Note: Descriptions are shown in the official language in which they were submitted.
VISOR
BACKGROUND OF THE INVENTION
1. Field of the Invention
[001] The present invention generally relates to a sun visor for interior use
in a vehicle, and
more particularly relates to a sun visor, having a visor body that includes a
vanity having a light
emitting diode (LED) to provide light therefore.
2. Description of Related Art
[002] Sun visors are well known and widely used in the prior art. Many
different types and
designs have been successfully employed in vehicles over the years. Many of
these prior art
visors have been developed in a variety of ways through which visor bodies and
other interior
components may be constructed and mounted within a vehicle. Advances in design
may often
add complexities to the manufacturing processes for interior components. There
has been and
continues to be a premium in the automotive industry on cost savings, weight
reduction, and
improvements in the efficiency and speed in the manufacturing processes for
such components
therein. One area of particular focus in the automobile technology field has
been reducing the
number and the complexity of steps required to assemble interior components
such as sun visors
or visors for use in a vehicle.
[003] Generally, in the prior art, manufacturing simplicity continues to
drive innovations in the
automotive industry, loss of quality and performance in manufactured interior
components for
the sake of facilitating production is seldom, if ever acceptable. There is a
substantial body of
prior art relating to the specific structure of the visor to provide a strong,
lightweight construction
1
CA 3010309 2020-05-11
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
that matches or compliments the vehicle interior trim in a cost effective
manner. Of particular
interest has been the "clamshell" type construction, which involves the
molding of two shell
pieces or clamshell halves, which are joined to form the visor. In one typical
clamshell design,
the visor halves are formed as a single piece attached along a longitudinal
edge, and then folded
to form the visor body. The exterior surface can be molded to provide a
suitable visor surface, or
a desired outer covering may be added in a variety of ways known in the prior
art.
[004] The clamshell design allows the visor body to be constructed relatively
quickly and
easily, however, the various components that are attached to the visor
clamshell halves must in
some cases be incorporated with several assembly steps prior to securing the
clamshell halves
together. For example, several known designs require insertion of additional
mounting or
journaling pieces for retention of the visor pivot rod within the visor body.
The construction of
visors having such a design is relatively time-intensive. Moreover, the
various slides, journals,
retainers, etc., utilized in the construction may add significant expense and
weight to the overall
visor, along with unwanted noise, and increase the number of components
necessary to build one
therein. Many of these prior art visors use standard light bulbs, such as
incandescent bulbs to
provide light for either a vanity which includes a mirror arranged within the
visor, or for a map
light that is sometimes arranged within the visor. The use of the incandescent
bulb draws more
current and power than that of newer technologies, such as a LED bulb.
[005] In come cases, eliminating parts may reduce the expense of manufacturing
and
constructing the visor. Decreasing size and weight, however, can be
accompanied by decreases
in strength. Furthermore, the visors that attempt to change well accepted
technology, like
incandescent light bulbs with new technology, such as a LED, may run into
problems with
consumers and users of the vehicle not accepting the look and feel of the
light emitted by an
2
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
LED versus that of a light emitted by an incandescent prior art light bulb.
The use of new
technology, such as a LED over a prior art light bulb, may increase the
efficiency and reduce
manufacturing assembly times for visors in the automotive and other vehicular
art. Hence, it is
desirable in the art to provide a visor that is light weight, easy to
manufacture and uses relatively
few components, yet utilizes a design imparting significant durability to
withstand heavy and
repeated use and to provide a solid construction with tight tolerances
throughout the entire
system. Furthermore, there is a need in the art for an improved visor that has
a LED lighted
vanity and/or map light arranged therein. There also is a need in the art for
a sun visor that uses
a variety of methods of aligning a LED with a lens for use in the vanity or a
LED used in
conjunction with a light guide in a vanity to provide a more even appearance
and distribute the
light in a more aesthetic pleasing fashion than prior art light bulbs. There
also is a need in the art
for a vanity that may use one light to light both sides of a vanity mirror
through the use of a light
guide system arranged therein.
SUMMARY OF THE INVENTION
[006] One object of the present invention may be that it provides an improved
visor.
[007] Another object of the present invention may be that it provides a visor
that has a light
emitting diode (LED) for use in illuminating a mirror of a vanity.
[008] Yet a further object of the present invention may be that it provides a
visor that uses a
LED as a direct replacement for a prior art light bulb.
[009] Still another object of the present invention may be that it provides a
visor that uses a
LED as the light source along with a light guide to illuminate a vanity mirror
in a visor.
3
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
[010] Still another object of the present invention may be that it provides a
visor that includes a
light base that is capable of holding a circuit board having a LED thereon in
either a horizontal or
vertical position.
[011] Yet another object of the present invention may be that it provides a
visor that has a map
light that is illuminated with a LED.
[012] Still another object of the present invention may be that it provides a
visor that includes a
wire arranged between a circuit board and the electrical system of the vehicle
to provide LED
lighting in a visor vanity.
[013] Still another object of the present invention may be to provide a visor
that is easier to
manufacture and more efficient through the use of a LED lighted vanity.
[014] Still another object of the present invention may be that it provides a
visor that is more
robust and includes a lighting system that is more reliable and longer lasting
than prior art
lighting systems.
[015] Yet another object of the present invention may be that it provides a
visor that has a
frameless vanity with a mirror having clear ends on both ends thereof.
[016] Still another object of the present invention may be that it provides a
visor having an
LED with a mirror with clear ends arranged at each end thereof.
[017] According to the present invention, the foregoing and other objects and
advantages are
obtained by a novel design for a visor for use in a vehicle. The visor
generally comprises a pivot
rod and a carrier arranged over the pivot rod. The visor further comprises a
first and second shell
engagable to form a visor a body. The visor also comprises a vanity arranged
within the visor
body. The visor further comprises a light base secured to the second shell of
the visor body and
4
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
a circuit board engaging the light base. The visor also comprises a light
emitting diode secured
to a surface of the circuit board.
[018] One advantage of the present invention may be that it provides for an
improved visor.
[019] A further advantage of the present invention may be that it provides for
a visor that uses a
LED as the light source for a vanity.
[020] Yet another advantage of the present invention may be that it provides
for a direct
replacement of a prior art light bulb with a LED arranged on a circuit board
for a vanity in a
visor.
[021] Yet another advantage of the present invention may be that it provides
for a light base for
use in a visor that is capable of holding a LED arranged on a circuit board in
either a vertical or
horizontal position relative to the visor body.
[022] Still another advantage of the present invention may be that it provides
a visor that uses a
LED in conjunction with a light guide to provide illumination for a vanity.
[023] Still another advantage of the present invention may be that it provides
a visor that uses a
light base to align a LED in proper position with respect to a vanity therein.
[024] Still another advantage of the present invention may be that it provides
a visor that
replaces prior art light bulbs with more energy efficient, reliable and longer
lasting LED light
sources.
[025] Still another advantage of the present invention may be that it provides
for a visor that is
easier to manufacture and more robust than prior art visors.
[026] Still another advantage of the present invention may be that it provides
for a visor that
includes a frameless vanity having a mirror with clear ends on both ends
thereof.
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
[027] Yet another advantage of the present invention may be that it provides a
visor that uses a
LED in conjunction with a mirror having clear ends for use in illuminating the
mirror.
[028] Other objects, features and advantages of the present invention will
become apparent
from the subsequent description and appended claims, taken in conjunction with
the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[029] Figure 1 shows a plan view of a visor according to the present
invention.
[030] Figure 2 shows a cross section of a visor according to the present
invention.
[031] Figure 3 shows a cross section of a visor according to the present
invention.
[032] Figure 4 shows a plan view of a circuit board and LED for use in a
visor.
[033] Figure 5 shows a top view of a light base for use in a visor according
to the present
invention.
[034] Figure 6 shows a bottom view of a light base for a visor according to
the present
invention.
[035] Figure 7 shows a section view of a visor according to an alternate
embodiment of the
present invention.
[036] Figure 8 shows a section view of a visor according to an alternate
embodiment of the
present invention.
[037] Figure 9 shows a section of a visor according to an alternate embodiment
of the present
invention.
