OVERMOLDED KEY ASSEMBLY WITH INSERT AND METHOD OF MAKING
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority benefit of U.S. Provisional Patent Application
No. 60/378,739 filed on May 7, 2002.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
Background Of The Invention
[0003] The present invention relates to keys for use in vehicles. More particularly, the
present invention relates to an overmolded key assembly having an insert.
[0004] Keys for use with electronic interlock systems typically include a key shank
having a toe end and a head. The toe end is inserted into a mechanical lock. A head formed
over the shank head end is grasped by the user to insert and turn the key in the lock. A
transponder is typically disposed in the key head end, and electronically interacts with the
electronic interlock system to allow the lock to turn.
[0005] A known key having a transponder includes a key shank having a toe end and
head end. A soft plastic molded over the head end forms the key head. The transponder is
embedded in the soft plastic. Unfortunately, the transponder can be damaged during the
molding process due to the heat and pressure required to mold the head.
[0006] In order to protect the transponder, a carrier can be used, such as disclosed in U.S.
Pat. Nos. 6,035,677. The transponder is inserted into the carrier which is attached to the
shank head end. A soft plastic is then molded over the head end and carrier to encapsulate
the carrier and form the key head. Although the transponder is protected, the added cost of attaching the carrier to the shank head end increases the cost of the key assembly. [0007] In the above described keys, a logo is typically formed in the soft plastic as the
head is formed. As a result, the molds forming the key can be used only for the customer
desiring the specific logo. If the customer desires to change the logo, or fails to place further
orders, the molds can no longer be used to make keys.
Summary Of The Invention
[0008] The present invention provides a key assembly for a lock. The key assembly
includes a key shank having a toe end and a head end. An insert is positioned relative to the
head end, , and has a pair of opposing faces. Material is overmolded onto the key shank head
end and at least a portion of the insert, hi one embodiment, at least a portion of at least one
of the faces is not covered by the material to provide at least one surface for displaying
indicia.
[0009] The key assembly is made by forming a key shank having a toe end and a head
end. The key shank is positioned in a mold for overmolding material onto at least a portion
of the key shank head end. An insert having a pair of opposing faces is positioned in the
mold proximal the key shank head end. At least a portion of at least one of the opposing
faces of the insert is covered. Material is molded over at least a portion of the head end and
insert except at least the covered portion of the at least one of the opposing faces of the insert
to provide an exposed surface for displaying indicia.
[0010] A general objective of the present invention is to provide a key assembly which
can display indicia independent of the key manufacturing process. This objective is
accomplished by providing a key assembly including an insert having at least one exposed
surface for displaying indicia. Indicia can be formed on the exposed surface prior to making
the key, or indicia can be fixed to the surface after the key is made.
[0011] Another objective of the present invention is to provide a key assembly which is
simple to manufacture. This is accomplished by providing an insert that is not attached to the key shank head end prior to overmolding a material onto the key shank head end. In
particular, the insert described herein is fixed relative to the key shank head end by the
overmolding material, and is not attached to the key shank head end, as in the prior art.
[0012] Another objective of the present invention is to protect a transponder, if provided,
during the manufacturing process. This objective is accomplished by providing an insert with
a cavity formed therein for receiving the transponder.
[0013] These and still other objectives and advantages of the present invention will be
apparent from the description which follows. In the detailed description below, preferred
embodiments of the invention will be described in reference to the accompanying drawings.
These embodiments do not represent the full scope of the invention. Rather the invention
may be employed in other embodiments. Reference should therefore be made to the claims
herein for interpreting the breadth of the invention.
Brief Description Of The Drawings
[0014] Fig. 1 is a perspective view of a key assembly incorporating the present
invention;
[0015] Fig. 2 is an exploded perspective view of the key assembly of Fig. 1 without the
overmolding material;
[0016] Fig. 3 is an edge view of the key assembly of Fig. 1; [0017] Fig. 4 is a sectional view along line 4-4 of Fig. 3;
[0018] Fig. 5 is a side view of the key assembly of Fig. 1;
[0019] Fig. 6 is a sectional view along line 6-6 of Fig. 5;
[0020] Fig. 7 is a sectional view along line 7-7 of Fig. 5;
[0021] Fig. 8 is a sectional view of an alternative key assembly incorporating the present
invention including a medallion;
[0022] Fig. 9 is a sectional plan view of another alternative key assembly incorporating
the present invention;
[0023] Fig. 10 is a plan view of the key shank of Fig. 9;
[0024] Fig. 11 is a bottom view of the insert of Fig. 9; and
[0025] Fig. 12 is a side view of the insert of Fig. 9.
