Abstract: A sun visor assembly includes a foundation folded unto itself to form first and second foundation halves. A first skate member is secured to the first foundation half and includes a first rounded edge portion of predetermined radius. A second skate member is secured to the second foundation half and includes a second rounded edge portion of predetermined radius. The first and second rounded edge portions cooperatively define a rounded edge of predetermined radius. In an embodiment, one of the first and second skate members also includes a sun visor accessory support formation.

Abstract: A sun visor assembly is provided that includes a core member, a foundation extending over the core member, and a cover extending over the foundation and forming an outer surface of the sun visor assembly. In an embodiment, the core member includes a plate having at its upper edge a hinge portion and at its lower edge a rounded bead. The core member may also be corrugated to include one or more peaks and troughs.

Abstract: A retainer clip assembly for securing a variety of components interiorly in an automobile. The assembly includes a movable lever which secures the retainer clip assembly to a vehicle ceiling panel. The lever includes a release member that is accessible from the exterior of the retainer clip, so that the lever may be disengaged from the ceiling panel, whereby the component may be removed. A transportation clip is disclosed for use with the retainer clip assembly. The transportation clip connects the retainer clip to a headliner module during transportation to the final point of assembly. At the final point of assembly, the retainer clip can be pushed into its installed position.

Abstract: A sun visor, which generally includes a foundation which may be folded unto itself to form two foundation halves, and an upholstery cover disposed over the foundation, the foundation halves include connecting elements which engage one another to secure the foundation halves together. Additionally, a frame member may be disposed between the folded foundation halves, the frame member including connecting elements which engage corresponding connecting elements of the foundation halves to secure the foundation halves to the frame member. The foundation halves include a liner board and a bead member section. The bead member section is secured to the outer edge of the liner board with a liner board interlocking mechanism which prevents the liner board and the bead member section from separating. A cover retention assembly is associated with each of the foundation halves and engages the ends of the upholstery cover to secure the cover to the sun visor foundation.

Abstract: A sun visor, which generally includes a foundation which maybe folded unto itself to form two foundation halves, and an upholstery cover disposed over the foundation, the foundation halves include connecting elements which engage one another to secure the foundation halves together. Additionally, a frame member may be disposed between the folded foundation halves, the frame member including connecting elements which engage corresponding connecting elements of the foundation halves to secure the foundation halves to the frame member. For example, in one embodiment, a plurality of clips may be integrally formed in a pair of connecting strips which are each associated with a foundation half, the clips of the connecting strips engaging one another when the foundation halves are pressed together to secure the foundation halves together.

Abstract: A vehicle sun visor assembly is provided that includes a foundation having a pair of foundation halves. The foundation halves include corresponding shapes that define at least a portion of an edge of the sun visor. A connecting member is secured to an upper portion of each foundation half to define an upper edge of the sun visor. The connecting member includes a pair of connecting halves that cooperatively form a channel. A rotation control member, which is disposed within the channel, is moveably connected to a first end of a visor support rod. A second end of the visor support rod extends outwardly from the foundation is attached to a mounting bracket assembly. The sun visor assembly is slidable along the support rod and the support rod is extensible from and retractable into the sun visor assembly.

Abstract: A retainer clip assembly for securing a variety of components interiorly in an automobile. The assembly includes a movable lever which secures the retainer clip assembly to a vehicle ceiling panel. The lever includes a release member that is accessible from the exterior of the retainer clip, so that the lever may be disengaged from the ceiling panel, whereby the component may be removed. A transportation clip is disclosed for use with the retainer clip assembly. The transportation clip connects the retainer clip to a headliner module during transportation to the final point of assembly. At the final point of assembly, the retainer clip can be pushed into its installed position.