[038] Figure 10 shows a top view of a light base according to an alternate
embodiment of the
present invention.
6
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
[039] Figure 11 shows a light base with a circuit board arranged therein
according to an
alternate embodiment of the present invention.
[040] Figure 12 shows a light base according to an alternate embodiment of the
present
invention.
[041] Figure 13 shows a plan view of a light base according to an alternate
embodiment of the
present invention.
[042] Figure 14 shows a section view of a light base according to an alternate
embodiment of
the present invention.
[043] Figure 15 shows a top view of a light base according to an alternate
embodiment of the
present invention.
[044] Figure 16 shows a top view of a visor shell according to the present
invention.
[045] Figure 17 shows a plan view of an alternate embodiment of a light base
according to the
present invention.
[046] Figure 18 shows an exploded view of a vanity according to an alternate
embodiment of
the present invention.
[047] Figure 19 shows a view of a visor according to an alternate embodiment
of the present
invention.
[048] Figure 20 shows a view of a visor according to an alternate embodiment
of the present
invention.
[049] Figure 21 shows a top view of a frame of a vanity for use in a visor
according to the
present invention.
[050] Figure 22 shows a vanity lens for use according to the present
invention.
7
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
[051] Figure 23 shows a vanity for use according to an alternate embodiment of
the present
invention.
[052] Figure 24 shows a vanity for use in an alternate embodiment according to
the present
invention.
[053] Figure 25 shows a map light arranged in a visor according to the present
invention.
[054] Figure 26 shows a map light arranged in a visor according to an
alternate embodiment of
the present invention.
[055] Figure 27 shows a map light arranged in a visor according to an
alternate embodiment of
the present invention.
[056] Figure 28 shows a LED attached to a circuit board according to the
present invention.
[057] Figure 29 shows a plan view of a visor according to an alternate
embodiment of the
present invention.
[058] Figure 30 shows a top view of a visor according to an alternate
embodiment of the
present invention.
[059] Figure 31 shows a top view of a visor according to an alternate
embodiment of the
present invention.
[060] Figure 32 shows a back view of a visor according to an alternate
embodiment of the
present invention.
[061] Figure 33 shows a cross sectional view of a visor according to an
alternate embodiment
of the present invention.
[062] Figure 34 shows a plan view of a visor according to an alternate
embodiment of the
present invention.
8
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
[063] Figure 35 shows a top view of a visor according to an alternate
embodiment of the
present invention.
[064] Figure 36 shows a top view of a visor according to an alternate
embodiment of the
present invention.
[065] Figure 37 shows a cross sectional view of a visor according to an
alternate embodiment
of the present invention.
[066] Figure 38 shows a cross sectional view of a visor according to an
alternate embodiment
of the present invention.
[067] Figure 39 shows a bottom view of a visor according to an alternate
embodiment of the
present invention.
[068] Figure 40 shows a bottom view of a visor according to an alternate
embodiment of the
present invention.
BRIEF DESCRIPTION OF THE EMBODIMENT(S)
[069] Referring to the drawings, there is shown a visor 30 according to an
embodiment of the
present invention. Generally, the present invention broadly provides a clam
shell type vehicle
sun visor 30 having a pivot rod 32 mounted to a carrier 34, wherein the pivot
rod 32 and carrier
34 are slidably captured during assembly with the single step of attaching
visor shell portions
36,38 together. The carrier 34 thus rides in the visor body 42 itself rather
than a separate carrier
and is preferably retained between surfaces and/or features, such as channels
40 molded
integrally within the shell portions 36,38. Similarly, the pivot rod 32 rides
in the visor body 42,
and a separate bracket, bezel or similar piece is not necessary to support the
pivot rod 32.
Related aspects of the present invention include methods for manufacturing a
sun visor 30 also
described herein. Furthermore, it should be noted that the visor 30 as shown
in the present
9
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
application can be used in any known type of vehicle, such as but not limited
to, automotive
vehicles, maritime vehicles, aerospace vehicles, military vehicles and any
other known vehicle
that has a need for the sun to be blocked from filtering into the interior
compartment of the
vehicle. It should also be noted that generally all of the components of the
visor 30, according
to the present invention, may be made of a plastic material that is capable of
either being
extruded, molded or shaped by any known manufacturing process. However, any
other known
metal, ceramic, plastic, composite, natural material or any other known
material may also be
used for any of the parts or components of the visor 30 described herein.
Furthermore, it should
be noted that the visor 30 of the present invention may be any known type of
visor, such as a
sliding visor, a non-sliding visor, a moveable visor, or any other type of
visor known in the
vehicle industry.
[070] In one embodiment shown in the Figures, the visor 30 includes first 36
and second shell
38 halves or shells which are engageable to form an elongate visor body 42.
Various molded
features 48 may be included on each shell 36,38 to facilitate engagement of
the shells. For
example, complementary structures may be formed on the respective visor shells
36, 38 that
allow a snap-fit therebetween. In one contemplated embodiment, the shells
36,38 may be
formed having integral or connected longitudinal peripheral edges 44,46 and,
respectively.
Other embodiments are contemplated in which shells are formed as separate,
unconnected
members. Although connected shells are preferred, the visor 30 has shown in
the Figures may
have unconnected shells also. The visor 30 further may include a pivot rod 32
that is arranged
into one end of the visor body 42 and connect on the opposite end to a
headliner or roof of the
vehicle into which the sun visor 30 is arranged. The visor 30 is preferably
formed such that the
shells 36,38 may be closed about pivot rod 32 and as such capture the pivot
rod 32 therebetween
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
in a single assembly step. Also, the visor 30 may include a carrier 34 which
is slidably captured
by the closure or engagement of the shells 36,38, slidably securing the
carrier between the shells
36,38 without the need for installation of an internal slide member, retainer
or similar mechanism
for mounting the pivot rod 32. All the component parts of the visor 30 may be
manufactured
from any known materials and by known processes, such as but not limited to,
any type of
plastic, metal, ceramic, composite, natural material or any other known
material, and by any type
of molding technique, forming technique, chemical and mechanical process to
design and make
the components as described herein.
[071] Generally, the shells 36,38 are formed by injection molding a plastic
material in a
conventional manner. For example, the shells 36,38 may be formed from a molded
polyethylene, or by some other suitable method and/or material. The first 36
and second shells
38 generally include retaining surfaces in any known shape, such as arcuate
retaining surfaces,
flat or angled retaining surfaces, all of which may be elongate or trough
shaped surfaces
extending parallel to an edge of a visor shells and defining a portion of a
cylinder or wall. It
should further be appreciated that the present invention may encompass designs
with retaining
surfaces that vary in dimension between longer, trough-shaped features and
more narrow arcuate
ledges as shown. It should further be noted that an arcuate pair of surfaces
may be aligned near
one end of the visor shells 36,38 to allow for the pivot rod 32 to be properly
supported and
capable of rotating and sliding with relation to the visor body 42. The visor
half shells 36,38 also
may have a channel formed near one edge thereof, wherein the channel may have
a first and
second bearing surface. These bearing surfaces may be arranged at any known
angle with
relation to a center line of the visor body 42. In one contemplated
embodiment, these angled
surfaces may be arranged on each side of a channel that extends a
predetermined distance along a
11
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
longitudinal axis of the visor body 42 and these angled surfaces may be any
approximate angle
with relation to a center line of the visor body 42. It should be noted that
these angled bearing
surfaces may be arranged on each inner surface thereof. It should also be
noted that the visor
half shells 36, 38 may include other surfaces that receive and hold various
components of the
sliding visor 36, such as but not limited to the pivot rod 32, a D-ring, a
vanity 66, and covering
material 52 arranged over the visor body 36 to complete assembly thereof.
[072] The shell halves 36,38 that form the visor body 42 of the visor 30
according to the
present invention also may include a plurality of hybrid snap and ultrasonic
weld joints. In one
contemplated embodiment, a plurality of profile snaps may be arranged around
the front edge
and the side edges of the arcuate shells of the visor shells 36,38. One of the
shells may have the
male portion of the profile snap while the other shell may have the female
portion, which
receives the male portion and holds the first shell to the second shell in
order to provide robust,
zero flex interface between the two half shells 36,38 to form a robust visor
body 42. These
snaps, which are arranged around the outer profile, may allow for enough flex
for the front edge
and side edges to allow for a tucking process to occur as described hereafter.
