HK1084995B - Rekeyable lock assembly and method of operation - Google Patents

Description

Rekeyable lock assembly and method of operation

Technical Field

The present invention relates generally to lock cylinders and more particularly to lock cylinders that are rekeyable. More particularly, the present invention relates to lock cylinders that are rekeyable without the use of a master key.

Background

When rekeying a lock cylinder using a conventional lock cylinder design, the user is required to remove the cylinder plug from the cylinder body and replace the appropriate pin so that a new key can be used to unlock the lock cylinder. It is often necessary for the user to remove the cylinder mechanism from the lock casing and then disassemble the cylinder to some extent to remove the bolt and then replace the pin. This requires knowledge of the operation of the lock sleeve and lock cylinder mechanism, which is typically only operable by locksmiths and trained professionals. In addition, this process often requires special tools and requires the user to have access to the kit of pins to replace the connecting tools of the pins to enable replacement of parts that are lost or damaged during repeated latching procedures. Finally, a professional using a suitable tool can easily pry open a conventional lock cylinder.

The present invention overcomes these and other deficiencies of conventional lock cylinders. The operation of the lock cylinder of the present invention follows the familiar conventional operation of inserting a key and rotating the key in the lock cylinder in the event that a conventional lock cylinder is used. In the present invention, however, the same familiar operation can be used on a re-locking cylinder. In this way, the user can repeatedly lock the lock cylinder of the present invention without any special knowledge, training or tools.

Disclosure of Invention

The present invention provides a simple means for "guiding" a lock cylinder for a new key when the old key is revoked. In accordance with the present invention, a rekeyable lock cylinder includes a cylinder body having a longitudinal axis and a plug assembly disposed within the cylinder body. The plug assembly includes a plug body and a carrier sub-assembly disposed adjacent the plug body. The latch assembly also includes a plurality of pins. The carrier sub-assembly is movable parallel to the longitudinal axis of the cylinder body and includes a plurality of racks that engage the pins. The rack disengages the pin in response to movement of the carrier in a first direction and engages the pin in response to movement of the carrier in a second direction. The lock cylinder is in a re-locked state when the rack is disengaged from the pin.

The invention also includes a new method of locking a rekeyable lock cylinder once again. According to the invention, the method for locking a relockable lock cylinder again comprises the following steps: providing a lock cylinder having a plug body and a locking face, the locking face having a locking slot and a tool receiving aperture; inserting a first mating key (valid) in the keyway, rotating the plug body to a first position; inserting a tool into the tool receiving bore and extracting the first mating key from the keyway; a second mating key is inserted into the keyway to rotate the plug body away from the first position. The step of inserting the tool includes the step of moving the rack out of engagement with the pin.

According to one aspect of the invention, the lock cylinder comprises a carrier movable parallel to the longitudinal axis of the lock cylinder, and the step of inserting the tool comprises the step of moving the carrier.

Other features and advantages of the invention will be apparent from the following drawings and appended claims.

Drawings

FIG. 1 shows a lock cylinder of the present invention;

FIG. 2 is an exploded view of the lock cylinder of FIG. 1;

FIG. 3 is a perspective view of the plug assembly showing the carrier sub-assembly with the locking bar in the locked position to lock the plug assembly within the cylinder body;

FIG. 4 is a top view of the latch assembly of FIG. 3;

FIG. 5 is a side elevational view, partially in cross-section, of the latch assembly of FIG. 3;

FIG. 6 is a partially exploded view of the latch assembly of FIG. 3;

FIG. 7 is a cross-sectional view of the latch assembly and lock cylinder body of FIG. 3, the section being taken transversely along one of the pins and showing the position of the pin, rack and lock bar relative to the other components, and showing the lock cylinder body in a locked configuration;

FIG. 8 is a perspective view of the plug assembly of FIG. 3 with a matching key inserted therein, showing the locking bar in an unlocked position to allow the plug assembly to rotate within the cylinder body;

FIG. 9 is a top view of the latch assembly of FIG. 8;

