Key assemblies and methods of making same

Details Key assemblies and methods of making same Key assemblies and methods of making same

1997-10-09

2001-10-30

Boucher, Darnell (Department: 3627)

Locks

Operating mechanism

Key

C070S460000, C070S278300, C340S870030

Reexamination Certificate

active

06308542

ABSTRACT:

FIELD OF THE INVENTION
The invention relates to a key assembly containing an electronic transponder mounted therein, and to methods of making the key assembly. The transponder may be employed for theft deterrence and for control of various circuits in a mechanism in which the key assembly may be selectively inserted and removed.
BACKGROUND OF THE INVENTION
In recent years, it has become common to provide key assemblies which have devices therein which either generate a coded signal or are sensitive to an outside code reading mechanism which reads the code contained in each key assembly's device. One such device may be an electronic transponder. A common use in recent years has been in a motor vehicle ignition key and lock arrangement.
When the key assembly is inserted in its receiving mechanism, such as an ignition key lock, the code embedded in or emitted by the transponder of the key assembly is matched with a corresponding code detector to permit the key to unlock the lock so that the vehicle engine ignition system may be actuated. Actuation of the key may also unlock a steering shaft lock which has prevented the steering wheel from being moved, and it may unlock a lock installed in an electrical circuit or a door or the like which is locked.
Should a key assembly which does not provide a proper code signal be inserted in the lock, the code detector may actuate any controlled unlocked locks. It may actuate a theft warning device, interior and/or exterior lights, and render a starter mechanism inoperative, by way of example.
Numerous patents have been issued on this general subject, the more pertinent ones known to the inventor of the invention claimed herein showing conventional transponder key assemblies being the U.S. Pat. No. 5,433,096—Janssen et al (1995) and U.S. Pat. No. 5,632,168—Yano (1997). The list below includes these patents and less pertinent patents and publications disclosing conventional transponder key assemblies or other broadly related arrangements being the following, listed in patent number order in the case of the U.S. patents:
U.S. Pat. No. 4,200,227—Lemelson (1980); U.S. Pat. No. 4,257,030—Bruhin et al (1981); U.S. Pat. No. 4,287,735—Brunken et al (1981); U.S. Pat. No. 4,663,952—Gelhard (1987); U.S. Pat. No. 4,858,453—Namazue (1989); U.S. Pat. No. 4,922,736—Tanaka et al (1990); U.S. Pat. No. 4,924,686—Vonlanthen (1990); U.S. Pat. No. 4,947,662—Imedio (1990); U.S. Pat. No. 5,003,801—Stinar et al (1991); U.S. Pat. No. 5,038,590—Sawyer (U.S. Pat. No. 5,083,362—Edgar et al (1992); U.S. Pat. No. 5,156,032—Edgar (1992); U.S. Pat. No. 5,195,341—Nieuwkoop (1993); U.S. Pat. No. 5,307,658—Kokubu et al (1994); U.S. Pat. No. 5,311,757—Spahn (1994); U.S. Pat. No. 5,337,588—Chhatwal (1994); U.S. Pat. No. 5,433,096—Janssen et al (1995); U.S. Pat. No. 5,461,386—Knebelkamp (1995); U.S. Pat. No. 5,469,727—Spahn et al (1995); U.S. Pat. No. 5,532,522—Dietz et al (1996); U.S. Pat. No. 5,561,420—Kleefeldt et al (1996); U.S. Pat. No. 5,561,430—Knebelkamp (1996); and U.S. Pat. No. 5,632,168—Yano (1997).
Also, PCT International Publication No. WO 87/00234 published Jan. 15, 1987; European Patent Office published summary of a German-language application filed Jun. 26, 1991, claiming priority as of Dec. 22, 1989, and identified as Veröffentichungsnummer: 0 434 176 A1; Japanese Patent Application Publication Nos. 2-164647 (1990) and 4-11179 (1992); and UK Patent Application GB 2 155 988 A published on Oct. 2, 1985.
SUMMARY OF THE INVENTION
A key assembly embodying one aspect of the invention includes a key blank having a particular construction on one end in which a transponder and a transponder holder are mounted, and a key head cover molded over the portion of the key blank in which the transponder and its holder are mounted. The key blank has a head section and a shank section, with a portion connecting those two sections. While various key shank sections may be employed, their precise construction is not a part of this invention. Therefore, the invention is shown with a simple shank section connected to the head section and having a simple key profile. It is to be understood that other known key shank section shapes, both in cross section and in profile, may be employed in a key assembly embodying the invention. The shank section of the illustrative key therefore includes that part of the key typically having a profile which cooperates with the mechanical portion of the lock to release the locking mechanism when the key shank profile mates with the lock profile and the key is rotated. Such key shank sections, once cut to a specific profile, are used in most cylindrical locks of the type commonly used in automotive vehicle doors and ignition systems, as well as many keys fitting locks for doors in buildings.
More particularly relating to the invention, the head end of the key blank is shaped to provide a pair of legs defining, with the inner axial end of the key shank, a generally U-shaped recess configuration with the open end of the recess extending in an opposite axial direction on the key blank from the shank end of the key. The transponder holder is snap-fitted within the U-shaped recess after the transponder has been fitted within the transponder holder and is resiliently supported within that holder. The portions of the transponder holder which are engaged with the key blank legs also are resiliently connected to the portion of the transponder holder which resiliently supports the transponder.
The key blank legs are preferably provided with protrusions which mate with corresponding depressions or openings formed in the transponder holder so that the snap-fitted action of the transponder holder in relation to the legs occurs when the transponder holder is inserted into position between the key blank legs until the protrusions mate with their corresponding openings.
It is another feature of the invention that the transponder holder depressions or openings are within the bottom portions of channels defined along the edges of the transponder holder, with the laterally inwardly extending edges of the key blank legs being received in sliding relation in said channels as the transponder holder is moved into its snap-fitted position within the U-shaped recess. The side portions of the channels engage the sides of portions of the key blank legs and minimize any movement of the holder in any direction which is substantially perpendicular to the direction of sliding movement assembly of the transponder holder to the legs of the key blank. This is particularly important from the time that the transponder and its holder are inserted in place in the key blank until the key head cover is molded about the key head and the transponder and its holder, permanently securing them in place in relation to the key head.
Another feature of the invention is provided wherein the transponder holder is fabricated of a suitable plastic material which is sufficiently stiff at its channels and at its transponder mounting section to hold the transponder in a precisely defined position in the key blank while also having resilient sections which provide a resilient mounting arrangement between the transponder and its mounting section and also provides a resilient mounting arrangement between the transponder mounting section and its channels. It is particularly desirable, and is a feature of the invention that is preferably used, wherein the transponder mounting section of the transponder holder is resiliently supported in cantilever spring fashion by the transponder holder legs and their spring connections to the transponder mounting section. This resilient support is particularly advantageous when the transponder and its holder are assembled together and handled as a subassembly before being installed into the key blank head section having the U-shaped recess, as well as the subassembly of the transponder, transponder holder and the key blank before the key head in molded in place.
Another feature of the invention resides in the molding of the key head cover over the key head end, including legs

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