THIS METHOD Field of the Invention

The present invention relates to a production method for a sunvisor which is used in motor vehicles such as automobiles, buses (passenger car), trucks, construction equipments in automotive sector in order to get protected from sun rays, and the sunvisor produced by this method.

Background of the Invention

In the existing situation weight of sunvisors and number of components are the issue. The labor intent is higher and, in the meantime manufacturing inefficiencies are another problem area.

Some patent applications has been observed related with this invention. One of these is the utility model application No. 2010/06735 titled "a modular sunvisor". In the abstract of this application, the following discloses: "The invention relates to a modular sunvisor (1 ) which prevents sun rays from falling on the eyes of the driver and the passenger. The sunvisor (1 ) according to the invention comprises a fixing bracket (2) fixed at the vehicle ceiling, a connection axle one end of which gets into the fixing bracket (2), a shaft holding bracket (4) into which the other end of the connection shaft (3) gets, a hook holding bracket (5) getting through the hook at the vehicle ceiling, a wire (6) on which the axle holder bracket (4) and the hook holder bracket (5) are fixed, one slot (7) in which the wire (6) is places wherein it further comprises two body pieces (7) being mounted on each other, and two covers (8) which frames the surfaces of the body pieces (7) which do not contact with each other. Modular sunvisor (1 ) is produced by assembling these pieces together. The US patent document No. US201 1012387, another application known in the state of the art discloses a sunvisor produced by the method of molding by injection.

The above mentioned applications and the state of the art do not disclose lamination of craft paper and cross linked polyethylene foam.

Consequently, there is a need for a development in the state of the art, due to the above mentioned disadvantages and the inefficiency of existing solutions about the subject.

Object of the Invention

The present invention aims at solving the disadvantages mentioned above, being developed inspiring from the existing conditions.

The object of the invention is to decrease the diversity of materials used in the internal parts of the sunvisor, enable the piece to be lighter, decrease laboring costs due to insufficient mounting pieces and increase production capacity, by means of the sunvisor which is produced by connecting the foam preferably made of polyurethane and cross linked polyethylene with preferably craft paper lamination in the mold.

Craft paper and lamination of the foam made of cross linked polyethylene material, used in the preferred embodiment of the invention, is used together in such an operation for the first time. The product obtained as a result of lamination both provides rigidity to the material and enables to decrease sub-materials used in the existing products and reduce the costs significantly. Also, as its production is practical, it makes a great contribution to capacity increase and significantly reduces laboring costs as mentioned before. Besides, the product gets lighter due to the low number of the used materials. The used materials are localized, because the weldable foam material (duflex) used in the previous products is exported from abroad and the prices are high for the unit product. What makes this exported product special is that it can make welding in high frequency machine. However, we can perform this welding in high frequency welding machines with craft paper and the foam made of cross linked polyethylene material that we use. We also make it cheaper by localizing the used product.

Structural and characteristic features and all advantages of the invention will be understood more clearly by the detailed description with references to the attributed figures; therefore evaluation should be made considering these figures and the detailed description.

Description of the Figures

Figure 1 shows the layers of the preferred embodiment of the sunvisor obtained as a result of the inventive method of production.

Piece References

1. Outer Layer

2. Foam

3. Paper

4. Filler Layer

The drawings must not be scaled and unnecessary details to understand the present invention may be neglected. Besides, the pieces which are at least widely identical or having functions at least widely identical are shown by the same numbers.

Detailed Description of the Invention This detailed description discloses the preferred embodiments of the invention for a better understanding of the subject without creating any limiting effects.

The sunvisor according to the invention is composed of 4 layers: outer layer (1 ), foam (2), paper (3) and filler layer (4). The outer layer (1 ) is made of PVC (polyvinyl chloride) and covers the sunvisor from outermost. The foam (2) is layer which is under the outer layer (1 ) and is laminated by the paper (3). The paper (3) is the layer laminated by the foam (2). Filler layer (4) is the innermost layer made of polyurethane material.

The sunvisor, the features of the layers of which are given above comprises the operation steps of: - laminating paper (3) and foam (2) to each other in lamination device,

placing the material containing paper (3) and foam (2) obtained by said lamination process into the mould in polyurethane injection machine,

- injecting the filler layer (4) made of polyurethane material into said mould, after placement,

removing the material in the mould out of the mould after injection, removing the flashes by means of emery, if there is flash on the material taken out of the mould,

- welding the outer layer (1 ) made of PVC material onto said filler layer (4) in the high frequency welding machine.

In a preferred embodiment of the invention, after welding the outer layer (1 ) made of PVC material onto the filler layer (4), the coating is notched and the flashes of the outer layer detaches by itself.

In the preferred embodiments of the invention, craft paper can be used as said paper (3). Besides, as equivalent to craft paper, testliner or fluting or craftliner type paper can also be used. Characteristics of these types of paper are given below:

Testliner type paper is the type of paper which is recycled paper based and has lower resistance to explosion and damp than craftliner paper than craftliner paper according to its class. Density of testliner paper ranges between 100-250 g/m ² .

Fluting type paper is produced from recycled paper, and is used in the curves of paper-based corrugated board (mid-layers (b+c+e wave)). As it was produced from hay, it is also known as hay paper. Density of fluting type paper ranges between 90-200 g/m ² . Craftliner type paper is produced from trees with soft wood such as pine, fir, spruce with long fiber, by sulphate process, and it has high endurance. Craftliner is cellulose-based and has more than 3.5 explosion index up to 400 gr/m ² , with high resistance to damp. The density of craftliner type paper ranges between 1 15-400 g/m ² .

In other preferred embodiments of the invention, foam (2) made of cross linked polyethylene (XLPE) or polyurethane or polyester or polypropylene material is used as said foam. For polyurethane material, diphenylmethane diisocyanate (MDI)) or (toluene diisocyanate (TDI)) can be used.

In the preferred embodiments of the invention, foam (2) may have open or close cell structure.

In another preferred embodiment of the invention, in the step of laminating paper (3) and foam (2) to each other in lamination device, lamination process is carried out by the infrared type hot melt method.

In the production method for sunvisor according to the invention, the method of laminating paper (3) and foam (2) to each other in lamination device by infrared type hot melt method is carried out like this: First of all, lamination device with infrared heating works with the principle of hot air blowing. The lamination device includes a head with 15 heating resistors. The air is blown by the help of a pump and the air passing through the hot resistor is heated. At the rear part of the device, there are two feeding parts one at the upper and the other at the lower part. Preferably, the XLPE (cross linked polyethylene) foam (2) that we produce is hanged on the upper feeding part in a roller shape. The paper (3) is hanged on the lower feeding part. Both the paper (3) and the foam (2) are passed through cylinders and are combined in front of the head including the resistors. Tensions of both materials are adjusted. The pressing cylinder is lowered to apply the proper pressure. Then, the head blowing hot air is approached to the connection point of the two materials and the lamination process starts. When the surface of the foam (2) made of XLPE material contacts with hot air, it melts and sticks to the paper (3) by passing through pressing cylinder. The product obtained after sticking is rolled to the shaft and the processes are completed.