FIG. 10 is a side elevational view, partially in section, of the latch assembly of FIG. 8;

fig. 11 is a partially exploded view of the latch assembly of fig. 8;

FIG. 12 is a cross-sectional view of the latch assembly and lock cylinder body of FIG. 8, the section being taken transversely along one of the pins and showing the position of the pin, rack and lock bar relative to the other components, and showing the lock cylinder body in an unlocked configuration;

FIG. 13 is a perspective view similar to FIG. 8 but with the carrier assembly moved axially to a re-latching position;

FIG. 14 is a top plan view of the latch assembly of FIG. 13;

15A-15E are various views of a lock cylinder body for use in the present invention;

fig. 16A-16F are various views of a plug body for use in the present invention;

FIGS. 17A-17F are various views of a carrier for use in the present invention;

18A-18B are views of a rack used in the present invention;

FIGS. 19A-19B are views of a spring pin used in the present invention;

FIGS. 20A-20B are views of a pin used in the present invention;

FIGS. 21A-21B are views of a locking bar for use in the present invention;

FIGS. 22A-22D are views of a spring retention cap for use in the present invention;

FIG. 23 is an exploded perspective view of another embodiment of the present invention;

24A-24E are views of another embodiment of a lock cylinder body;

FIG. 25 is a transverse cross-sectional view of another embodiment of the present invention;

FIGS. 26A-26B are views of another embodiment of a spring pin;

FIGS. 27A-27E are views of another embodiment of a carrier;

28A-28B are views of another embodiment of a pin;

29A-29B are views of another embodiment of a rack;

fig. 30A-30B are views of another embodiment of a lock bar.

Detailed Description

Fig. 1-2 illustrate a lock cylinder 10 of the present invention. The lock cylinder 10 includes a longitudinal axis 11, a cylinder body 12, a plug assembly 14 and a retainer 16. In fig. 1, the plug assembly 14 is in a reset position relative to the cylinder body 12.

As shown in fig. 15A-15E, the lock cylinder body 12 includes a generally cylindrical body 20 having a front end 22, a rear end 24 and a cylindrical wall 26 formed as an inner surface 28. The cylinder wall 26 includes an inner locking bar engaging slot 29 and a pair of positioning slots 30, 32. A generally V-shaped locking bar engagement slot 29 extends longitudinally along a portion of the cylindrical body 12 from the front end 22. The first detent 30 is located at the rear end 24 and extends to a first depth. The second detent 32 is adjacent to the first detent 30 and extends to a short depth. A positioning bore 34 extends radially through the cylindrical wall 26 to receive a positioning ball 36 (fig. 2).

The plug assembly 14 includes a plug body 40, a carrier sub-assembly 42 and a plurality of spring-loaded pins 38 (fig. 2 and 20A-20B). The plug body 40 shown in fig. 16A-16F includes a plug face 44, an intermediate portion 46 and a drive portion 50. The bolt face 44 defines a lock slot opening 52, a repeating locking tool opening 54 and a pair of radially outwardly extending grooves 56 to receive an anti-drill ball bearing 60 (fig. 2). The transmission portion 50 includes an annular wall 62 with a pair of opposed projections 64 extending radially inwardly to drive spindle blades or torque blades (neither shown). The drive portion 50 also includes a pair of slots 66 formed in its periphery to receive the retainer 16 to retain the plug body 40 in the cylindrical body 12.

The intermediate portion 46 includes a main body portion 70 and a plurality of channels 74 that receive the spring-loaded pins 38, the main body portion 70 being formed as a cylindrical section and having a first longitudinal planar surface 72. The grooves 74 extend transversely to the longitudinal axis of the plug body 40 and are parallel to the planar surface 72. The second planar surface 76 extends perpendicular to the first planar surface 72 and is formed with a recess 80 (fig. 2 and 22A-22D) that receives a retaining cage 82. A groove 74 extends from the second planar surface 76 partially through the plug body 40, with the side walls of the groove opening to the first planar surface 72. The first planar surface 72 also includes a plurality of bullet-shaped rack engaging members 78. A bore 86 for receiving the spring-loaded ball 36 (fig. 2) extends radially inwardly relative to the first planar surface 72.