Detailed Description Of Preferred Embodiments
[0026] A key assembly 10 shown in Figs. 1-7 includes an insert 12 embedded into a head
end 14 of a key shank 16. Material 18 is overmolded onto the key shank head end 14 and
insert 12. to form a key head 20. The insert 12 has a pair of opposing exposed surfaces 22
which are not covered by the overmolding material 18 to provide surfaces for displaying a
logo 24 or other indicia. A transponder 26 can be provided which is disposed in a cavity 28
formed in the insert 12. Access to the cavity 28 is cut off by the overmolding material 18
after the transponder 26 is inserted therein.
[0027] The key shank 16 is preferably formed from a metallic material, such as nickel
plated brass, and has a toe end 30 and the head end 14. The head end 14 is substantially U-
shaped, and has a pair of opposed spaced apart legs 32 defining a space 34 therebetween.
The toe end 30 can be formed to match the profile specifications of any automobile or lock
manufacturer.
[0028] The insert 12 is disposed in the space 34 between the head end spaced apart legs
32, and includes a body 36 having a pair of opposing faces 38. Preferably, the insert 12 is
molded from engineered resin, such as an acrylonitrile-butadiene-styrene (ABS) +
thermoplastic urethane (TPU) blend and the like, having a specified hardness. As best shown
in Fig. 7, an outwardly opening groove 40 formed on the insert peripheral edge 42 receives
the legs 32 to guide the insert 12 into the space 38 between the head end spaced apart legs
32. Advantageously, the insert 12 can be a carrier for the transponder 26 by forming the
cavity 28 in the body 36 between the insert opposing faces 38. Preferably, the cavity 28 has
an opening 52 which opens into the peripheral edge 42 of the body 36 for inserting the
transponder 26 into the cavity 28.
[0029] Each opposing insert face 38 includes an upper surface 44 surrounded by a lower
surface 46. The upper surface 44 is spaced above the lower surface 46 to provide a raised
surface on which a logo, such an automobile logo, or other indicia can be displayed. The
indicia can be molded into the upper surface 44, formed independently of the insert 12 and
attached thereto, printed onto the upper surface 44, and the like without departing from the
scope of the invention. Advantageously, by providing a separate insert 12 which displays the
indicia, the assembly 10 can be provided for a plurality of customers, and only the insert 12
need be changed.
[0030] As best shown in Fig. 4, the transponder 26 is inserted into the body cavity 28
through the opening 52. Advantageously, the insert 12 protects the transponder 26 from
damage due to pressure from subsequent overmolding or mishandling during the
manufacturing process. Although a rectangular transponder 26 is disclosed, the cavity 28 can be formed to receive any shape transponder, such as a transponder having a cylindrical or
square shape, or the cavity can be left empty, or not provided at all, without departing from the scope of the present invention.
[0031] The key head 20 is formed by overmolding the material 18, such as an ABS+
TPU blend over the key shank head end 14 and portions of the insert 12. Preferably, the
overmolding material 18 selected is the same material used to form the insert 12 in order to form a strong bond between the insert 12 and overmolding material 18. However, the
overmolding material can be any material used in the art, such as a material having a
hardness which is less than the insert 12 in order to provide the key with a soft covering,
without departing from the scope of the invention. The overmolding material 18 locks the
insert 12 relative to the head end spaced apart legs 32 by embedding the insert 12 and legs 32
in the overmolding material 18. A key ring through hole 50 is formed in the key head 20 for
storing the key assembly 10 on a key ring. Advantageously, an attachment means is not
required to fix the insert relative to the shank head end, thus simplifying the key
manufacturing process. Although an attachment means is not required to fix the insert
relative to the shank head end, a means for attaching the insert to the shank can be provided
without departing from the scope of the invention.
[0032] The lower surfaces 46 of the insert faces 38 are covered with the overmolding
material 18 to embed the insert 12 in the overmolding material 18. Preferably, the
overmolding material 18 overlaps the peripheral edge of the upper surface 44 to form a
cavity 47 surrounding indicia displayed by the insert 12. The upper surfaces 44 of the insert
12, however, are preferably, spaced from the outer surface 48 of the overmolding material 18
which surrounds the upper surfaces 44 of the key head 20 to form the cavity 47. Although,
providing insert upper surfaces 44 which are spaced from the outer surface 48 of the
overmolding material 18 is preferred, the uncovered portion of the insert faces 38 can also be
above or flush with the outer surface 48 of the overmolding material 18 and/or the upper
surface 44 can be flush or spaced below the lower surface 46 without departing from the
scope of the invention.