The visor body 42
may also include at least one weld bar joint and at least one weld boss joint
arranged at a
predetermined position on the visor body 42. It should be noted that other
contemplated
methodologies and fasteners may be used to secure the two visor shell halves
36,38 to one
another, and it is also contemplated that the visor 30 is formed as one single
body member and
not of two separate shell halves.
[073] One of the shell halves also may include a predetermined shaped orifice
or cavity 54 on
an outer surface thereof that may be used to receive and secure a vanity 66 to
the visor body 42.
The orifice or cavity 54 for receiving a vanity 66 may include a plurality of
locking surfaces or
12
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
locking arms that may interact with locking surfaces or flanges of a frame 50
of the vanity 66 to
ensure the vanity 66 is secured to the outer surface of one of the shells of
the visor body 42.
These locking surfaces and fingers may take any known shape and are arranged
such that both
illuminated and non-illuminated visor vanities may be arranged therein. Other
surfaces may also
be molded into the visor half shells 36,38 to allow for placement of wires 58
to illuminate a visor
vanity mirror 60 or to receive a universal garage door opener or other
component directly into
the visor body 42. The visor half shells 36,38 according to the present
invention, may also
include a plurality of teeth 62 arranged around an outer periphery of the
front edge and side
edges of each of the shell halves 36,38. These teeth 62 generally have a
pyramidal or triangular
like shape tooth and may either be directly aligned with one another from each
half shell or
offset with one another from each half shell, depending on the design
requirements and the
tucking process to be used. This use of the teeth 62 to form a tuck edge and
to have the cover
material 52 placed by a tuck edge process into engagement with the teeth may
create an
aesthetically pleasing visor body 42 having a crisp and clean outer cover
material 52 arranged
thereover. It should be noted that in one contemplated embodiment the cover
material 52 may be
formed in the shape of a sock, wherein the sock is arranged over one end of
the visor body 42
then the tuck process is used to create the clean front edge and side edges of
the visor 30.
However, any other known tuck process and cover material 52 that is not in the
form of a sock
may also be used depending on the design requirements and the visor 30 being
created.
[074] The visor 30, according to the present invention, may also include a D-
ring secured to the
visor body 42 on a top edge thereof. The D-ring may be any known D-ring. The D-
ring of the
present invention may partially assist in holding the cover material 52 in a
taught, clean manner
over the outer surface of the visor half shells 36,38 formed into a visor body
42. It should be
13
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
noted that any shape may be used for the D-ring body and D-ring pin associated
therewith. The
visor 30 may include a pivot rod 32 which is attached at one end to a bracket
or connector which
is secured to the headliner or roof of a vehicle. The bracket may have a
connector secured
thereto to connect the electrical system of the vehicle via a wire 58 to the
bracket, the wire 58 is
then passed through the pivot rod 32, which generally is hollow according to
the present
invention. However, it should be noted that a solid pivot rod 32 may be used,
as long as it will
be capable of passing electricity therethrough to allow for illumination of
the vanity mirror 60 if
necessary or map light 64. The bracket may be secured to the roof of the
vehicle via fasteners or
any other known methodology. The bracket may include an orifice that will
receive one end of
the pivot rod 32 near an elbow of the pivot rod 32, wherein the pivot rod 32
generally has an
angle of 60 -120 at the elbow. The pivot rod 32 may be secured and capable of
rotation within
the orifice of the bracket and may also be swung between a front windshield of
the vehicle and a
side window of the vehicle to block the sun from any angle. The pivot rod 32
may be of any
known length and diameter depending on the design of the visor 30 and the
automobile into
which it is arranged. The wire 58 may be connected from the electrical system
of the automobile
and is passed through to a LED 64 for illumination of a visor mirror 60 in the
vanity 66. It
should be noted that the visor 30, pivot rod 32 and bracket may be made of any
known material,
such as but not limited to plastic, ceramic, composites, metals, or natural
material, etc.
10751 The visor pivot rod 32 is arranged within a carrier 34 that is arranged
within the visor
body 42. The carrier 34 is capable of slidable movement if the visor 36 is a
sliding visor. If the
visor 30 is not a sliding visor, the carrier 34 is fixed with respect to the
visor body 42. In the
sliding visor the carrier 34 may slide within a channel 68 of the visor body
42 to allow for the
visor 30 to be extended out towards an end of the visor rod 32 secured within
the visor body 42.
14
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
Any known carrier 34 may be used to secure the pivot rod 32 to the visor body
42, such as but
not limited to a floating carrier, a fixed carrier or any other known carrier
associated with a visor
32 rod and visor body 42.
[076] The visa 30 may also include a wire routing system that passes a wire 58
from the
bracket through the pivot rod 32 to the LED 64 vanity light for illumination
of a vanity mirror 60
therein. Any known wire routing system may be used to pass the wire 58 through
the visor body
42 to a circuit board 70 used to control and operate an LED 64 thereon. It
should further be
noted that it is also contemplated to use an onboard electric source to
illuminate the LED 64 of
the vanity 66 for the visor 30.
[077] The visor 30 also may include a vanity 66. The vanity 66 generally
includes a vanity
door 72, door springs, a vanity spring, and a vanity mirror 60, with optional
lights arranged
thereon. If the vanity 66 is illuminated, the vanity 66 may also include at
least one lens 74 to
disperse light in a predetermined manner. In another contemplated embodiment,
the vanity
frame 50 may include two lens 74, one arranged on each side of the vanity 66
to illuminate the
mirror 60. The vanity frame 50 generally may include at least one, but in the
embodiment
shown, two connecting flanges arranged near or at a bottom surface of the
vanity frame 50. The
opposite end of the vanity frame 50 may have arranged therein at least one
locking shoulder or
surface that may interact with locking tabs arranged on a surface of one of
the visor shell halves
36,38. This may allow for the vanity frame 50 and vanity 66 to be secured to
the visor body 42
without fasteners, such as screws, etc. However, it should be noted that
another embodiment
may use fasteners and screws to connect the vanity frame 50 to the visor body
42. One
contemplated embodiment may create a snap in vanity 66. Generally, the vanity
frame 50 and
door 72 may have a rectangular or oval shape, however any other shaped vanity
66 may be used
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
depending on the design requirements of the visor 30. The vanity 66 and frame
50 may also
include a flex hook arranged at one end thereof and a leaf spring arranged on
an opposite edge of
the orifice defined in the middle of the vanity frame 50. Adjacent to the leaf
spring may be one
or two locking tabs. This combination of the flex hook, leaf spring and
locking tabs along with
lens tabs that are used to secure the lens 74 to the vanity frame 50, may be
used to secure a
mirror 60 into a flexible interface without adhesives. In operation, the
mirror 60 is placed under
the flex hook and then snapped under the locking tabs and against the leaf
spring to secure the
mirror 60 without adhesives to the vanity frame 50. However, it is also
contemplated to secure
the mirror 60 to the vanity frame 50 with adhesives or any other methodology.
The lens tabs,
generally which are arranged on either side of the vanity frame 50 may keep
the vanity mirror 60
positioned properly in a side to side direction with relation to the vanity
frame 50. Hence, the
vanity mirror 60, which may be of any shape, size or thickness, may be held in
place to the
vanity frame 50 without adhesives, which are generally used to hold a vanity
mirror 60 to a
frame 50 in the prior art. It should be noted that any number of leaf springs,
locking tabs and
flex hooks may be used to hold the vanity mirror 60 according to the present
invention. The
vanity frame 50 may be inserted into the visor body 42 by securing a first and
second flange
arranged near one end of the vanity frame 50 underneath inboard hooks that are
molded into an
outer surface of one of the core visor body half shells 36,38. These flanges
may be arranged
under these inboard hooks and then the opposite end of the vanity frame 50 may
be snapped into
place with a downward force, such that the locking shoulders or surfaces of
the vanity frame 50
may interact with the locking tabs or snaps molded onto and into the visor
half shell 36,38 in an
outer surface thereof. This may secure the vanity 66 into the visor body 42
with a snap in system
that does not require fasteners, such as screws, to secure the vanity system
to the visor body 42.