The carrier sub-assembly 42 (fig. 2, 6 and 10) includes a carrier 90 (fig. 17A-17E), a plurality of racks 92 (fig. 18A-18B), a spring pin 96 (fig. 19A-19B), a spring loaded lock lever 94 (fig. 21A-21B) and a return spring 98 (fig. 2). The carrier 90 includes a body 100 in the form of a cylindrical section that is complementary to the body portion 70 of the plug body 40 so that the carrier 90 and the body portion 70 combine to form a cylinder that fits inside the lock cylinder body 12. Carrier 90 includes an arcuate surface 102 and a planar surface 104. Arcuate surface 102 includes a lock bar recess 106 and a spring pin recess 108. The locking bar recess 106 also includes a pair of return spring receiving holes 109 (fig. 17C) to receive the locking bar return springs. The planar surface 104 includes a plurality of parallel rack-receiving slots 103 extending perpendicular to the longitudinal axis of the carrier. A semi-circular slot 111 extends along the planar surface 104 parallel to the longitudinal axis of the carrier 90. The rear end of the carrier 90 includes a recess 112 for receiving the return spring 98.

Each spring loaded pin 38 includes a pin 113 and a biasing spring 115. The pin 113 shown in fig. 20A-20B is substantially cylindrical with annular gear teeth 114 and a central longitudinal bore 116 that receives a biasing spring 115 (fig. 2). The racks 92 shown in fig. 18A-18B include a pin engaging surface 118 having a plurality of gear teeth 122 shaped to engage the annular gear teeth 114 on the pins 113 as shown in fig. 7 and 12, and a semi-circular recess 124 engaging the bullet rack engaging members 78 on the flat surface 72 as shown in fig. 12. The racks 92 also include a second surface 126 having a plurality of anti-pry slots 128 and a pair of locking bar-engaging slots 132.

The snap lock bar 94 shown in fig. 21A-22B is sized and shaped to fit into the lock bar recess 106 in the carrier 90, and the snap lock bar 94 includes a triangular shaped edge 134 shaped to fit into the V-shaped lock bar engagement slot 29. In contrast to the triangular edge 134, the locking bar 94 includes a pair of longitudinally extending gear teeth 136 shaped to engage the locking bar engaging grooves 132 formed in the racks 92 as shown in FIG. 12.

As shown in fig. 22A-22D, the spring retention cap 82 includes a curvilinear portion 140 having an upper surface 142 and a lower surface 144. The thickness of the curvilinear portion 140 is such that the curvilinear portion 140 can fit within the recess 80, as shown in fig. 7 and 12, with its upper surface 142 flush with the intermediate portion 46 of the plug body 40. A plurality of spring alignment tips 146 extend from the lower surface 144 to engage the springs 148. In addition, a pair of retaining cap tips 152 extend from the lower surface 144 to engage aligned openings 154 (fig. 16E-16F) formed in the latch body 40.

To assemble the lock cylinder 10, the pin 113 and spring 115 are placed in the groove 74 of the plug body 40. The spring retention cup 82 is positioned in the recess 80 with the retention cup tip 152 positioned in the alignment opening 154 and the spring alignment tip 146 engaged with the spring 115. The carrier sub-assembly 42 is assembled by placing the racks 92 in the slots 103 and the spring loaded lock rods 94 in the lock rod recesses 106, with the gear teeth 136 engaging the lock rod engaging slots 132 in the racks 92. The spring catch 96 is located in a spring catch recess 108 of the carrier 90. The carrier sub-assembly is placed adjacent the lock cylinder 40 by inserting a matching key 160 into the keyway 52, the return spring 98 being compressed in the return spring recess 112, as shown in fig. 3. The plug assembly 14 is positioned in the cylinder body 12 and the retainer 16 is positioned in the slot 66 in the plug body 40 to retain the plug assembly 14 in the cylinder body 12. The lock cylinder 10 is now locked by the matching key 160.

