Key fob device and method

• US 20070227866A1
• Filed: 03/30/2006
• Published: 10/04/2007
• Est. Priority Date: 03/30/2006
• Status: Active Grant

• Current Assignee: Chemetall GmbH (BASF SE), Strattec Security Corporation
• Original Assignee: Strattec Security Corporation
• Inventors: Dimig, Steven
• Granted Patent: US 7,897,888 B2
• Time in Patent Office: Days
• US Class Current: 200/302.200
• CPC Class Codes: E05B 19/0082 Keys or shanks being removably stored in a larger object, e.g. a remote control or a key fob general constructional details of electronic keys G07C9/00944
• CPC Class Codes: G07C 9/00944 Details of construction or manufacture
• CPC Class Codes: H01H 2011/0093 Standardization, e.g. limiting the factory stock by limiting the number of unique, i.e. different components
• CPC Class Codes: H01H 2219/028 Printed information
• CPC Class Codes: H01H 2221/004 U-shaped openings surrounding keys
• CPC Class Codes: H01H 2223/003 Membrane embracing all keys
• CPC Class Codes: H01H 2229/002 Screen printing
• CPC Class Codes: H01H 2229/02 Laser
• CPC Class Codes: H01H 2231/026 Car
• CPC Class Codes: H01H 2231/032 Remote control
• CPC Class Codes: H01H 9/0235 specially adapted for remote control, e.g. of audio or video apparatus
• CPC Class Codes: Y10T 29/49155 Manufacturing circuit on or in base

Abstract

A device and method for a key fob. The key fob device can include a housing, a lid defining one or more apertures, a circuit board including one or more switches, and a flexible film coupled to the housing and/or the lid. The flexible film can include one or more contact surfaces and stylized graphics.

Claims

1. A key fob comprising:

a housing;

a lid defining at least one aperture;

a circuit board including at least one switch positioned within the at least one aperture; and

a flexible film coupled to at least one of the housing and the lid, the flexible film including at least one contact surface, the at least one contact surface flexing when a force is applied in order to actuate the at least one switch.

2. The key fob of claim 1, wherein a portion of at least one of the flexible film and the lid transmits energy from a laser beam to a portion of the housing in order to seal at least one of the flexible film and the lid to the housing.

3. The key fob of claim 1, wherein the housing includes a hook and an elongated aperture, and wherein a mechanical key blade at least partially conceals the hook when inserted into the elongated aperture.

4. The key fob of claim 1, wherein the housing includes a removable battery access door.

5. The key fob of claim 4, wherein the battery access door is sealed to the housing with an o-ring.

6. The key fob of claim 1, wherein the flexible film includes silk screen-printed stylized graphics.

7. The key fob of claim 1, wherein the at least one switch includes at least one of a tact switch and a dome switch.

8. The key fob of claim 1, wherein at least one of the flexible film and the lid is coupled to the housing with at least one of a laser weld, a sonic weld, an adhesive, and a snap-fit connection.

9. The key fob of claim 1, wherein the lid defines up to seven apertures, the flexible film includes up to seven contact surfaces, and the circuit board includes up to seven switches.

10. The key fob of claim 1, wherein the lid includes a first number of apertures greater than a second number of contact surfaces and switches.

11. The key fob of claim 1, wherein the flexible film includes stylized graphics for a particular make of vehicle.

12. The key fob of claim 1, wherein the flexible film is coupled to the lid with at least one of a laser weld, a sonic weld, an adhesive, and injection molding the lid onto the flexible film.

13. A key fob comprising:

a housing;

a lid defining at least one aperture;

a circuit board including at least one switch positioned within the at least one aperture; and

at least one of a flexible film and the lid laser welded to the housing, a portion of at least one of the flexible film and the lid capable of transmitting energy from a laser to a portion of the housing.

14. The key fob of claim 13, wherein the flexible film includes at least one contact surface, wherein the at least one contact surface flexes when a force is applied in order to actuate the at least one switch, and wherein the flexible film includes stylized graphics for a particular make of vehicle.

15. The key fob of claim 14, wherein the lid defines up to seven apertures, the flexible film includes up to seven contact surfaces, and the circuit board includes up to seven switches.

16. The key fob of claim 14, wherein the lid includes a first number of apertures greater than a second number of contact surfaces and switches.

17. The key fob of claim 13, wherein the housing includes a hook and an elongated aperture, and wherein a mechanical key blade at least partially conceals the hook when inserted into the elongated aperture.

18. The key fob of claim 13, wherein the housing includes a removable battery access door.

19. The key fob of claim 18, wherein the battery access door is sealed to the housing with an o-ring.

20. The key fob of claim 13, wherein the flexible film includes silk screen-printed stylized graphics.

21. The key fob of claim 13, wherein the at least one switch includes at least one of a tact switch and a dome switch.

22. The key fob of claim 13, wherein at least one of the flexible film and the lid is coupled to the housing with at least one of a laser weld, a sonic weld, an adhesive, and a snap-fit connection.

23. The key fob of claim 13 wherein the flexible film is coupled to the lid with at least one of a laser weld, a sonic weld, an adhesive, and injection molding the lid onto the flexible film.

24. A key fob comprising:

a housing including a hook and an elongated aperture;

an lid defining at least one aperture;

a circuit board including at least one switch positioned within the at least one aperture; and

a mechanical key blade removably coupled to the housing, the mechanical key blade at least partially concealing the hook when inserted into the elongated aperture.

