Abstract: A visor, according to one embodiment, comprises a closed-cell, semi-rigid urethane foam material thermoformed from sheets into a visor core construction with a reinforced backbone mounted along an edge thereof for mounting the visor to a vehicle. The visor is upholstered utilizing an adhesive and scrim laminate and is formed by heating, pressing and cutting to assure the outer upholstery material adheres smoothly to the visor core and provides a trim edge in appearance. According to another embodiment of the invention, a blend of kenaf fibers are employed as the core material, which is laminated with upholstery material as in the first embodiment to complete the visor construction. In yet another embodiment of the invention, a butterfly-type core construction is made of high density kenaf blend and upholstered in a manner employed for other butterfly visor core constructions.

Abstract: A visor comprises a fiberboard butterfly-shaped core having a first or inner surface coated with a co-adhesive and has its opposite surface covered with a suitable upholstery material having an edge which extends over the periphery of the butterfly core. The core is folded over a pivot rod and torque control such that the facing adhesive surfaces adhesively engage one another to complete the visor construction. The methods of manufacturing the visor includes the steps of applying a co-adhesive to sheets of fiberboard and cutting the sheets into the butterfly shape of a desired visor configuration. The individual butterfly sheets are stacked on one another with the adhesive layers facing in the same direction, such that the adjacent butterfly cores do not adhere to one another. Subsequently, the single core members are placed on butterfly-shaped upholstery having a slightly larger dimension than that of the core.

Abstract: A visor is disclosed of the type used in an automobile which has an attached ear portion. The visor has a self-supporting cardboard butterfly inner support which includes a pair of ear portions, one of which is attached to the major portion of the butterfly along a crease line formed between the major portion and the ear portion while the other ear portion is joined to the major portion of the butterfly by a slotted line having strips of material between slots. One side of the butterfly is covered with a decorative material. The butterfly is folded to form opposing edges and a urethane adhesive is used to bind the sides of the butterfly together. The adhesive contacts the edge of the decorative material contained within the folded butterfly and fixes it firmly in place. As the urethane resin cures, it expands to form a rigid foam member which forms a stiffening member for the visor.

Abstract: A visor is disclosed of the type used in an automobile. The visor has a self-supporting cardboard butterfly inner support which is covered with a decorative material. The butterfly is folded to form opposing edges and a urethane adhesive is used to bind the sides of the butterfly together and to clamp the decorative material in place. The adhesive contacts the edge of the decorative material contained within the folded butterfly and fixes it firmly in place. As the urethane resin cures, it expands to form a rigid foam member which forms a stiffening member for the visor. A torque member is attached to the visor within the folded butterfly and has a member for attachment to the ceiling of an automobile. The method of making the visor is also disclosed.

Abstract: A visor includes several overlapping sliding panels mounted to a vehicle roof by support arms which together with the panels retract within a slot in the vehicle headliner for storage. The visor can be extended as desired from the headliner to provide selected or full window coverage.