Automated sun visor for vehicles

[0001] The present invention was first described in and claims the benefit of U.S. Provisional Application No. 61/292,999 filed Jan. 7, 2010, the entire disclosures of which are incorporated herein by reference.

[0002] The present invention relates generally to deployable automobile sun visors, and in particular, to a motorized deployable automobile sun visor with an electronic control.

[0003] Bright sunlight is a prominent cause of poor visibility, distraction, and discomfort when driving an automobile. In a case where a driver is forced to drive towards the sun, particularly during sunny periods and periods where the sun is low in the sky, bright sunlight is directly incident upon the driver's field of vision. This causes discomfort due to the high intensity of the light and decreased visibility when attempting to look in a direction near the sun.

[0004] A common solution to decrease direct incident sunlight and increase visibility during such conditions is the use of automobile sun visors. These visors commonly pivot downwardly from a front roof position of the automobile and provide an opaque shield to a top portion of the windshield while leaving the direct-forward view unhindered. In most cases, the sun is high enough in the sky that such visors block a significant portion of the incident rays.

[0005] However, use of such visors contributes to what is possibly the most significant safety concern in the field of automobiles—attempting to operate or focus on non-driving manual tasks while driving a vehicle. Such distractions are a leading cause of accidents and injuries. The deployment of a sun visor is such a distraction in and of itself; however, in particular, the adjustment of the visor once it is deployed is particularly troublesome. This is due to the fact that the driver generally must look directly at the visor in order to dislodge it and position it in a desired spot, thereby taking their eyes off of the road ahead for a period of time.

[0006] Various attempts have been made to provide automatic vehicle shade or visor assemblies. Examples of these attempts can be seen by reference to several U.S. patents, including U.S. Pat. No. 3,226,151; U.S. Pat. No. 3,343,868; U.S. Pat. No. 4,178,035; U.S. Pat. No. 4,468,062; U.S. Pat. No. 5,298,732; U.S. Pat. No. 5,873,621; and U.S. Pat. No. 6,318,788.

[0007] While these apparatuses fulfill their respective, particular objectives, each of these references suffer from one (1) or more of the aforementioned disadvantages. Many such apparatuses are not adapted for use with both a windshield and a side window portion of a vehicle. Also, many such apparatuses are not readily retrofittable to existing vehicles and require installation by the original manufacturer. Furthermore, many such apparatuses are not adjustable or movable once installed. In addition, many such apparatuses do not provide simple controls which can be selectively located by the driver for ease of access during driving. Accordingly, there exists a need for an automated sun visor for motor vehicles without the disadvantages as described above. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.

[0008] In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for an automated sun visor for a motor vehicle which is utilizable with existing vehicles in a variety of adjustable configurations to allow a user to safely and automatically provide sun protection while driving, according to their preference. Thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.

[0009] To achieve the above objectives, it is an object of the present invention to provide an automated electrically deploying sun visor for a motor vehicle in order to reduce sun radiation through a windshield or window. The system comprises a housing enclosure, a motor, and a switch.

[0010] Another object of the present invention is to allow a user to retrofit the system to an existing vehicle. The system can also be incorporated into the original equipment of a desired vehicle during manufacturing.

[0011] Yet still another object of the present invention is to replace a conventional sun visor on a driver side portion of a desired vehicle. The system is installed adjacent to the front windshield on an interior portion of the vehicle between a head liner and the roof of the vehicle. In this position, the system also provides shade to a steering wheel to prevent excessive heating of the steering wheel while driving.

[0012] Yet still another object of the present invention is to provide unobtrusive and customizable positioning of the housing enclosure within a motor vehicle. The housing enclosure comprises a flat generally rectangular structure which is attachable to an underside of the roof, preferably with a plurality of threaded studs and nuts. The studs can be installed in a desired position and orientation along the roof so as to retain the housing enclosure flush against the roof and minimize the amount of space disrupted by the system.

[0013] Yet still another object of the present invention is to provide a shading visor extendable from within the housing enclosure. The visor is constructed of a semi-rigid plastic which provides slight flexibility and allows the visor to conform to the profile of a windshield or window during deployment.

[0014] Yet still another object of the present invention is to enable the visor to move smoothly along the windshield or window during deployment by providing a slightly rounded front edge. This front edge also inhibits the visor from retracting entirely within the housing enclosure.