Abstract: A sun visor, which generally includes a foundation which may be folded unto itself to form two foundation halves, and an upholstery cover disposed over the foundation, the foundation halves include connecting elements which engage one another to secure the foundation halves together. Additionally, a frame member may be disposed between the folded foundation halves, the frame member including connecting elements which engage corresponding connecting elements of the foundation halves to secure the foundation halves to the frame member. For example, in one embodiment, a plurality of clips may be integrally formed in a pair of connecting strips which are each associated with a foundation half, the clips of the connecting strips engaging one another when the foundation halves are pressed together to secure the foundation halves together.

Abstract: A sun visor assembly having a rounded member partially defining the outer edge of the sun visor which forms a more user-friendly edge than existing sun visor designs. The sun visor is formed from a substantially flat foundation that is folded unto itself thereby forming two foundation halves. The halves have corresponding shapes that define the edge of the sun visor. An upholstery cover covers the foundation and forms an exterior surface of the sun visor. A bead member is attached to the foundation and includes a stem portion that attaches to the foundation. The bead member also includes the rounded member whose surface forms a substantially semicircular cross section which faces away from the sun visor. In one embodiment, the rounded member is integrally formed with the foundation, itself, and this embodiment therefore does not include an additional bead member.

Abstract: A sun visor assembly having a rounded member partially defining the outer edge of the sun visor which forms a more user-friendly edge than existing sun visor designs. The sun visor is formed from a substantially flat foundation that is folded unto itself thereby forming two foundation halves. The halves have corresponding shapes that define the edge of the sun visor. An upholstery cover covers the foundation and forms an exterior surface of the sun visor. A bead member is attached to the foundation and includes a stem portion that attaches to the foundation. The bead member also includes the rounded member whose surface forms a substantially semicircular cross section which faces away from the sun visor. In one embodiment, the rounded member is integrally formed with the foundation, itself, and this embodiment therefore does not include an additional bead member.

Abstract: A sun visor assembly having a rounded member partially defining the outer edge of the sun visor which forms a more user-friendly edge than existing sun visor designs. The sun visor is formed from a substantially flat foundation that is folded unto itself thereby forming two foundation halves. The halves have corresponding shapes that define the edge of the sun visor. An upholstery cover covers the foundation and forms an exterior surface of the sun visor. A bead member is attached to the foundation and includes a stem portion that attaches to the foundation. The bead member also includes the rounded member whose surface forms a substantially semicircular cross section which faces away from the sun visor. In one embodiment, the rounded member is integrally formed with the foundation, itself, and this embodiment therefore does not include an additional bead member.

Abstract: A sun visor with a plate member disposed within the visor's shell. A vanity mirror is disposed within an opening in the shell and attaches to the plate member via heat stake technology. The plate member doubles as a conventional “core member,” thereby obviating the latter. The plate member is slanted relative to the shell and creates a cavity into which the vanity mirror fits. The vanity mirror is thereby attractively recessed within the opening. No adhesives or fasteners are used to secure the upholstery cover to the visor shell around the opening. Instead, the upholstery cover partially covers the opening and is stretched and securely held in place between the back of the vanity mirror and the plate member.

Abstract: A sun visor assembly which utilizes a plurality of modular visor core components and an outer covering. The visor core components each include an alignment element which cooperates with an alignment element on the outer covering thereby maintaining the visor core components in the proper location. The modularity of the visor core components allows for their use with any one of a plurality of differently configured outer coverings and in a plurality of different visor core component combinations. The modular components include a hinge block for rotatably engaging a visor support rod, a pin section having an exposed support member for supporting a free end of the visor blade and track components for slidingly engaging other components such as a sun visor extension panel.

Abstract: A sun visor assembly which is formed from an expanded polypropylene (EPP) shell having an upholstery cover fused to the exterior surface thereof. The polymer shell is further comprised of two shell halves which are joined together with a molded polymer band. The upholstery cover is fused to the exterior surface of the shell in the area of the polymer band so that the polymer band and the upholstery cover combine to form a hinge about which the shell halves are foldable together to form the completed sun visor. The shell halves are secured together by corresponding protrusions and slots formed in the two shell halves, respectively. The protrusions are fused into the slots. A vanity mirror assembly can be thermally fused to one of the shell halves or, alternatively, can be used to secure the two shell halves together.