Fig. 4-7 show the fully locked cylinder 10 without the key 160 inserted. The pins 113 are biased to the bottom of the slots 74 with the racks 92 located at different positions in the slots 103 of the carrier 90 depending on the profile of the key 160. In this configuration, the lock bar 94 extends from the carrier 90 to engage the slot 29 in the cylinder body 12 to prevent rotation of the plug assembly 14 in the cylinder body 12 while engaging the racks 92 with the pins 113 as shown in figure 4. In addition, the bullet-shaped member 78 is misaligned with the recess 111 in the rack 92, thereby blocking movement of the rack 92 parallel to the longitudinal axis of the lock cylinder 10, preventing the lock cylinder 10 from being locked again.

Fig. 8-12 show the internal configuration of the lock cylinder 10 with the mating key 160 inserted in the initial position. In this configuration, the locking bar 94 is free to project out of the slot 29 of the cylinder body 12, as shown in FIGS. 8, 9 and 12. The teeth of the key 160 engage the pins 113 in the grooves 74, thereby repositioning the racks 92 in the slots 103. When repositioned, the racks 92 are aligned with the locking bar engaging slots 132 with their protruding gear teeth 136 on the locking bar 94. When the key 160 is turned, the lock bar 94 freely protrudes out of the slot 29. Also as shown in fig. 12, the bullet-shaped member 78 is aligned with the recess 111 in the rack 92, allowing the rack 92 and carrier 90 to move parallel to the longitudinal axis of the lock cylinder 10.

To relock the lock cylinder 10, a matching key 160 is inserted into the lock slot 52 as shown in FIGS. 13-14 and rotated approximately 45 counterclockwise from the home position until the spring catch 96 moves into the second detent 32 in the lock cylinder body 12. A paperclip or other sharp device 162 is inserted into the tool hole 54 and pushed against the carrier 90 to move the carrier 90 parallel to the longitudinal axis of the lock cylinder 10 until the spring pin 96 moves into the first detent 30, followed by withdrawal of the sharp device 162. As shown in FIG. 14, with the spring pin 96 in the first detent 30, the racks 92 are out of engagement with the pins 113. The mating key 160 is withdrawn and a second mating key is reinserted and rotated clockwise to release the spring catch 96. When the spring pin 96 leaves the first detent 30, the carrier 90 is biased toward the latch face 44 by the return spring 98, thereby once again engaging the racks 92 with the pins 113. The lock cylinder 10 is now locked by the second mating key and the first mating key 160 no longer operates the lock cylinder 10. The cylinder 10 can also be locked again by a third mating key by replacing the first and second mating keys in the above process with a second and third mating key, respectively.

Fig. 23-29 illustrate another embodiment 210 of the present invention. This embodiment includes the same components shown in fig. 23, but with many of the components modified. Functionally, the two embodiments are identical.

As shown in fig. 23-24, the modified lock cylinder 212 includes a plurality of apertures 214 extending longitudinally along its bottom and a pair of vertical slots 216, 218 formed in the lock cylinder sidewalls. In addition, the side wall includes a removable side panel 220. The location of the rectangular aperture 214 may allow for the use of a manual override tool. The central slot 216 includes an aperture 222 extending through the sidewall of the lock cylinder. The aperture 222 allows a user to move the locking bar in a manual override operation. The side plate 220 has access for some manipulation when changing the cylinder master key.

As shown in fig. 23 and 25, the modified pin biasing spring 226 has a varying diameter, with the last few views of each end of the spring 226 having a reduced diameter. Such a taper may have a greater spring force at a smaller physical height.

As shown in fig. 23 and 26, the modified spring pin 228 includes a central U-shaped portion 230 and a pair of arms 232 extending from the U-shaped portion 230.