[0015] Yet still another object of the present invention is to provide even, secure, and controlled motorized motioning of the visor using the motor, a pair of gears, and a plurality of guiding pins within the enclosure. When the motor is actuated, it motions the gears which engage a corresponding toothed exterior track integrally molded within the visor. The visor is secured in a vertical position by the pins to prevent disruptive motion of the visor within the enclosure.

[0016] Yet still another object of the present invention is to allow a user to deploy or retract the visor in an electronically controlled manner using a microprocessor control unit located adjacent to the housing enclosure.

[0017] Yet still another object of the present invention is to allow a user to relay control signals to the control unit using a bi-directional switch. The switch can be installed in a desired location along a dashboard, a steering wheel, a door panel, or the like to facilitate safe use by a driver while operating a vehicle. The switch and control unit are interconnected to the vehicle's wiring harness with an appropriately gauged electrical wiring.

[0018] Yet still another object of the present invention is to allow a user to position the housing enclosure in such a manner that deployment of the visor provides shade within a side window of the vehicle.

[0019] Yet still another object of the present invention is to provide a method of utilizing the device that provides a unique means of acquiring the system; if retrofitting the system, removing the existing sun visors from the drivers-side portion in a desired vehicle, removing the head liner, installing the studs to the roof, fastening the housing enclosure to the studs with the nuts, and installing the switch to a desired location; routing electrical wiring from the control unit to the switch and to the vehicles wiring harness; depressing the switch to extend or retract the visor; repeating the abovementioned process to install the system on various locations in the vehicle; and, enjoying glare free driving in vehicles.

[0020] Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.

• • [0028] 10 automated sun visor for a motor vehicle
  • [0029] 15 driver
  • [0030] 17 sun radiation
  • [0031] 20 visor
  • [0032] 21a housing enclosure
  • [0033] 21b upper panel
  • [0034] 21c side panel
  • [0035] 21d rear panel
  • [0036] 21e front panel
  • [0037] 21f opening
  • [0038] 21g bottom panel
  • [0039] 22 ear
  • [0040] 23 aperture
  • [0041] 24 stud
  • [0042] 25 nut
  • [0043] 30 track
  • [0044] 35 visor front edge
  • [0045] 50 motor
  • [0046] 51 shaft
  • [0047] 52 side groove
  • [0048] 53 gear
  • [0049] 54 intermediate pin
  • [0050] 55 rear pin
  • [0051] 60 switch
  • [0052] 65 electrical wiring
  • [0053] 67 control unit
  • [0054] 70 driver-side portion
  • [0055] 71 side window
  • [0056] 72 front windshield
  • [0057] 74 steering wheel
  • [0058] 75 head liner
  • [0059] 76 roof
  • [0060] 78 dashboard
  • [0061] 80 alternate embodiment

[0062] The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 and alternately within FIG. 6. However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.

[0063] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.

[0064] The present invention describes an automated sun visor for a motor vehicle (herein described as the “system”) 10, which provides a means for electrically deploying at least one (1) sun visor 20 in a vehicle. The system 10 is preferably a part of the original equipment of a desired vehicle, yet may also be retrofitted without limiting the scope of said system 10. The system 10 is preferably utilized on the driver-side portion 70 in the vehicle to reduce sun radiation 17 from the front windshield 72 in a simple but high-tech manner for the safety of not just the driver 15 of a motor vehicle but all surrounding motorists and pedestrians as well. The system 10 may also be installed in various other positions within the vehicle such as the side window 71 (see FIG. 6) or the like.

[0065] Referring now to FIG. 1, an environmental view of the system 10 depicting an active state within a vehicle, according to the preferred embodiment of the present invention, is disclosed. The system 10 replaces a conventional sun visor utilized on the driver side portion 70 of the desired vehicle. The system 10 is installed adjacent to the front windshield 72 on an interior portion of the vehicle particularly between the head liner 75 and the roof 76. During the original equipment manufacturing process of the vehicle an opening should be left vacant between the head liner 75 and the roof 76 nearest to the windshield 72 to enable the visor 20 to freely deploy and retract. The system 10 comprises a housing enclosure 21a, a motor 50, and a switch 60, and other mechanical and electrical components as mentioned herein below. The system 10 is preferably installed above the front windshield 72 to eliminate sun radiation 17 which is directed to the driver 15 in multiple directions during driving. The visor 20 reduces the sun radiation 17 from the driver 15 by blocking a portion of the windshield 72 similar to conventional vehicle sun visors, yet in an electrically deployable manner. The visor 20 also reduces the steering wheel 74 from becoming overly heated by reducing sun radiation 17 from coming in contact with said steering wheel 74. The visor 20 is fabricated from a semi-rigid plastic and made available in a variety of colors and designs to complement the existing vehicle interior.