16
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
It should be noted that the vanity 66 of the present invention may include
fasteners and screws to
secure it to the visor body 42.
[078] It should be noted that the visor half shell 36,38 that holds and
supports the vanity 66 also
may include a light base 80 secured thereto. In one contemplated embodiment
the light base 80
is molded into one of the shells 36,38, such as the second shell 38 of the
visor body 42. The light
base 80 may include a pocket 82 therein which secures a circuit board 70
therein to hold the
circuit board 70 in a predetermined fixed position with respect to the second
shell 38 and the
vanity 66. The pocket 82 may be formed or molded into a predetermined inside
surface of the
second shell 38. The light base 80 in this embodiment has the pocket 82 which
in part is defined
by a first and second guide member 84, wherein the first and second guide
member 84 extends
from an inside surface of the second shell 38 and are parallel to each other.
Each of the first and
second guide members 84 may have an inward extending flange 86 extending from
a top end
thereof. The flanges 86 may engage with a top surface of the circuit board 70
to assist in
securing the circuit board 70 with relation to the vanity 66. The first and
second guide members
84 generally may have any known predetermined shape, but may have a generally
L shape when
viewed from the front. The L shape may define a seat on each of the guide
members 84 onto
which the circuit board 70 may rest or be seated. The seat portion of the
guide member 84 and
the bottom surface of the inward extending flange 86 of the light base 80 may
have a
predetermined distance therebetween. This predetermined distance generally may
be equal to or
greater than the thickness of the circuit board 70 that is arranged therein.
The light base 80 also
may include a stop wall 88 arranged at a back end thereof. The stop wall 88
may extend in a
predetermined direction away from the inside surface of the second shell 38 of
the visor body 42.
During operation, the circuit board 70 may be slid within the front side of
the pocket 82 of the
17
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
light base 80 until one end of the circuit board 70 engages the stop wall 88
of the light base 80.
The light base 80 may also include a locking arm 90 arranged generally at a
mid line of the
pocket 82. The locking arm 90 may engage with a predetermined portion of the
circuit board 70
and secure the circuit board 70 within the light base 80. The locking arm 90
generally may have
a rectangular shape with a locking shoulder 92 arranged on the end thereof.
One end of the
locking arm 90 may be molded directly into a surface of one of the half shells
36,38 of the visor
body 42. The other end may be moveable or flexible thus allowing for the
locking arm 90 to
pivot about the first end which is fixed and molded into the visor body half
shell. This may
allow for movement of the locking shoulder 92 and the locking arm 90 in order
to engage with a
predetermined portion of the circuit board 70. The locking arm 90 may have a
predetermined
spring co-efficient which may allow for the locking arm 90 to securely hold
the circuit board 70
at a predetermined position with relation to the vanity 66.
[079] The light base 80 may also include a gap or recess 94 formed between two
predetermined
surfaces to form a wire routing channel for the circuit board 70. The wire 58
may connect to one
end of the circuit board 70 and on the other end to the electronic system of
the vehicle, wherein
the wire 58 may run through a predetermined area of the visor body 42 and
through the pivot rod
32 into the electrical system of the vehicle. The circuit board 70 generally
may have a
rectangular shape, with a predetermined length, width and thickness. It should
be noted that the
circuit board 70 may be of any known shape, but in the embodiment shown is a
rectangular
shape. Arranged on a top surface of the circuit board 70 is an LED 64. It
should be noted that
the LED 64 may be of any type, color and any known shape. The LED 64 as shown
in the
drawings is generally a square LED 64. Electrical components 96 may be
arranged on the circuit
board 70 and form the necessary circuitry for illuminating the LED 64 and
passing such
18
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
illuminated light 70 to a lens 74 and mirror 60 of the vanity 66. The
electronic components 96
may be, but are not limited to, diodes, resistors, capacitors, integrated
circuits or any other
known electrical component necessary to operate an LED 64. It should be noted
that the LED 64
in the embodiment shown is secured within the light base 80, such that the
circuit board 70 is
parallel to an inside surface of the visor body 42. This in effect holds the
circuit board 70 in a
horizontal position with relation to the visor body 42. The use of this
embodiment of the light
base 80 may provide for a direct bulb replacement version of the LED lighted
visor. This may
allow for the circuit board 70 and LED 64 to be positioned in generally the
same place or area as
the prior art bulb and socket which was used in prior art visor designs.
Generally, no changes to
the vanity sub assembly are required other than the molding of the light base
80 therein. It
should be noted that the circuit board 70 generally has the plurality of
electronic components 96
arranged on a bottom surface thereof and on the opposite side of the LED 64,
which may be
arranged on a top surface of the circuit board 70. The circuit board 70 may
also include a
locking member 98 extending from the bottom surface, wherein the locking
member 98 may
interact and inter-engage with the locking shoulder 92 of the locking arm 90
of the visor body
42. It should be noted that the light base 80 and circuit board 70 may be
arranged on each side of
a vanity 66. However, it is also contemplated to have a LED 64 arranged on
only one side of the
vanity 66 and it is even contemplated to use a LED 64 on only one side of the
vanity 66 and pass
the light from that one LED 64 via a light guide to both ends or sides of the
mirror 60 of the
vanity 66.
[080] Another embodiment of the visor 30 may include a light base 100 that is
a separate
component that is molded or formed separate from the visor body half shells
36,38. In this
embodiment, the light base 100 generally has a rectangular shaped body that
includes a first and
19
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
second rail parallel 102 to one another on a bottom surface thereof. The rails
102 generally have
a circular shape and extend from the bottom corner edge on each side thereof.
The parallel rails
102 may have a predetermined diameter, which may mate and inter-engage with a
predetermined
channel molded onto one of the shells 36,38 of the visor 30. The light base
100 may also include
a first and second arm 104 with one of the arms extending from each side
thereof near a mid
portion of the light base 100. The arms 104 generally may have any known
shape, such as but
not limited to a semi-circular or semi-silo shape when viewed from above. The
arm 104 may
extend a predetermined distance from the side of the light base 100. The arms
104 may have an
angled surface on a top side thereof. The light base 100 may also include a
locking tab 106
extending from a bottom surface thereof, wherein the locking tab 106 interacts
and engages with
a locking slot 108 arranged and molded within the shell 38. The locking tab
106 generally may
extend between the first and second parallel guide rails 102 and from the
bottom surface of the
light base 100 such that the tab 106 generally has an arcuate shape extending
from a bottom
surface of the light base 100, wherein the locking tab 106 extends a
predetermined distance
beyond a surface of the guide rails 102. In one embodiment, the locking tab
106 is generally
aligned along a mid point of the first and second arms 104, which extend from
a side of the light
base 100. Arranged on one end of the light base 100 is a slot 110. The slot
110 is fanned, such
that the circuit board 70 is placed within the slot 110 and secured in a
predetermined position
with respect to the second shell 38. The slot 110 is in part defined by a
first and second leg 112
that extend from the light base 100. The first and second leg 112 may each
have a groove that
has a generally square shape arranged at a mid point thereof. Each of the
grooves arranged in the
first and second leg 112 may be used to hold one edge of the circuit board 70
arranged therein.
A predetermined distance is arranged between the first and second grooves,
such that the
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
predetermined distance is generally equal to the width of the circuit board
70. This may allow
for the circuit board 70 to be slid within the slot 110 arranged on the front
end of the light base
100 and securing the circuit board 70 to the light base 100 via a locking snap
member 114
arranged on a surface of the light base 100. The locking snap member 114
generally may be
arranged near or on a surface near a mid point of the light base 100. Each of
the arms 112 of the
light base 100 may have a reinforcing rib 116 extending from a bottom surface
of the arm 112 to
a surface of the light base 100. The reinforcing ribs 116 generally may have a
triangular shape
when viewed from a side. The snap lock member 114 may be arranged between the
ribs 116
adjacent to a predetermined shaped cavity arranged within an end of the light
base 100. The
predetermined cavity generally may have any known shape, but generally has a
rectangular or
square shape in the current embodiment. This may allow for the lock member 98
extending from
a bottom surface of the circuit board 70 to inter-engage with the snap lock
member 114 and hold
the circuit board 70 in place within the light base 100 of the present
invention. The snap lock
member 114 may have any known shape and in one embodiment it generally has a
triangular
shape and extends a predetermined distance from an end of the light base 100
and a
predetermined distance into the cavity that holds the lock member 98 of the
circuit board 70.