[0033] The key assembly 10 is made by forming the key shank 16 having the toe end 30
and head end 14, using methods known in the art, such as stamping, molding, casting, and
the like. The key shank 16 is positioned in a mold for overmolding the material 18 onto the
key shank 16 to form the key head 20. The insert 12 is positioned in the mold between the
pair of opposed spaced apart legs 32 of the key shank head end 14.
[0034] At least a portion of at each insert face upper surface 44 is covered, such as by a
part of the mold, a clamp, or other device. The portion of the insert upper surface 44 is
covered to prevent the overmolding material 18 from flowing over and covering the upper
surfaces 44 of the insert faces 38 and the indicia, if provided, on the upper surfaces 44 prior
to applying the overmolding material 18. The overmolding material 18 is, preferably,
injected into the mold to form the key head 20 and fix the insert 12 relative to the key shank
16.
[0035] Advantageously, upon separating the key assembly 10 from the mold, the portion
of the insert faces 39 covered prior to overmolding the material 18 onto the key shank head
end 14 provides an exposed surface for displaying the logo or other indicia. Of course, if
indicia is not molded onto the exposed surface of the insert or secured to the exposed surface
by the overmolding material 18, indicia can be applied to the exposed surface, such as by
adhesively attaching molded or printed media, printing directly onto the exposed surface, and
the like.
[0036] In another embodiment shown in Fig. 8, the indicia 33 is formed on a medallion 35 which covers the upper surface 44. The medallion 35 is secured to the insert by the
overmolding material 18 which is overmolded onto a peripheral edge of the medallion 35.
Preferably, the insert includes a lip 37 surrounding the upper surface 44 to form a cavity
which receives the medallion 35 to prevent the medallion 35 from moving relative to the
insert 12 during the molding process. Advantageously, by providing a separate medallion 35
which displays the indicia, the assembly 10 can be provided for a plurality of customers, and
only the medallion 35 need be changed.
[0037] h yet another embodiment disclosed in Figs. 9-12, a key assembly 60 includes a
key shank 62 which positions and retains an insert 64 prior to overmolding material 66 onto
the key shank 62 and insert 64. As shown in Fig. 9, the key shank 62 includes a pair of
opposed spaced apart legs 68 defining a space 70 therebetween for receiving the insert 64, as
described above. Each leg includes a protrusion 72 extending into the space 70.
[0038] The protrusion 72 engages the insert 64 to retain the insert 64 in the space 70.
Preferably, the protrusion 72 is formed as an integral part of the leg 68, however, the
protrusion can be formed as a separate piece joined to the leg without departing from the
scope of the invention. Although a single protrusion proximal a distal end 74 of each leg 68
is shown, one or more protrusions can be provided anywhere on only one leg 68 or both legs
68 without departing from the scope of the invention.
[0039] The insert 64 is disposed in the space 70 between the legs 68, and includes a body 80 having a pair of opposing faces 82. An outwardly opening groove 84 formed on at least a
portion of the a peripheral edge 78 of the insert 64 receives the legs 68 to guide the insert 64
into the space 70. A cavity 86 can be formed in the body 80 between the opposing faces 82
for receiving a transponder 88.
[0040] An indent 76 formed in a peripheral edge 78 of the insert 64 receives each of the
protrusions to positively retain the insert 64 in the space 70. Advantageously, the indent 76
allows the insert 64 to be snapped into the space 70 between the legs 68 to retain the insert
64 in the space 70 prior to overmolding the material 66 thereon without any additional means
for holding the insert 64 in the space 70. This allows the insertion of the insert 64 into the
space 70 independent of the overmolding process which overmolds the material 66 onto the key shank 62. Of course, the protrusion can be formed on the insert, and the indent formed
in the leg, without departing from the scope of the invention.
[0041] The insert 64 is properly oriented within the space 70 between the legs 68 by shoulders 90 extending into the space 70 from the legs 68. Preferably, each shoulder 90 is
proximal a proximal end 92 of one of the legs 68, and engages a shelf 94 formed in the
peripheral edge 78 of the insert 64. The shelves 94 prevent the insert 64 from rotating about
an axis orthogonal to a plane including both legs 68 which could result in indicia formed on
the insert 64 from being properly aligned with the key shank 62. Although a pair of shoulders
engaging a like number of shelves is disclosed, one or more shoulders can be provided that
engage the insert without departing from the scope of the invention.
[0042] While there has been shown and described what are at present considered the
preferred embodiments of the invention, it will be obvious to those skilled in the art that
various changes and modifications can be made therein without departing from the scope of
the invention defined by the appended claims. For example, the key assembly can include
only one exposed surface for displaying a logo without departing from the scope of the present invention.