[0066] Referring now to FIG. 2, a perspective view of the system 10 depicting a slightly deployed state, according to the preferred embodiment of the present invention, is disclosed. The housing enclosure 21a comprises a six-sided rectangular shape further including an upper panel 21b, a pair of side panels 21c, a rear panel 21d, a front panel 21e, and a bottom panel 21g. The housing enclosure 21a is fabricated from materials such as metal or plastic. The housing enclosure 21 is preferably manufactured in various dimensions to accommodate various vehicles. Each opposing longitudinal perimeter edge of the side panels 21c comprises a pair of ears 22 which are utilized to secure said housing enclosure 21 to an underside surface of the roof 76, above the head liner 75. Threaded studs 24 are attached to the underside surface of the roof 76 by common welding techniques and align with an aperture 23 located on each ear 22. Each stud 24 is inserted into each aperture 23 and a common nut 25 secures to said stud 24 to further secure the housing enclosure 21 to a fixed position. Other attachment means may also be utilized without limiting the scope of the system 10.

[0067] Referring now to FIG. 3, another perspective view of the system 10 depicting a removed upper panel and a slightly deployed state and FIG. 4, a bottom perspective view of the system 10 depicting a slightly deployed state, according to the preferred embodiment of the present invention, are disclosed. Internally, the housing enclosure 21a comprises the visor 20, a motor 50, a shaft 51, and a pair of gears 53. A portion of the visor 20 is depicted as being cut-away for illustration purposes only. The visor 20 is fabricated from a semi-rigid plastic material with shading or shielding characteristics as abovementioned which provides a flexibility to conform to the shape of the windshield 72 when deployed. The visor 20 is preferably a length similar to the housing enclosure 21a and a width slightly smaller than said housing enclosure 21a. The visor 20 is deployed from an opening 21f on the front panel 21e of the housing enclosure 21a which comprises dimensions slightly larger than the dimensions of the visor 20. A proximal perimeter edge of the visor 20 comprises a visor front edge 35 which enables said visor 20 to move smoothly with the curvature of the front windshield 72. The visor front edge 35 is integral to the visor 20 and comprises a slightly rounded shape which also prohibits the visor 20 from being retracted completely within the housing enclosure 21a due to the fact that the visor front edge 35 is slightly larger than the opening 21f.

[0068] Each opposing intermediate perimeter edges and the distal perimeter edge of the visor 20 comprises an intermediate pin 54 and a rear pin 55, respectively which are integral to said visor 20. The rear pin 55 spans an entire rear edge of the visor 20. The pins 54, 55 engage a side groove 52 which is located on an inner surface of each side panel 21c to enable the visor 20 to be retracted and deployed in an even and secured manner. The intermediate pins 54 also prohibit the visor 20 from coming completely deployed from the housing enclosure 21a because said intermediate pins 54 come in contact with a rear portion of the opening 21f upon the front panel 21e.

[0069] The motor 50 and the pair of gears 53 are oriented below a proximal portion of the visor 20 and are secured about a shaft 51 mounted to interior surfaces of said pair of side panels 21c. The motor 50 is comprised of a conventional direct current (DC) motor, yet other similar devices may be utilized without limiting the scope of the system 10. The gears 53 comprise a toothed exterior surface which engages a corresponding toothed track 30. The track 30 is located on an underside surface of the visor 20 and is integrally molded into said visor 20. The motor 50 rotates the shaft 54 which concurrently rotates each gear 53 to retract or deploy the visor 20 wherein the intermediate pins 54 and rear pin 55 slide laterally within the side grooves 52. The visor 20, motor 50, and gears 53 are interconnected via electrical wiring 65 to a switch 60 and a control unit 67 which enables the driver 15 to deploy or retract said visor 20 as necessary. The control unit 67 is depicted within FIG. 1 as being located between the head liner 75 and the roof 76, yet other locations may be utilized without limiting the scope of the system 10. The control unit 67 is comprised of a microprocessor or the like and other similar electronics that will relay the state of the switch 60 (see FIG. 5) to the motor 50 to correspondingly retract or deploy the visor 20 from the housing enclosure 21a.