This may allow for the interaction and engagement of the snap lock member 114
with the lock
member of the circuit board 70. It should be noted that the snap lock member
115 is only one
contemplated embodiment to secure the circuit board 70 within the light base
100 and that any
other known locking feature may be used to secure the circuit board 70
therein. The light base
100 of this embodiment may interact with a plurality of features that are
molded into an inner
surface of one of the half shells 36,35 of the visor body 42. The second shell
38 may have a first,
a second, a third and a fourth locking surface 118 molded therein. The locking
surfaces 118
21
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
generally are defined as slightly angled surfaces molded within one of the
visor half shells 36,38.
The surfaces 118 may be across from one another and hence, form a
predetermined sized gap.
This predetermined sized gap may generally be the same or slightly greater
than the thickness of
one of the arms 104 of the light base 100. This may allow for the light base
100 to be slid
through these gaps, such that the arms 104 interact with the first and second
locking surfaces
118, wherein the first locking surface 118 may create a force that may push
the first locking
surface 118 down onto the arm 104 of the light base 100, while the second
locking surface 118
may in effect push with an upward force onto the arm 104 of the locking
surface 118, which in
effect may wedge the light base 100 into the half shell 38 via the arm 104
extending from each
side thereof. Therefore, the first and second locking surfaces 118 may be
arranged on each side
of the light base 100 and formed within the visor half shell 38. The visor
half shell 38 may also
have molded therein a third and fourth locking surface 118. The third and
fourth locking surface
118 generally may be defined by edges or surfaces extending from predetermined
flanges
molded within the visor half shell 38. The third locking surface may inter-
engage with one of
the guide rails 102, while the fourth locking surface 118 may inter-engage
with the other of the
guide rails 102 of the light base 100. Therefore, the third and fourth locking
surfaces 118 may be
arranged near one another such that the gap therebetween may generally be the
same or greater
than the diameter of one of the guide rails 102. It should also be noted that
the third and fourth
locking surfaces 118 may be angled with relation to the guide rails 102, such
that each of the
guide rails 102 may be wedged between the third and fourth locking surfaces
118 that are
molded into one of the visor half shells 38. It should be noted that generally
all of the locking
surfaces 118 or features described herein are formed by flanges or channels
molded directly into
the visor half shell 38. In operation, the light base 100 described in this
embodiment may be slid
22
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
and locked into place within the visor half shell 38. The locking tab 106 may
inter-engage with a
locking slot 108 that is formed and molded into a surface of the second shell
38 generally at a
mid point of the light base 100. This may allow for the light base 100 to
inter-engage with the
visor half shell 38 at four points and be locked via one point, thus securing
the light base 100 in a
predetermined position with relation to the visor half shell 38 and vanity 66.
After inserting and
securing the light base 100 into the visor half shell 38, a wire 58 may be
connected between a
surface of the circuit board 70 and the electrical system of the vehicle. This
may allow for a
direct replacement of the light bulb system of the prior art visors.
[081] Still another embodiment of the light base 120 may generally have the
same body, guide
rails 102 and arms 104 as the light base 100 described above. This embodiment
of the light base
120 may further include a first slot 122 arranged along a transverse portion
of a top surface of the
light base 120. The slot 122 may extend across the entire width of the light
base 120. The slot
122 may be used to secure and hold one longitudinal edge of the circuit board
70. Directly
adjacent to the slot 122 on the top surface of the light guide 120 may be a
locking member 124
extending from a top surface thereof. The locking member 124 may be directly
adjacent to the
slot 122 and have a generally U-shape when viewed from a front thereof. The
locking member
124 may have a first and second leg 126 extending from a top surface of the
light base 120 and a
cross member 128 extending between the two legs 126. Generally, the front of
the locking
member 124 may share the same plane as one of the inward extending surface
walls of the slot
122. Each of the legs 126 generally may have a triangular shape when viewed
from a side,
however any other shape may also be used. The locking member 124 may be of
such
construction that there may generally be fofined a rectangular orifice through
a center of the
locking member 124. An electrical component or other locking member extending
from a
23
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
surface of the circuit board 70 may be used to interact with at least one
surface of the locking
member 124 of the light base 120. This may secure and hold the circuit board
70 in a
predetermined position with respect to the light base 120. A wire 38 may be
connected to the
circuit board 70 on either side or end of the circuit board 70. The top side
of the circuit board 70
may have a LED 64 secured thereto and in electrical communication with the
electronics of the
circuit board 70 and the electrical system of the vehicle. The light base 120
may also include a
pocket 130 arranged adjacent to the slot 122 on the side opposite that of the
locking member 124.
The pocket 130 may extend a predetermined distance into the light base 120.
The pocket 130
generally has a rectangular shape when viewed from above. The slot 122 of the
alternate
embodiment of the light base 120 generally may hold the circuit board 70 in a
vertical position
with respect to the visor body half shell 38. This may allow for the LED 64 to
be held in place in
the visor 30 in a vertical manner, thus allowing for the use of a light guide
132 in conjunction
with the vanity 66.
[082] The light guide 132 may generally be of any known shape, but in the
embodiment shown
it has generally a modified pyramidal shape with a generally circular bottom
portion and a
parallelogram type top portion. It should be noted that any known shape may be
used for the
light guide 132 of the present invention. One end of the light guide 132
having the smaller
dimension generally may have a notch or cut out 134 arranged therein. The cut
out 134 may be
used to align with the LED 64 arranged on the circuit board 70 of the present
invention. The
light guide 132 having any known shape may be used in any known visor 30. The
notch or cut
out 134 is arranged on one edge of the light guide 132 and may have any known
shape, but is
generally a square type cut out shape that may mimic the square shape of the
LED 64 used
herein. The LED 64 may shine its light directly in a head on manner into the
edge or end of the
24
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
light guide 132, thus allowing for dispersion of the light evenly throughout
the entire light guide
132. The use of the light guide 132 may provide for a warmer and more even
appearance of the
light through the lens 74 of the vanity 66. The distribution of the light via
the light guide 132
may ensure no hot spot when compared to that from a regular light bulb. It
should be noted that
the LED 64 may touch or engage the light guide 132 but it does not have to and
that the vanity
66 may have one or more lights arranged therein. It is also contemplated to
use a light guide 132
that extends from both sides of the vanity 66, such that a light may be
emitted via one LED 64
onto both sides of a mirror 60 within a vanity 66. However, it is also
contemplated to use two
separate light guides 132, one arranged on each end of the vanity 66, along
with a light base 120
arranged on each end thereof to form the illuminating light for the visor 30
according to the
present invention. It should be noted that the light guide 132 has a
predetermined thickness and
is made of any known predetermined material that is capable of producing the
distribution of the
light as required by the present invention. It should be known that any known
or unknown
material may be used for the light guide and light guide systems arranged
herein. It should
further be noted that the LED or LED's 64 may be directly affixed or attached
to the light guide
132 at a predetermined position thereon, such as but not limited to, at the
notch 134, etc. The
necessary electronics to operate the LED 64 directly attached to the light
guide 132 may be
arranged between the LED 64 and a power source for the visor or vehicle.
