In an age where electronic devices are expected to last only a few years, if that, Ford said it had introduced a “super-tough” new version of the ignition key designed to last a lifetime in the hands of the most demanding drivers.

The automaker tested the key – for Transit and Transit Custom vans – to ensure it could survive being submerged underwater for 30 minutes, dropped 50 times onto a concrete floor and exposed to temperatures from 60deg C to minus 20deg C.

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The fob looks like any other modern ignition key, with a keypad to lock the vehicle and a flip-style key blade. However, to ensure it is completely waterproof, it is permanently sealed shut, with the two halves of the plastic housing joined by friction welding. The inside of the key is carefully designed to resist typical workplace impacts, and a rechargeable battery cell is charged whenever the key is placed in the ignition, to ensure it never runs out of charge.

“Our customers want a key which can tackle the hard knocks of construction sites and city deliveries, and keep coming back for more,” said Jonathan Allan, electrical engineering supervisor, Ford of Europe. “While a mobile phone can sometimes let you down, Ford has ensured that Transit drivers have a key which is just as rugged as their vehicle.”

Engineers also tested the key using using climatic chambers in temperatures simulating everything from desert heat to arctic cold, and in humidity levels of up to 100%. Further tests included ensuring:

  • Dust resistance – five hours surrounded by a fine, penetrating dust
  • Chemical resistance – up to 96 hours continuous exposure to diesel, petrol, ethanol, detergents and sweat
  • Pocket simulation – four hours non-stop vibration with coins and other keys
  • Button durability – 10 button presses with 12 times the usual force
  • Endurance – 100,000 activations in temperatures ranging from 50deg C to -10deg C

The shockproof key is the latest generation of a design which has been refined and developed with 10 years of feedback from Transit customers.

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