Abstract: A sun visor assembly for a vehicle having a yieldable edge. The visor assembly has a rotatable visor body which may be positioned against the headliner in the roof of the vehicle or against the windshield or side window of the vehicle. The visor body includes a relatively rigid inner foundation member and a more flexible outer covering. The outer covering projects beyond the borders of the foundation member to form the edges of the visor body. The edges formed by the projecting outer covering are yieldable upon impact and may thereby cushion the force exerted by the visor body against a body impacting the yieldable edge of the visor body. The outer longitudinal edge of the visor body has a width of at least approximately 0.75 inches and the visor body may also include yieldable transverse edges.

Abstract: A sunshade mounting bracket assembly for mounting a sunshade to a vehicle without the use of tools or fasteners. The bracket assembly includes an outer bracket, an inner bracket, and an elbow to which the sunshade is attached. The outer bracket is mountable to an apertured panel such as the sheet metal interior roof of the vehicle. The inner bracket includes resilient locking prongs which define an interior cavity into which the elbow is inserted. The resilient locking prongs are structured to be insertable into an opening in the outer bracket. After their insertion into the outer bracket, the prongs engage the outer bracket when the inner bracket is axially rotated relative to the outer bracket from a first rotational orientation to a second rotational orientation for use. During their engagement with the outer bracket, the prongs are compressed radially inward and drawn axially into the outer bracket.

Abstract: A sun visor assembly which utilizes a plurality of modular visor core components and an outer covering. The visor core components each include an alignment element which cooperates with an alignment element on the outer covering thereby maintaining the visor core components in the proper location. The modularity of the visor core components allows for their use with any one of a plurality of differently configured outer coverings and in a plurality of different visor core component combinations. The modular components include a hinge block for rotatably engaging a visor support rod, a pin section having an exposed support member for supporting a free end of the visor blade and track components for slidingly engaging other components such as a sun visor extension panel.

Abstract: The present invention involves a mounting assembly for use in a vehicle with a pre-existing primary sunshade assembly. The mounting assembly may provide support for an amenity such as a secondary sunshade. A secondary sunshade may be mounted in a position parallel to the windshield of the vehicle and, when the primary sunshade is positioned alongside a side window of the vehicle, the secondary sunshade can be tilted downward to shade the windshield. The mounting assembly includes a mounting block having an aperture into which a structural projection of the primary sunshade assembly is inserted and a set of pre-drilled holes forming a screw hole pattern which is alignable with the screw hole pattern of the primary sunshade mounting assembly.

Abstract: A sunshade mounting bracket assembly for mounting a sunshade to a vehicle without the use of tools or fasteners. The bracket assembly includes an outer bracket, an inner bracket, and an elbow to which the sunshade is attached. The outer bracket is mountable to an apertured panel such as the sheet metal interior roof of the vehicle. The inner bracket includes resilient locking prongs which define an interior hollow into which the elbow is inserted. The resilient locking prongs are structured to be insertable into an opening in the outer bracket. After their insertion into the outer bracket, the prongs engage the outer bracket when the inner bracket is axially rotated relative to the outer bracket from a first rotational orientation to a second rotational orientation for use. During their engagement with the outer bracket, the prongs are compressed radially inward to compress the elbow maintained within the hollow, which results in rotation of the elbow relative to the inner bracket being frictionally resisted.

Abstract: A sun visor assembly including a core member and an outer covering assembly which folds over the core member and fastens to itself to secure the core member therein. The core member includes one or more first aligning elements, such as pegs outwardly projecting from the surfaces of the core member, and the outer covering assembly includes one or more complementary second aligning elements, such as holes in the rigid foundation of the cover which is externally covered by an upholstery material. When the outer covering assembly is folded over the core member during visor assembly, the first and second aligning elements mate to secure the core member substantially within the outer covering assembly.