Truck Sun Visor

This invention relates generally to sun visors for mounting upon a vehicle, and more particularly it concerns a sun visor and method for mounting the same upon a vehicle utilizing a novel mounting extension which capitalizes on structural features already existing on the vehicle for supporting the sun visor.

Sun visors for mounting on the exterior of vehicles, such as trucks, are well-known. Such sun visors are typically mounted adjacent the vehicle's front windshield and provide a shaded area upon the windshield and added shade for an occupant or occupants of the vehicle.

Sun visors in the past have typically been attached to a vehicle by providing an additional physical connection or connections to the vehicle in the form of some type of drilled, or otherwise affixed external structure upon the vehicle cabin for supporting the sun visor. Provision of this type of mounting arrangement is undesirable for a number of reasons, not the least of which is the physical degradation of the body of the vehicle when such drilling connections are made. A depreciation in the appearance is also caused by such drilling or other external structure is affixed. Removal of the visor typically does not leave the original vehicle appearance intact. In addition, mounting such prior sun visors has proven difficult due to the extent to which the vehicle body must be prepared for receiving and holding the sun visor.

Additionally, individuals often will purchase a vehicle, and then at a later date decide to add a sun visor. In addition to the cost associated with the purchase of this additional accessory, such individual must often pay a dealer or another person specializing in post-purchase accessory application to actually mount the sun visor. This is typically done because the average vehicle owner normally does not have the required time, tools or expertise to undertake such a task. In mounting such an accessory, the dealer or accessory specialist must often drill or otherwise provide physical mounting structure on the vehicle. Again, from the standpoint of vehicle body degradation, this is an undesirable condition.

The ability of a manufacturer or owner to easily mount a sun visor on a vehicle would significantly add to the vehicle's value and flexibility in a couple of different ways. First, from the manufacturing standpoint, less assembly-line time spent actually mounting the sun visor on the vehicle results in cost savings. Second, from the ownership standpoint, the ability to quickly and easily mount or retrofit a purchased vehicle with a sun visor greatly enhances the owner's perceived and actual value of the vehicle. There may also be instances, such as repair or change of ownership, where it is desirable to be able to conveniently remove a sun visor.

This invention grew out of the need to provide a durable rugged sun visor which may be easily mounted or de-mounted upon or from a vehicle. This is preferably done either as part of the factory-installed equipment, or as a post-purchase retrofit. It is further desirable to accomplish such without drilling the cab or adding special mounting fixtures thereto.

Preferred embodiments of the invention are described below with reference to the accompanying drawings, which are briefly described below.

FIG. 1 is a side elevational view of a vehicle upon which a sun visor is mounted according to a preferred embodiment of the present invention.

FIG. 2 is a front elevational view of the vehicle of FIG. 1 upon which the preferred sun visor is mounted.

FIG. 3 is a perspective view of the sun visor of FIG. 1.

FIG. 4 is a perspective view from the rear of the sun visor of FIG. 1. FIG. 4 shows one of a plurality of mounting extensions.

FIG. 5 is a sectional view taken along line 5--5 of FIG. 3.

This disclosure of the invention is submitted in furtherance of the objectives of patent laws to promote the progress of science, technology and the useful arts.

Visor Body

sun visor 10

visor body 12

mounting extensions 14

vehicle 16

windshield 18

shaded area 13

light aperture 20

light aperture lens 21

seals or grommets 23

Mounting Extensions

annular flange or shoulder 15

end part or cap 17

conduit part 19

electrical wire or wires 25

wire harness 22

Mounting Connections

clearance light fixture 24

receptacle wall 26

back piece 28

annular flange portion 32

annular seal 30

mounting connection 34

bolt 36

engagement piece or washer 38

nut 40

light source 43

holder or case 45

light bulb or other source 47

Operation and Method

FIGS. 1 and 2 show a sun visor 10 according to a preferred embodiment of this invention. Sun visor 10 includes a visor body 12 and a plurality of mounting extensions 14. Portions of the mounting extensions are shown detailed in FIG. 4 and described below.

The visor body is for installation upon a vehicle 16. In the preferred embodiment, vehicle 16 is a truck cab which is suitable for use in a truck and tractor trailer configuration. As positioned, visor body 12 is proximate or adjacent the vehicle's front windshield 18 and casts a shadow or shaded area 13 upon the windshield for an occupant of the vehicle. Shaded area 13 provides an occupant of the vehicle with shade and protects against the sun's glare.