[0070] Referring now to FIG. 5, an environmental view of a vehicle interior, according to the preferred embodiment of the present invention, is disclosed. The switch 60 is preferably located on the dashboard 78 of the vehicle, yet other positions may be utilized such as, but not limited to: the steering wheel 74, the door panel, or the like. The switch 60 is interconnected to the motor 50 and control unit 67 as abovementioned, yet is also routed to the vehicles wiring harness via appropriately gauged electrical wiring 65 to supply the system 10 with power. The switch 60 is comprised of a conventional single pole double throw switch, yet other switching devices may be utilized such as, but not limited to: a toggle switch, a pushbutton, or the like. The switch 60, in use, is depressed in one (1) direction to deploy the visor 20 to a desired length and may depressed in an opposing direction to retract said visor 20. In a retrofit embodiment the switch 60 would be attached to a desired area upon the dashboard 78 with attachment means such as, but not limited to: mechanical fasteners, adhesives, or the like.

[0071] Referring now to FIG. 6, an environmental view of an alternate embodiment 80 positioned about a side window 71 and depicting an active state within a vehicle, according to the alternate embodiment of the present invention, is disclosed. As abovementioned the system 10 may alternately be utilized for a side window 71 particularly on the driver-side portion 70. The alternate embodiment 80 would block sun radiation 17 from the driver 15 upon a side orientation. The alternate embodiment 80 is preferably original equipment to the vehicle, yet may also be retrofitted to a desired vehicle without limiting the scope of the system 10. To be arranged for utilization on the side window 71, the system 10 is turned ninety degrees (90°) with the front panel 21e toward said side window 71. Internally, the system 10 would remain as abovementioned and the switch 60 may also remain upon the dashboard 78.

[0072] It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.

[0073] The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10, it would be installed as indicated in FIG. 1.

[0074] The method of utilizing the system 10 as an original equipment embodiment may be achieved by performing the following steps: acquiring the system 10; depressing the switch 60 to send a signal to the control unit 67 to activate the motor 50, rotating the shaft 51 and gears 53 which engage the tracks 30 to extend the visor 20 to a desired length to block sun radiation 17 from the driver 15 on the front windshield 72; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.

[0075] The method of utilizing the system 10 as a retrofit may be achieved by performing the following steps: acquiring the system 10; removing the existing sun visors from the drivers-side portion 70 in a desired vehicle; removing the head liner 75; installing the studs 24 to the roof 76; fastening the housing enclosure 21a to the studs 24 with the nuts 25 with the front panel 21e toward the front windshield 72; altering the head liner 75 to enable the visor 20 to retract and deploy in an expected manner; reinstalling the head liner 75; installing the switch 60 to a desired location; routing electrical wiring 65 from the control unit 67 to the switch 60 and to the vehicles wiring harness; repeating the abovementioned process to install the system 10 on various locations in the vehicle; depressing the switch 60 to extend the visor 20 to a desired length; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.

[0076] The alternate embodiment 80 of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10, it would be installed as indicated in FIG. 6.

[0077] The method of utilizing the alternate embodiment 80 as original equipment may be achieved by performing the following steps: acquiring the alternate embodiment 80; depressing the switch 60 to send a signal to the control unit 67 to activate the motor 50, rotating the shaft 51 and gears 53 which engage the tracks 30 to extend the visor 20 to a desired length to block sun radiation 17 from the driver 15 on the side window 71; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.

[0078] The method of utilizing the alternate embodiment 80 as a retrofit may be achieved by performing the following steps: acquiring the alternate embodiment 80; removing the existing sun visors from the drivers-side portion 70 in a desired vehicle; removing the head liner 75; installing the studs 24 to the roof 76; fastening the housing enclosure 21a to the studs 24 with the nuts 25 with the front panel 21e toward the front windshield 72; altering the head liner 75 to enable the visor 20 to retract and deploy in an expected manner; reinstalling the head liner 75; installing the switch 60 to a desired location; routing electrical wiring 65 from the control unit 67 to the switch 60 and to the vehicles wiring harness; repeating the abovementioned process to install the alternate embodiment 80 on various locations in the vehicle; depressing the switch 60 to extend the visor 20 to a desired length; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.

[0079] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.