Generally, the light
guide 132 of the present invention may be arranged within the visor vanity
frame 50 with a lens
74 arranged over a top surface thereof to protect the light guide surface. The
lens 74 may be of
any known type or design. In one contemplated embodiment the notch 134 of the
light guide
132 may be approximately four millimeters wide, however any other shape, width
or notch may
be used for the input light area for the light guide 132. The vanity frame 50
of the present
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
invention may include a predetermined shaped orifice therein that generally
mimics the outer
shape of the light guide 132. The light guide 132 may then be held within the
vanity frame 50
through a press fit by using crush ribs 136 at strategic locations, such as on
each corner end of
the light guide 132. However, it should be noted that it is also contemplated
to have the light
guide 132 slid into position or held in place via snaps or a staking operation
to ensure that the
light guide 132 remains fixed with respect to the vanity frame 50 and light
base 120 which holds
and secures the LED 64 in relation to the light guide 132. Therefore, any of
the known
methodologies of holding such as a press fit, snap or staking may be used to
hold the light guide
132 in position on one or both ends of the vanity frame 50, then the vanity
frame 50 may have a
lens 74 arranged over a top of the light guide adjacent to the mirror 60 to
provide illumination,
for the user, of the mirror 60 via the LED light 64 and light guide 132. It
should also be noted
that predetermined openings or pass-through 142 in ribs and other components
of the visor half
shell 38 may be arranged therethrough in order to pass the wire 58 from the
electrical system of
the vehicle to the circuit board 70 of the light base 120, wherein the circuit
board 70 is being held
in a vertical position.
[083] It is also contemplated in the LED visor vanity of the present invention
that instead of
using a lens 74 over either a light guide 132 or a direct replacement LED 64,
that either may be
covered by extending the mirror 60 to the ends of the visor vanity frame 50
and eliminating any
of the adhesive on the bottom of the mirror 60. This may allow for the light
to shine directly
through the mirror 60 and remove the need of the use of a lens 74 to disperse
the LED light in a
predetermined manner. Furthermore, it is also contemplated that a grid 140 may
be molded into
the vanity frame 50 in order to protect the light guide 132 or LED 64 and
disperse the light from
the light guide 132 or LED 64 in a predetermined manner. It is contemplated
that these grids
26
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
140 may be of any known shape, such as a honey comb design, or arc lines with
a support arm
design as shown in the drawings. Any of these molded grids 140 or the
extending of the mirror
60 while eliminating the tape on the bottom of the mirror may be used in
conjunction with the
LED system of the present invention. It should be noted that it is also
contemplated that a map
light 138 that may be arranged in the first or second shell 36,38 of the visor
body 42 may use a
light emitting diode 64 and a light base 80 associated therewith according to
the present
invention to provide a map light 138 for use by the user of the vehicle,
wherein the map light 138
may be a separate lighting system from that of the vanity mirror lighting
system described
herein.
[084] Figures 29 through 33 show an alternate embodiment of an LED visor 230
according to
the present invention. Like numerals indicate like parts. The visor 230 of the
alternate
embodiment may include visor half shells 236 that may include other surfaces
that receive and
hold components of the sliding visor 230, such as but not limited a pivot rod,
a D-ring, a vanity,
and covering material arranged over the visor body 242 to complete assembly
thereof. The
manner in which all of these components described herein are connected to each
other and the
components used and formed in each of these components are generally the same
as those
described above. The visor body 242, being composed of a first half shell 236
and a second half
shell 238, may allow for a frameless vanity 266 to be secured to the visor
body 242, thus
allowing for the vanity 266 to be used by an occupant of the vehicle. In one
contemplated
embodiment, one of the half shells, in this case the first half shell 236,
includes a vanity pocket
235 arranged in a predetermined top surface of the first half shell 236. In
one contemplated
embodiment the vanity pocket 235 is arranged near one end of the visor half
shell 236.
However, the vanity pocket 235 may be arranged anywhere along the visor half
shell surface.
27
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
The vanity pocket 235 generally has a rectangular shape, although it should be
noted that any
other shape, including but not limited to oval, circular, square, triangular,
or any other shape may
be used to form the vanity pocket 235. The vanity pocket 235 may be recessed
into the top
surface of the visor first half shell 236 a predetermined distance. This
distance may allow for all
of the components necessary to operate the vanity 266 to be arranged therein
and to form an
aesthetically pleasing surface for the user of the visor 230 within the
vehicle. The vanity pocket
235 may include a plurality of channels formed therein. In one contemplated
embodiment the
vanity pocket 235 may include a first and second circuit board channel 249 for
which a circuit
board 270 may be arranged and secured therein for the vanity 266. The vanity
pocket 235 may
also include a wire harness channel 237 arranged along or near a top end of
the vanity pocket
235. In one contemplated embodiment the wire harness channel 237 and the
circuit board
channels 249 generally have a rectangular shape when viewed from above. It
should be noted
that any other shaped channel may be used for the channels described herein.
The wire harness
channel 237 and the first and second circuit board channels 249 are connected
to one another and
generally form a C shape when viewed from above. It should further be noted
that each of the
circuit board channels 249 may include a projection member or finger 251 that
extends a
predetermined distance from an inside surface of each of the circuit board
channels 249. These
fingers 251 may be used to align and secure the circuit board 270 in a
predetermined position
with relation to the channel 249. Directly adjacent to the first and second
circuit board channel
249 may be a first light guide channel and a second light guide channel 253.
The light guide
channel 253 generally may mimic the outer shape of the light guide 232, which
may be used
within the visor 230 according to the present invention. In one contemplated
embodiment the
light guide channel 253 may have a generally ovular partial shape or a semi
circular shape
28
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
depending on the design and outer edge shape of the light guide 253 for the
present invention. It
should be noted that in one contemplated embodiment the light guide channel
253 extends a
predetermined distance from the bottom of the vanity pocket 235, but not as
far as the circuit
board channel 249 and wire harness channel 237. However, it is also
contemplated to have all of
the channels extend the same distance from the bottom of the vanity pocket
235, such that the
light guide channel 253, circuit board channel 249, and wire harness channel
237 all extend the
same distance from the bottom of the vanity pocket 235. Arranged between each
light guide
channel 238 and circuit board channel 249 in one contemplated embodiment are a
first and
second triangular wedge member 255. These wedge members 255 may allow for
proper
positioning of the circuit board 270 with relation to the light guide 232 such
that the wedges may
mimic one surface of the light guide 232, thus allowing for the light guide
232 to be securely set
within the light guide channel 253 without any movement relative to the visor
body 242. It
should further be noted that the vanity pocket 235 may include a predetermined
angled surface
that extends from the top surface of the first half shell 236 of the visor
body down to the vanity
pocket 235 in any known shape at any known angle.
[085] Arranged within the vanity pocket 235 is a mirror 260. The mirror 260
may have any
known shape, such as generally rectangular with curved ends as shown or any
other shape. The
mirror 260 is generally made of glass with the appropriate coating thereon,
however it is also
contemplated that the mirror 260 may be made from any other material, such as
plastic,
composite, natural material, etc. The mirror 260 is arranged such that it is
secured to the bottom
surface of the vanity pocket 235 via any known connecting methodology. Some of
these
methodologies may be adhesives, tape, hook and loop connectors, mechanical
connectors or any
other known chemical or mechanical connecting methodologies. It should be
noted that the
29
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
mirror 260 in one contemplated embodiment may have a first and second clear
end 247 arranged
at each end thereof. The clear end portion 247 of the mirror 260 may be in any
known shape,
such as a semi circular or semi ovular shape shown in the drawings. The clear
end 247 may
extend any distance from the end of the mirror 260 or may be positioned
anywhere on the
surface of the mirror 260. However, it is also contemplated to have no clear
ends on the mirror
260 and/or to have only one clear end 247 on the mirror 260 depending on the
design
requirement for the visor 230. The use of the clear ends 247 on the mirror 260
may allow for
light from a light guide 232, which is illuminated by an LED 264 arranged on
the circuit board
270, to illuminate the vanity mirror 260 from underneath the mirror 260. This
may allow for the
light to pass through the clear ends 247 of the mirror 260 thus illuminating
the mirror 260 for the
user of the vanity during darkness and at all other times. It should be noted
that the shape of the
clear ends 247 may be any known shape that is capable of passing light
therethrough to
illuminate the vanity mirror 260 of the present alternate embodiment. In use,
the mirror 260 may
be secured to the vanity pocket 235, such that the mirror 260 is arranged over
a first and second
light guide 232 which are arranged within a first and second light guide
channel 253, which are
adjacent to a first and second circuit board 270 that are arranged and secured
within a first and
second circuit board channel 249. The circuit boards 270 are connected
electrically to the
electrical system of the vehicle, via a wiring harness 258. The wiring harness
258 is arranged
within the wire harness channel 237, and is connected to each circuit board
270 on one end
thereof while the opposite end of the wiring harness 258 is connected to the
electrical system of
the vehicle. As described above any type of switch may be used to control the
power of the LED
264, such as a plunger switch, or a mechanical switch in which the user
chooses to turn the light
on or off manually. As noted above, the light guide 232 may be arranged on
each end of the
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
vanity pocket 235, on just one end of the vanity pocket 235 or in no portion
of the vanity pocket
235. The light guide 232 as described above may be of any known shape,
thickness and may or
may not be used in the present invention. The LED 264 is arranged on the
circuit board 270 and
the circuit board 270 is connected to the electrical system of the vehicle as
described above in
previous embodiments.