Before describing in detail the preferred embodiment or embodiments, it should be understood that sun visor 10 may be factory-installed on vehicle 16, or may be retrofitted by any owner after purchase of the vehicle using structure which is already in place on the vehicle, as part of the structural support for supporting visor body 12 thereon. This makes mounting the visor on a vehicle much more easier than previous known visors as will become apparent below.

FIG. 2 shows that visor body 12 extends completely across windshield 18 in a manner which provides shade for both a driver and an occupant of the vehicle. It is possible, however, for the visor body to extend across less than the complete length of the windshield. Visor body 12 is preferably an elongate, rigid band-like structure which includes a somewhat flat central portion which extends across the front of the vehicle. The visor body has end portions which are joined to the central portion and which curve or bow to wrap into the corners of the vehicle rear to front corner posts. Preferably, visor body 12 is formed from a material possessing sufficient strength characteristics which enable it to withstand the stresses to which it will be subjected in the operating environment. More specifically, during highway travel, stresses are generated from commonly encountered weather phenomena and manmade conditions. Weather phenomena such as sun, wind, rain, snow, hail, and the like; and, manmade conditions such as flying rocks or pebbles such as the kind kicked up by other vehicles, place structural demands on the materials utilized to form visor body 12. As such, materials like sheet molding compounds, rigid thermoplastics, or fiberglass composites are likely candidates for forming visor body 12. Other materials will be apparent to those of skill in the art.

Referring to FIGS. 2 and 3, at least one light aperture 20, and preferably five such apertures are provided in visor body 12. Such apertures are most easily seen in FIG. 3. Each of light apertures 20 defines a portion of a so-called clearance light. Clearance lights are advantageously spaced across visor body 12 so that three apertures appear in or near the center of the visor body, and two apertures appear at either end of the visor body. Clearance lights are useful for a number of reasons which include providing a driver of the vehicle with an extra degree of visibility, and providing drivers in other approaching vehicles with a visual indication that vehicle 16 is approaching. The terms "light aperture" as used herein shall be understood to mean that structure on visor body 12 from or through which light may originate or pass,

Each of light apertures 20 may include a light aperture lens 21 secured in place by suitable seals or grommets 23 (FIG. 5). The terms "light aperture lens" are intended to mean a lens or any part of a translucent structure associated with a respective one of the light apertures and through which light is permitted to pass. The lens covers at least a portion of the light aperture with which it is associated and protects an internal source of light 47 (FIG. 5) from the elements. The apertures allow light from the source of light to be beamed therethrough for providing a visual indication that the vehicle upon which the visor body is mounted is approaching. Each light aperture lens 21 protects a respective one of the light sources.

FIGS. 3 and 4 show mounting extensions 14 in more detail. FIG. 4 is a perspective view which looks from the back side upon a single one of the mounting extensions. It will be understood that each of the mounting extensions is configured similar to that described with reference to FIG. 4. FIG. 3 shows a plurality of mounting extensions 14, and preferably five such mounting extensions which are attached or connected to visor body 12. Any suitable number of mounting extensions could be conveniently located or attached to visor body 12. Each of the mounting extensions 14 projects rearwardly from visor body 12 and forms an operative connection between the visor body and the vehicle described in more detail below. Each mounting extension is a tubular extension which is somewhat frusto-conical in shape, such shape defining at least a portion of an enclosure within or from which light from a light source may be conveyed or beamed. The tubular extensions support the visor body 12 in a spaced relationship relative to the vehicle's cab and windshield in a manner enabling the visor body to cast a shadow as mentioned above.

FIG. 4 shows a respective one of mounting extensions 14. Mounting extension 14 includes an annular flange or shoulder 15 and an end part or cap 17. Each end part 17 is adjacent shoulder 15 and projects rearwardly therefrom. Each end part includes an aperture 29 for two purposes which will be described below.

In the preferred embodiment, a plurality of light sources 47 are provided and each light source is mounted at or interiorly within a respective one of the enclosures defined by the mounting extensions. Such light sources define a plurality or bank of clearance lights which are mounted upon the visor body.

FIG. 4 also shows a conduit part 19 which is operatively connected with each of the mounting extensions for providing an enclosed wiring passage along which an electrical wire or wires 25 may pass for electrically interconnecting each of the respective light sources. Conduit parts 19 also serve as structural beams forming a part of the visor body to add rigidity.

