Abstract: Methods and processes of making and assembling key assemblies each having a key blank, a transponder, a transponder holder and a key head section cover molded to encapsulate the transponder and at least part of its holder. If a logo is desired on the finished key, it may be provided on one or both sides of the key head section cover, or on a transponder holder which is molded about a part of the key head section.

Abstract: Key assemblies each having a key blank, a transponder, a transponder holder and a key head section cover molded to encapsulate the transponder and at least part of its holder. A logo may be provided on one or both sides of the key head section cover, or on a transponder holder which is molded about a part of the key head section. In one embodiment, the transponder holder is premolded, after which the transponder is inserted in it and resiliently held in place by resilient parts of the holder. The transponder and holder subassembly is then slid into a generally U-shaped key head with the legs defining the sides of that key head sliding in open channels formed by legs of the holder which are moved against the resilience of the cantilever mounting of the legs to the transponder mounting section of the holder.

Abstract: To prevent a key cylinder from being punched out of an automotive door or the like and to simplify assembly, a stepped key cylinder retention cavity structure that is rigid with an outer panel of the door, is arranged to extend into the interior of the door. A key cylinder is disposed in the cavity from outside of the door so that a shaft that rotates synchronously with a rotor of the key cylinder, extends through an opening formed in an inboard end of the cavity and is connected to a key lever through a lost motion connection that allows for key backlash. The key lever is connected to the cavity structure by resilient barbed members that can be pressed in through the opening from the interior of the door. The barbed members snap into a locking position in suitable recesses formed in the structure. Rotation-limiting projections that are rigid with the structure are provided to limit the amount of rotation of the key lever.