[086] The alternate embodiment visor 230 may also include a door mounting
panel 231. The
door mounting panel 231 or member may snap directly into the first half shell
236 of the visor
body 242. The door mounting panel 231 generally has a rectangular shape with
curved ends at
each end thereof. This generally forms a wing like shape when viewed from
above. The door
mounting panel 231 generally has an S shape when viewed in cross section. The
door mounting
panel 231 may include in one contemplated embodiment a first and second
orifice 257
therethrough for receiving a door hinge 243 of a door 272 for the vanity 266.
The orifice 257
may be of any known shape, but generally is of a rectangular shape when viewed
from above. In
one contemplated embodiment, a first and second orifice 257 for the door
hinges 243 are
arranged through the door mounting panel 231. Generally, two door hinges 243
are arranged
from a top surface of the door 272, one near or at an end thereof and the
other near or at the other
end thereof. However, it should be noted that a single door hinge 243 is
contemplated to be used
and also multiple door hinges, i.e., more than two, are also contemplated to
be used with the door
mounting panel 231. The door mounting panel 231 may also include panel snap or
snap locking
members 241 arranged from a bottom surface of the door mounting panel 231. The
panel snap
members 241 generally are rectangular in shape and include a triangular wedge
at the end
thereof. The triangular wedge may form a locking shoulder that may interact
with a locking
surface of the first visor half shell 236 according to the present invention.
The locking shoulder
31
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
of the panel snaps 241 may allow for the door mounting panel 231 to be pushed
through the
substrate orifices and interengage therewith. The length of the door mounting
panel 231
generally extends almost the entire width of the vanity pocket 235. In the
embodiment shown it
is a little less than the width of the vanity pocket 235, such that the vanity
pocket 235 has an
angled surface that tapers down towards the end of the door mounting panel
231. A plurality of
panel locking snaps 241 are arranged from a bottom surface thereof. In the
embodiment shown
three multi sized snaps 241 are arranged along a first edge of the bottom
surface of the door
mounting panel 231 and a single panel snap 241 is arranged along the opposite
edge of the door
mounting panel 231. It should be noted that the first half shell 236 has a
plurality of locking
slots or orifices 259 arranged therethrough. Generally, the locking slots 259
have a rectangular
shape when viewed from above, however any other known shape may be used for
the locking
slots 259. The locking slots 259 may be used to receive and secure against a
locking surface of
the locking shoulder of the door mounting panel snap lock members 241, such
that an
interengagment between the locking shoulder and locking slots occurs. The
panel locking snaps
241 generally have a predeteimined co-efficient of flexibility that may allow
for the panel
locking snap members 241 to bend in order to interengage the locking shoulder
thereof with the
locking surface of the locking slot 259 in a snap type arrangement. The door
mounting panel
231 may also include a first and second door connector member 261. The door
connector
members 261 generally may be arranged from a bottom surface of the door
mounting panel 231.
The door connector member 261 generally may have a first and second leg
interconnected by a
cross member therebetween. The cross member may have a first and second pocket
arranged in
a top surface thereof, along with a smaller pocket arranged through a surface
thereof. The door
connector member 261 may also include in a side surface of the cross member a
spring pocket
32
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
245, which may be used to secure one end of a spring 239, for the door 272,
within the spring
pocket 245. It should be noted that the door connector member 261 may also
include a flange
263 extending from one of the legs thereof that includes an orifice through a
predetermined
portion thereof. This orifice may be used to have a hinge 243 arranged
therethrough in order for
the door 272 to pivot about a predetermined axis between an open and closed
position over the
minor 260. In the embodiment shown, two door connector members 261 are
arranged from the
bottom surface of the door mounting panel 231. It should further be noted that
the door
mounting panel 231 may also have the cross member formed as a solid member
without the
pockets in the top surface thereof, with only the spring pocket 245 arranged
through a side
surface of the cross beam of the door connector member 261. It should be noted
that the door
272 may have any known dimensions and any known shape, such that it is a shape
that mimics
the general shape of the vanity pocket 235, thus concealing the mirror 260
thereunder during
closure of the door 272 on the visor body 242. As shown in the embodiment, it
is generally
ovular or a rectangular shaped wherein the door 272 has a predetermined
indentation arranged at
a bottom surface thereof for easy opening and closing of the door 272 by the
user of the vehicle.
The door 272 may also include a first and second hinge 243 arranged off the
top end of the door
272. It should be noted that any other number of hinges including one or more
than two may
also be used depending on the design of the visor 230 according to the present
invention. The
door hinge 243 may generally have a U shaped when viewed in cross section. The
door hinge
243 may include a dowel or pin arranged at one end thereof. This pin may be
arranged through
the orifice of the door connector member 261 arranged on each end thereof
allowing for a pivot
point, such that the door 272 may pivot about the hinge to allow for the door
272 to open to
expose the mirror 260 for viewing and to close and shut the mirror 260 from
viewing by the user
33
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
of the vehicle. The door spring 239, as described above, generally has a C or
U shape when
viewed from a side. The second end of the door spring 239 may be engaged with
a cam surface
arranged on the door hinge 243 near a generally center portion of the door
hinge 243. This may
allow for the opening and closing of the door in a controlled and easy effort
manner without any
extraneous noise. It should be noted that the door spring 239 shown includes a
split end on one
end thereof. This split end may have one portion of the split end engage with
a top surface of the
cam of the door hinge 243 and a second portion engaged with a bottom surface
of the cam of the
door hinge 243. This split end for the door spring 239 may allow for the easy
opening and
closing efforts along with reduced noise. It should be noted that the door
spring 239 may be
made of any known material, but in one preferred embodiment is made of a metal
material,
however any other plastic, composite, or natural material may also be used. It
is also
contemplated to use any other type of plastic, metal, ceramic, composite or
natural material for
any of the other parts herein. It should further be noted that it is also
contemplated to use at least
one cylindrical lock or alignment member 265 extending from a bottom surface
of the door
mounting panel 231. These are generally arranged near each outer end of the
door mounting
panel 231. The cylindrical lock members 265 generally may have a tapered head
that is capable
of interengaging with a locking surface of the first half shell 236. The first
half shell 236 may
include a first and second cylindrical orifice 267 therethrough which may
align with and
interengage with the cylindrical locking members 265 of the door mounting
panel 231. It is also
contemplated that one door connecting member 261 may be used along with one
hinge 243
arranged near a center of the vanity pocket 235.
[087] Figures 34 through 40 shows yet another alternate embodiment of a visor
330 according
to the present invention. Like numerals indicate like parts. This alternate
embodiment includes
34
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
a first half shell 336 and a second half shell formed together to create a
visor body 342. The
visor half shells may include many other surfaces that receive and hold
various components of
the visor 330, such as but not limited to a pivot rod, a D ring, a vanity 366,
and covering material
arranged over the visor body 312 to complete assembly thereof, such as those
described above.
The visor 320 in this alternate embodiment may have a first half shell 336
with a vanity pocket
335 arranged therein. The vanity pocket 335 generally may have the overall
outer shape of the
vanity frame 351, which is used to connect the vanity 366 to the visor body
342. In the
embodiment shown it is generally a rectangular shape with rounded edges.