FIG. 3 shows a wire harness 22 which, according to a preferred aspect of the invention, forms part of the operative connection between visor body 12 and the vehicle. Wire harness 22 provides an electrical connection between the vehicle and visor body 12 and serves to provide electrical power from the vehicle to the light sources which are provided at the apertures 20. Electrical power is conveyed to the light sources from harness 22 by the aforementioned wire or wires which extend through conduit 19. It will be appreciated that any suitable source of power can be used to provide the required electrical power to light the light sources 47. In the most preferred form, wire harness 22 is operatively connected through the centermost mounting extension, although the operative connection could be alternatively formed with through any of the mounting extensions.

Mechanical connection between visor body 12 and vehicle 16 is achieved in part through the use of at least one mounting connection which is described directly below. Preferably the mounting connection or mounting connections are configured to provide a mechanical connection between at least one of the mounting extensions 14 described above and at least a portion of a clearance light fixture 24 (FIG. 5) as is described in detail below. Clearance light fixture 24 comprises part of the truck cab or other vehicle structure.

FIG. 5 is a side sectional view of one of the mounting extensions 14 and the structure on vehicle 16 with which mechanical interconnection is made. For purposes of ongoing discussion, it will be understood that the depicted mounting extension is not the centermost mounting extension of visor body 12 with which wire harness 22 is operatively associated.

A clearance light fixture or feature 24 is provided and forms an integral part of the truck cab. As shown, clearance light fixture 24 includes a receptacle into which a light source may be inserted for providing clearance light operations when visor 10 does not form part of the truck cab's structure. Normally, when sun visor 10 does not form part of the truck's cab structure, a conventional clearance light is housed or connected somewhere within or proximate to clearance light fixture 24. However, when sun visor 10 is to be added, either as part of the factory-provided original equipment or as a retrofit, clearance light fixture 24 and others like it take on a new, added role which includes mechanically supporting visor body 12, and providing conduits through which electrical wiring can pass.

More specifically, a portion of clearance light fixture 24 includes a receptacle wall 26 with a back piece 28 connected or joined thereto. Back piece 28 includes an aperture which may be used to pass a wire or wires for providing electrical power to originally-mounted clearance lights. Mounting extension 14 is insertable into fixture 24 through an aperture 27. When so inserted an annular flange portion 32 serves to engage annular shoulder 15 of mounting extension 14 restricting further insertion thereinto. An intermediate annular seal 30 includes an amount of closed cell foam which ensures that the region internally of clearance light fixture 24 is protected against water entry and other debris. The seal also adds a degree of structural coupling. A preferred mounting connection 34 includes the structures explained above which are in the preferred form secured using a bolt 36, a first engagement piece or washer 38, second engagement piece or washer 39, and a nut 40 screw threadedly fastened to an end of bolt 36 for bearing against back piece 28.

Mounting connection 34 is configured to provide a mechanical connection between mounting extension 14 and at least a portion of clearance light fixture 24. More specifically, engagement piece 38 includes a central aperture 29 (FIG. 4) through which bolt 36 may be inserted. After so inserted, bolt 36 passes through an aperture in end cap 17, and then an aperture in back piece 28. Nut 40 engages bolt 36 and draws the bolt and engagement piece 38 into abutting confrontation with an interior end surface of end cap 17. This serves to firmly engage annular flange 15 against shoulder portion 32 (and seal 30). Each of the mounting extensions, except for the centermost extension, is connected in an identical or similar manner. It will be understood that other mounting connections may be utilized and that the above-described mounting connection is only a preferred connection and is not intended to limit the invention to the specific version shown.

As shown, the light source 43 is preferably provided as an integrated assembly with lens 21. The assembly includes a holder or case 45 within which a suitable light bulb or other source 47 is mounted. Seal or grommet 23 allows the assembly to be detachably mounted in the aperture at rim 49. Rim 49 is an annular flange into which light source 43, and more particularly holder 45 is snapped for a fitting engagement using grommet 23.

Although a particular mounting connection has been described above, it is to be understood that other mounting connections may be used and incorporated herein according to the present invention. For example, selectively releasable, spring-loaded locking mechanisms may be utilized to reduce the number of discrete parts, i.e. bolt 36, engagement piece 38, and nut 40. An actuation button may be conveniently located adjacent one or each mounting extension for enabling an individual to selectively release the locking mechanism for applying/removing sun visor 10 to (from) a vehicle. There are numerous manners of providing a mechanical connection between the mounting extensions and an associated clearance light fixture, and many of such manners may be suitable for use in this invention.

In operation, the present invention provides a vehicle-mounted sun visor and method for mounting the same. The sun visor is versatile, rugged and extremely convenient for an owner of a vehicle to mount, use and enjoy. The method of mounting the sun visor of the present invention provides a quick and convenient means by which an individual, whether at a factory or manufacturing facility installing the sun visor as part of the vehicle's original equipment, or as an owner retrofitting the sun visor on a currently owned vehicle.