As shown in fig. 23 and 27, the modified carrier 236 includes means for retaining the spring catch 228 in the spring catch recess 238. In this embodiment, it includes a guide rail 240 projecting outwardly at the center of the spring pin recess 238, and a pair of leaves 242 radially offset from the guide rail 240. The guide 240 prevents the spring catch 228 from moving laterally in the recess 238 while allowing the spring catch to move radially outward to engage the lock cylinder 12, 212 as described above. The leaves 242 engage the arms 232 of the spring catch 228 and prevent the arms 232 from tilting outwardly, thereby directing the compressive force of the spring catch 228 to extend the U-shaped portion 230 outwardly to engage the lock cylinder 12, 212.

As shown in fig. 23 and 28, the modified pin 244 includes only a single gear tooth 246 in place of the plurality of gear teeth of the pin 113 described above. The single gear tooth 246 preferably includes beveled sides 248 to provide for smoother engagement with the rack during the rekeying process.

As shown in fig. 23 and 29, the modified rack 250 includes angled gear teeth to improve engagement with the pins during the re-latching process. In addition, the pair of locking bar engagement slots 132 in the rack 92 are replaced by a single locking bar engagement slot 251.

As shown in fig. 23 and 30, the modified lock bar 252 is thinner than the lock bar 94, with a single gear tooth 256 replacing the pair of gear teeth 136 and wrapping around the triangular edge 134. The thinner design reduces any rocking of the locking bar 252 in the locking bar recess 106.

The above embodiments are of course not to be taken as limiting the scope of the invention. Other arrangements which can be modified without departing from the spirit and scope of the invention are defined by the appended claims.

Claims (14)

1. A re-lockable lock cylinder comprising:

a lock cylinder body having a longitudinal axis;

a plurality of pins disposed in the lock cylinder body; and

a carrier subcomponent disposed in the lock cylinder body, including a carrier, a spring-loaded lock bar, a return spring, and a plurality of racks for engaging pins, a rear end of the carrier including a recess for receiving the return spring, the carrier subcomponent moving parallel to a longitudinal axis of the lock cylinder body between a first position and a second position to disengage from the pins.

2. The lock cylinder of claim 1 further comprising a plug assembly including a plurality of pins, said carrier sub-assembly including a plurality of racks for engaging said plurality of pins.

3. The lock cylinder of claim 1, wherein the rack disengages the pin in response to movement of the carrier from the first position to the second position, and the rack engages the pin in response to movement of the carrier from the second position to the first position, the lock cylinder being in a rekeyable state when the carrier is in the second position.

4. The lock cylinder of claim 1, wherein each pin includes at least one gear tooth.

5. The lock cylinder of claim 1, wherein each of the plurality of pins comprises a hollow cup-shaped body.

6. The lock cylinder of claim 1, further comprising a plurality of springs having a non-constant diameter.

7. The lock cylinder of claim 6, wherein the pin is cup-shaped and is configured to receive a plurality of springs.

8. The lock cylinder of claim 1, further comprising a spring pin for retaining the carrier in the second position.

9. The lock cylinder of claim 8, wherein the spring pin includes a U-shaped central portion and a pair of arms extending from the central portion.

10. The lock cylinder of claim 9 wherein the carrier sub-assembly further includes a spring pin recess including a guide configured to receive the U-shaped center portion of the spring pin and a pair of leaves configured to engage the pair of arms.

11. The lock cylinder of claim 8, wherein the lock cylinder body includes a slot for receiving the spring pin when the carrier sub-assembly is in the second position.

12. The lock cylinder of claim 8 wherein the spring pin moves out of the engaged position to a non-engaged position in response to rotation of the carrier subcomponent within the lock cylinder body, wherein the spring pin retains the carrier subcomponent in the second position in the engaged position.

13. The lock cylinder of claim 1, wherein each rack gear includes at least one locking bar receiving slot and a plurality of engaging pin gear teeth, each pin including at least one gear tooth between two of the plurality of engaging pin gear teeth for engaging the rack gear.

14. The lock cylinder of claim 1, wherein the carrier subcomponent further comprises a carrier having a plurality of rack-receiving slots and a locking bar recess.