25. The key fob of claim 24, further comprising a flexible film coupled to at least one of the housing and the lid, the flexible film including at least one contact surface, the at least one contact surface flexing when a force is applied in order to actuate the at least one switch, the flexible film including stylized graphics for a particular make of vehicle.

26. The key fob of claim 25, wherein at least one of the flexible film and the lid is coupled to the housing with at least one of a laser weld, a sonic weld, an adhesive, and a snap-fit connection.

27. The key fob of claim 25, wherein the lid defines up to seven apertures, the flexible film includes up to seven contact surfaces, and the circuit board includes up to seven switches.

28. The key fob of claim 25, wherein the lid includes a first number of apertures greater than a second number of contact surfaces and switches.

29. The key fob of claim 25, wherein a portion of at least one of the flexible film and the lid transmits energy from a laser beam to a portion of the housing in order to seal at least one of the flexible film and the lid to the housing.

30. The key fob of claim 24, wherein the housing includes a removable battery access door.

31. The key fob of claim 30, wherein the battery access door is sealed to the housing with an o-ring.

32. The key fob of claim 24, wherein the flexible film includes silk screen-printed stylized graphics.

33. The key fob of claim 24, wherein the at least one switch includes at least one of a tact switch and a dome switch.

34. The key fob of claim 24, wherein the flexible film is coupled to the lid with at least one of a laser weld, a sonic weld, an adhesive, and injection molding the lid onto the flexible film.

35. A key fob comprising:

a housing;

a lid defining a plurality of apertures;

a circuit board including at least one switch positioned in at least one of the plurality of apertures; and

a flexible film coupled to at least one of the housing and the lid and defining at least one contact surface;

a first number of the at least one switch being equal to a second number of the at least one contact surface, the first number and the second number not being equal to a third number of the plurality of apertures.

36. The key fob of claim 35, wherein a portion of at least one of the flexible film and the lid transmits energy from a laser beam to a portion of the housing in order to seal at least one of the flexible film and the lid to the housing.

37. The key fob of claim 35, wherein the housing includes a hook and an elongated aperture, and wherein a mechanical key blade at least partially conceals the hook when inserted into the elongated aperture.

38. The key fob of claim 35, wherein the housing includes a removable battery access door.

39. The key fob of claim 38, wherein battery access door is sealed to the housing with an o-ring.

40. The key fob of claim 35, wherein the flexible film includes silk screen-printed stylized graphics.

41. The key fob of claim 35, wherein the at least one switch includes at least one of a tact switch and a dome switch.

42. The key fob of claim 35, wherein at least one of the flexible film and the lid is coupled to the housing with at least one of a laser weld, a sonic weld, an adhesive, and a snap-fit connection.

43. The key fob of claim 35, wherein the lid defines up to seven apertures, the flexible film includes up to seven contact surfaces, and the circuit board includes up to seven switches.

44. The key fob of claim 35, wherein the flexible film is coupled to the lid with at least one of a laser weld, a sonic weld, an adhesive, and injection molding the lid onto the flexible film.

45. A method of producing a key fob, the method comprising:

printing stylized graphics on a flexible film;

positioning a circuit board in a housing;

coupling the flexible film to a lid;

positioning the lid in the housing; and

coupling at least one of the flexible film and the lid to the housing.

46. The method of claim 45, further comprising coupling at least one switch to the circuit board and positioning the at least one switch in at least one aperture of the lid.

47. The method of claim 45, further comprising maintaining the housing in a first position until the at least one of the flexible film and the lid is sealed to the housing.

48. The method of claim 47, further comprising moving the housing to a second position in order to couple a battery door to the housing.

49. The method of claim 45, further comprising coupling an o-ring to a battery access door.

50. The method of claim 49, further comprising coupling the battery access door to the housing such that the o-ring seals the battery access door against the housing.

51. The method of claim 45, further comprising injection molding the lid onto the flexible film.

52. The method of claim 45, further comprising coupling at least one of the flexible film and the lid to the housing by using at least one of a laser weld, a sonic weld, adhesive, or a snap-fit connection.

53. The method of claim 45, further comprising selecting a stylized graphic arrangement depending on a make of a vehicle.

54. A method of producing a key fob, the method comprising:

selecting a stylized graphic depending on a make of a vehicle;

printing the stylized graphic on a flexible film sheet;

cutting an individual flexible film from the flexible film sheet;

coupling the individual flexible film to a lid;

positioning the lid in a housing; and

coupling at least one of the individual flexible film and the lid to the housing.

55. The method of claim 54, further comprising positioning a circuit board in a housing.

56. The method of claim 54, further comprising maintaining the housing in a first position until the individual flexible film is sealed to at least one of the housing and the lid.

57. The method of claim 56, further comprising moving the housing to a second position in order to couple a battery door to the housing.

58. The method of claim 54, further comprising coupling an o-ring to a battery access door.

59. The method of claim 58, further comprising coupling the battery access door to the housing such that the o-ring seals the battery access door against the housing.

60. The method of claim 54, further comprising injection molding the lid onto the individual flexible film.

61. The method of claim 54, further comprising coupling at least one of the individual flexible film and the lid to the housing by using at least one of a laser weld, a sonic weld, adhesive, or a snap-fit connection.