In order to mount the preferred sun visor upon a vehicle, the vehicle should be provided with a number of suitable and appropriately located clearance light fixtures, or similar features. Exemplary features are like the ones shown in sectional view at 24 in FIG. 5. Such clearance light features normally hold, surround or contain a light source or light bulb for providing illumination. Additionally, such clearance light fixtures normally include a lens which protects the light source held internally of the clearance light fixture.

If such a lens is provided on the clearance light fixture 24, it will typically first be removed. After removing or possibly adjusting the lens, the original light source (located internally of the clearance light fixture) may have to be removed. Alternatively, the same light source which is part of a truck cab's original lighting structure might be used as a light source on the sun visor. After removing the original light source in each of the clearance light fixtures, sun visor 10 is ready for mounting on the vehicle.

One aspect of the invention which is most convenient is the fact that sun visor 10 may be mounted on a vehicle using structure which is already in place on the vehicle, and without irreversible changes being made. That is, it is not necessary to provide any additional mounting features externally on the vehicle's body, e.g. drilled holes, mounting brackets and the like, for the purpose of mounting the sun visor. From this standpoint, the integrity of the vehicle's body is preserved.

In order to mount a sun visor according to the present invention, one must first insert each one of the mounting extensions 14 into an associated clearance light fixture 24. The mounting extensions are preferably dimensioned so that at least a portion thereof forms a snug fit with at least a part of the clearance light fixture. The mounting extensions are conveniently located so that each one lines up with a respective clearance light fixture along a central or longitudinal axis. Thus, it is contemplated that the insertion of each of the mounting extensions into a respective one of the clearance light fixtures would take place substantially simultaneously and along such central or longitudinal axis. Each mounting extension 14 should be inserted far enough into a respective clearance light fixture so that an annular shoulder 15 (FIG. 5) on the mounting extension comes into abutting contact with an annular flange portion 32 which forms part of the cab fixture or feature. This assists in forming the snug fit mentioned above. Seal 30 ensures that when mounting extension 14 is so inserted, the area internally of receptacle wall 26 is protected against the entry of water and other debris.

Additionally, it will be appreciated that the frusto-conical shape of the main body of mounting extension 14 may serve, in some particular clearance light fixture constructions, to exert a radially outwardly directed pressure upon the clearance light fixture, which, together with the mounting connection described above and below, may serve to more firmly mount the mounting extension on or within the clearance light fixture. In such instances, the receptacle into which mounting extension 14 is inserted could have a complementary shape.

Once the mounting extensions are inserted as described above, the methods preferably include applying a fastener or otherwise forcing or restraining the sun visor 10 in the direction of vehicle 16 to ensure that the visor remains securely held against the vehicle. More specifically, mounting connection 34 in FIG. 5 includes a bolt 36 and an engagement piece 38. The engagement piece may take the form of a standard washer which is suitably dimensioned to engage the interior surface of end cap 17. First, bolt 36 is inserted into the interior of mounting extension 14 so that it extends through: a) an aperture in end cap 17; and b) an aperture in back piece 28. Thereafter, a washer 39 and nut 40 are applied to the bolt end. Subsequent screw threaded advancement serves to draw the bolt, and hence engagement piece 38 into abutting confrontation with the interior surface of end cap 17.

Thereafter, light source 43 may be snapped or slid into place as the case may be. A suitable light aperture lens 21 such as that shown in FIG. 3 may be separately provided and fixed on or within each of light apertures 20 in visor body 12. It will be understood that each of the light aperture lenses may be separately provided and affixed on or within a respective one of the apertures, or that the light aperture lens may form an integral part of a light source (such as light source 43 in FIG. 5) by being provided on holder 45. The above operation is repeated for each of the mounting extensions as may be provided.

With sun visor 10 conveniently added to vehicle 16, the vehicle is configured for operation, and the occupant or occupants thereof are provided with a shaded area upon the windshield which greatly reduces the sun's blinding glare and heat buildup within the vehicle cabin.

The invention has been described in language more or less specific as to structural, methodological, or other aspects and features. It is to be more properly understood that the invention is not necessarily limited to the specific forms shown and described. Other equivalent structures and features may also be within the inventive concepts which are appropriately protected under the grant of patent rights being sought. The invention is therefore being claimed in an effort to define the invention but the various forms or modifications which the invention may take is difficult or impossible to define with certainty. Judgement must be utilized to properly interpret the scope of protection which is to be appropriately applied with regard to these new and inventive concepts.