Key assembly for vehicle ignition locks

• US 6,367,298 B1
• Filed: 09/14/1998
• Issued: 04/09/2002
• Est. Priority Date: 08/26/1993
• Status: Expired due to Fees

• Current Assignee: Strattec Security Corporation
• Original Assignee: Strattec Security Corporation
• Inventors: McGuire, Ronald J., Niles, Glenn A., Janssen, David C., Reetz, Brian J.
• Primary Examiner(s): Gall, Lloyd A.
• Application Number:
  US09/152,924
• Time in Patent Office: 1,303 Days
• Field of Search: 704/08, 702/781, 702/782, 702/783, 702/784, 702/785, 702/786, 702/787, 702/791, 702/831, 702/76, 702/77, 702/80--83, 703/95, 704/13
• US Class Current: 70/278.3
• CPC Class Codes: E05B 19/04 Construction of the bow or head of the key; Attaching the bow to the shank
• CPC Class Codes: G06K 19/04 characterised by the shape
• CPC Class Codes: G06K 19/048 the record carrier being shaped as a key
• CPC Class Codes: G07C 9/00944 Details of construction or manufacture
• CPC Class Codes: Y10T 70/7079 Key rotated [e.g., Eurocylinder]
• CPC Class Codes: Y10T 70/7802 Multi-part structures
• CPC Class Codes: Y10T 70/7876 Bow or head
• CPC Class Codes: Y10T 70/7904 Magnetic features

Abstract

A key assembly for mounting an electronic component in the head of the key. The electronic component is mounted in either an opening such as a bore or recess formed in the key head, or a carrier connected to the heel end of the key shank. In the former case, a closure member such as a plug or adhesively backed panel member is employed to close off the opening. In the latter case, the carrier is encapsulated within a plastic key head.

Claims

1. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier to the heel end of said key;

molding a transponder-receiving cage in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the cage of the plastic carrier after the carrier has been molded onto the heel end of the key; and

molding an outer shell over said transponder and the carrier.

2. The method of claim 1, wherein said outer shell is molded of a material that is softer than the material of the plastic carrier.

3. The method of claim 1, wherein molding the transponder-receiving cage in the carrier includes forming flexible supports in the carrier near first and second ends of the cage for supporting said transponder within the cage only near said first and second ends of the cage prior to molding the outer shell over the transponder and the carrier.

4. The method of claim 1, wherein the step of inserting the transponder includes supporting the transponder within the cage with an outer surface of the transponder spaced from an inner surface of the cage prior to molding the outer shell.

5. The method of claim 4, including causing a portion of the material of the outer shell to flow between the outer surface of the transponder and the inner surface of the cage to provide a layer of cushioning material substantially surrounding the transponder.

6. The method of claim 1, including causing a layer of cushioning material to be formed between an outer surface of the transponder and an inner surface of the cage for substantially surrounding the transponder.

7. The method of claim 1, wherein molding the cage includes molding a plurality of spaced bars each which having an inner surface, molding thin flexible membranes integrally with certain ones of the bars, and wherein the step of inserting the transponder includes using the membranes for supporting the transponder within the cage with an outer surface of the transponder spaced from the inner surfaces of the bars prior to molding the outer shell.

8. The method of claim 1, wherein molding the cage includes forming first and second flexible membranes near first and second ends of the cage for resiliently supporting the transponder.

9. The method of claim 1, including causing a layer of cushioning material to be formed between an outer surface of the transponder and an inner surface of the cage for substantially surrounding the transponder, the cushioning material being a softer material than the material of the carrier.

10. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier to the heel end of said key;

molding a transponder-receiving cage in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the cage of the plastic carrier; and

molding an outer shell over said transponder and the carrier, wherein the outer shell is molded of a material that is different from the material of the plastic carrier.

11. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier to the heel end of said key;

molding a transponder-receiving cage in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the cage of the plastic carrier; and

molding an outer shell over said transponder and the carrier, wherein forming the cage includes forming openings in the cage for causing a portion of the material of the outer shell to flow between an outer surface of the transponder and an inner surface of the cage during molding of the outer shell.

12. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier of a first material to the heel end of said key;

molding a transponder-receiving opening in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the opening of the plastic carrier after the plastic carrier has been molded onto the heel end of the key; and

molding an outer shell of a second material over said transponder and the carrier.

13. The method of claim 12 wherein the second material is softer than the first material.

14. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier of a first material to the heel end of said key;

molding a transponder-receiving opening in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the opening of the plastic carrier after the plastic carrier has been molded onto the heel end of the key; and

molding an outer shell of a second material over said transponder and the carrier,

is wherein molding the transponder-receiving opening in the carrier includes forming supports in the carrier for supporting said transponder within the opening prior to molding the outer shell over the transponder and the carrier.

15. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier of a first material to the heel end of said key;

molding a transponder-receiving opening in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the opening of the plastic carrier;

molding an outer shell of a second material over said transponder and the carrier; and

causing a portion of the material of the outer shell to flow between an outer surface of the transponder and an inner surface of the opening to provide a layer of cushioning material substantially surrounding the transponder.

16. A method of making a key for a lock, comprising the steps of:

providing a key having a heel end;

molding a plastic carrier of a first material to the heel end of said key;

molding a transponder-receiving opening in the carrier simultaneously with the molding of the carrier;

inserting a transponder into the opening of the plastic carrier; and

molding an outer shell of a second material over said transponder and the carrier,

wherein the second material is different from the first material.