However, any other
shape, such as a rectangle, square, circular, oval, triangular or any other
known shape may be
used for the vanity 366 and the vanity pocket 355 described herein. The vanity
pocket 335 may
extend a predetermined distance from the top surface of the first half shell
336. The vanity
pocket 335 may also include a first and second circuit board channel 353 and a
first and second
light guide channel 363 arranged therein. The first and second channels 353,
363 generally are
arranged near each outer end of the vanity pocket 325. In the embodiment shown
the light guide
channel 363 does not extend as far from the top surface of the first half
shell 336 as the circuit
board channel 353. As described above the circuit board channel 353 generally
has a rectangular
shape when viewed from above, and the light guide channel 363 generally has a
semi circular
shape or D shape when viewed from above. The light guide 332 may be placed
within the light
guide channel 363 such that the bottom surface of the light guide 332
interacts and engages with
a top surface of the light guide channel 363 and it may align with the circuit
board 370, which is
placed and secured within the circuit board channel 353, such that the LED
light connected to the
circuit board 370 may illuminate the light guide 332 as described above. The
outer periphery of
the light guide 332 may mimic the periphery of the light guide channel 363,
such that the light
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
guide 332 does not move with relation to the visor body 342. The generally
same design as
described above for the circuit board 370 may also be used in this embodiment,
so that the circuit
board 370 does not move within the circuit board channel 353, thus ensuring
proper alignment of
the LED to the light guide 332. In the embodiment shown for this alternate
embodiment a wire
harness channel is not used. However, it also may be incorporated into the
present design
depending on the design requirements. Hence, the circuit board channels 353
are parallel to one
another and each are arranged near an end or a predetermined distance from the
actual end of the
vanity pocket 335. The vanity pocket 335 may also include a flange or shoulder
357 arranged
around an entire inner circumferential periphery thereof. A mirror flange 365
is arranged
adjacent to the flange 357. The mirror flange 365 generally may mimic the
outer shape of the
mirror 360 and may allow for the outer edge of the mirror 360 to sit on the
mirror flange 365
within the vanity pocket 335. The flange 357 may be parallel to the top
surface of the first half
shell 336. The flange 357 may include a plurality of locking slots 367
arranged at predetermined
intervals around the entire periphery circumference of the vanity pocket
flange 357. Generally,
these locking slots 367 may be rectangular when viewed from above, however any
other shaped
locking slot may be used and any number of locking slots may also be arranged
in any known
manner around the vanity pocket flange 357.
[088] The visor 330 also includes a vanity frame 351. The vanity frame 351
generally may
have a rectangular shape with curved ends. This shape may mimic the outer
shape of the vanity
pocket 335 and hence may be any known shape. The vanity frame 351 may also
include at least
one, but in the embodiment shown, two slots 369 through which a door hinge may
be attached
thereto. Hence, the top portion of the vanity frame 351 may be wider than the
two side portions
and bottom portion of the vanity frame 351. Extending from a bottom surface of
the vanity
36
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
frame 351 may be a plurality of mirror frame snap or lock members 355. The
mirror frame lock
snap members 355 generally may be rectangular with a wedge or triangular shape
end thereon.
The triangular shape end may form a locking shoulder for the mirror frame
locking snap 355.
This locking shoulder may interengage with a locking surface arranged through
the locking slots
367 of the vanity pocket flange 357. Hence, the locking shoulder may
interengage with a bottom
surface of the vanity pocket flange 357 to secure the vanity frame 351 to the
visor body 342. It
should be noted that the mirror frame locking snaps 355 may be arranged in any
known pattern
around the outer circumference of the vanity frame 351. The mirror frame
locking snaps 355
may align with and interengage with the locking slots 367 arranged through the
vanity pocket
flange 357 as described above. The mirror frame locking snaps 355 may have any
known width
and length. In the embodiment shown a total of twelve vanity mirror frame
locking snaps 355
are arranged at predetermined positions around the vanity frame 351. Hence,
the number of
locking slots 367 is the same as the number of locking snaps 355 and the
locking slots 367 are
arranged through the first half shell 336. Arranged from the wider top portion
of the vanity
frame 351 maybe a first and second door connector member 361. The door
connector members
361 are generally the same as those described above for the other embodiments.
Hence, the door
connector members 361 may have a generally circular channel that is capable of
receiving a pin
of the hinge of the door 372 such that the door 372 may be pivotally connected
to the door
connector member 361 and hence to the visor body 342. It should be noted that
the first half
shell 336 may have a first and second orifice that generally have a
rectangular shape when
viewed from above, which may allow for the first and second door connector
member 361 to
extend therethrough. This may allow for the vanity frame 351 to snap in and be
connected and
secured to the visor body 342. It should be noted that this snap in system may
allow for easy
37
installation of the vanity 366 into the visor 330 of the automotive vehicle.
In the embodiment
shown an electrical connector 359 is arranged adjacent to one of the door
connector members
361 and secured via any known connecting methodology to an inside surface of
the first visor
half shell 359. The electrical connector 359 is then connected to an
electrical system of the
vehicle and connected to the circuit boards 378 electrically such that power
is provided to the
LEDs for providing a lighted and illuminated mirror 360 for the visor 330. It
should be noted
that the mirror 360 generally is the same as the mirror described above in
that it might have two
clear ends 347 on each end thereof, one clear end 347 on an end thereof or no
clear ends,
depending on the design requirements for the vanity 366. It should further be
noted that the
vanity frame 351 also may include a mirror flange 371 arranged around an inner
periphery of
the vanity frame 351. The mirror flange 371 generally may have an oval shape
or a rectangular
shape with curved ends to mimic the inner diameter of the inner circumference
of the vanity
frame 351. The mirror flange 371 generally maybe parallel to a top surface of
the first half shell
336. The mirror flange 371 may in part be used to secure the mirror 360 within
the visor body
342. In one contemplated embodiment the mirror 360 may be held in place and
secured within
the visor body 342 mechanically by the mirror flange 371 of the vanity frame
351 engaging
with and securing the mirror 360 within the vanity pocket 335 of the first
half shell 336. Hence,
the bottom of the mirror 360 may be arranged and in contact with a surface of
the vanity pocket
335 while the mirror 360 is also in contact with the mirror flange 371, which
may be arranged
along an inner periphery of the vanity frame 351. Hence, when the vanity frame
351 is snapped
into the visor first half shell 336, it may in turn secure the mirror 360 in
position with relation to
the light guide 332, circuit board 370, door 372 and visor body 342. It should
be noted that all
of the components, except for the door spring 339, may be made of a plastic
material, however any
38
CA 3010309 2020-05-11
CA 03010309 2018-06-29
WO 2017/123494 PCT/US2017/012692
other metal, ceramic, composite or natural material may also be used for any
of these
components. The same may also apply for the door spring, which may be made of
any known
metal, plastic, ceramic, composite or natural material. It should further be
noted that the door
372 and door hinge system generally are the same as those described above for
the other
alternate embodiment. The vanity frame locking snap 355 in one embodiment
generally may
have four locking snaps 355 arranged at predetermined positions along the
first long edge and
second long edge and two locking snaps 355 generally arranged at a
predetermined position on
the shorter length edges of the vanity frame 351. However, any other number of
locking snap
members 355 may also be used and in any type of set up or positioning.
[089] Therefore, in operation, the two alternate embodiments of the visor may
be easier to
manufacture and easier to have the vanities installed therein via the snap in
locking systems
deployed in both the frameless vanity and the locking vanity frame
embodiments. Such easy
installation of the vanities within the visor bodies may reduce manufacturing
time and reduce the
overall costs for the manufacturer while also allowing the reduction in costs
of materials as the
clear ends of the mirror may allow for the removal of lens and the associated
hardware to
connect lens to be arranged over the light guides or LEDs of the present
invention.
[090] The present invention has been described in an illustrative manner. It
is to be understood
that the terminology which has been used is intended to be in the nature of
words of description
rather than that of limitation.
[091] Many modifications and variations of the present invention are possible
in light of the
above teachings. Therefore, within the scope of the appended claims, the
present invention may
be practiced otherwise than as specifically described.
39
