Assembly method for vehicle anti-theft key with resistor

A method for assembling an anti-theft key, the method comprising:

• providing a key blade defined by:
• a shank portion for being inserted into a vehicle ignition, said shank portion including a through opening;
• and
• a handle portion;
• providing a resistor pellet defined by:
• an electrically insulative body having:
• a first end including a first flange having a perimeter larger than the perimeter of said through opening;
• and
• a second end having a perimeter smaller than the perimeter of said through opening and being configured for attachment to a second flange by a polymeric molding process;
• a resistor contained in said insulative body and having first and second electrical contact points;
• a first electrical conductor connected to the first electrical contact point of the resistor and extending beyond the first end of the insulative body;
• and
• a second electrical conductor connected to the second electrical contact point of the resistor and extending beyond the second end of the insulative body;
• inserting the second end of the insulative body trough said through opening so that the resistor pellet is loosely positioned within the through opening;
• attaching a second flange adjacent the second end of the insulative body, said second flange having a perimeter larger than the perimeter of said through opening such that said resistor pellet is captured within the through opening by said first and second flanges;
• and
• attaching a handle adjacent the handle portion of the key shank wherein said second flange and said handle are formed in place substantially simultaneously by a polymeric molding process.

A method for assembling a vehicle anti-theft key, the method comprising:

• providing a key blade defined by:
• a shank portion for being inserted into a vehicle ignition, said shank portion including a through opening;
• and
• a handle portion;
• providing a resistor pellet defined by:
• an electrically insulative body having:
• a first end including a first flange having a perimeter larger than the perimeter of said through opening;
• and
• a second end having a perimeter smaller than the perimeter of said through opening;
• a resistor contained in said insulative body and having first and second electrical contact points;
• a first electrical conductor connected to the first electrical contact point of the resistor and extending beyond the first end of the insulative body;
• and
• a second electrical conductor connected to the second electrical contact point of the resistor and extending beyond the second end of the insulative body;
• inserting the second end of the insulative body through said through opening so that the resistor pellet is loosely positioned within the through opening;
• forming a second flange adjacent the second end of the insulative body, said second flange having a perimeter larger than the perimeter of said through opening such that said resistor pellet is captured within the through opening by said first and second flanges;
• forming a handle adjacent the handle portion of the key shank;
• wherein said second flange and said handle are fanned during a single polymeric molding process;
• and
• removing excess material formed between the second flange and the handle during said polymeric molding process.