Patent ID: 7530884
Filing Date: 2009-05-12
Classification: B23C,B24B,Y10T

Abstract:
1. A method of forming a duplicate of an original key from a key blank, comprising the steps of: providing a rotary tool characterized by an elongated dielectric housing, a motor, a rotary shaft in driven engagement with the motor, a non-rotatable threaded tip portion surrounding an end of the rotary shaft, and a rotatable threaded tip portion driven by the rotary shaft and a threaded cap in threaded mating engagement with the non-rotatable threaded tip portion; providing a key duplication system having a free-standing base assembly defining a lower surface dimensioned and arranged to rest upon a substantially planar support surface, the retaining structure being dimensioned and arranged to retain and support the rotary power tool and including a stylus supported at an elevation above the lower surface, the stylus having a surface region dimensioned and arranged to contact a selected corresponding surface region of an original key when the end portion of the rotary shaft extends through the aperture to thereby bring the cutting element and stylus into working alignment; and a carriage movable linearly and angularly relative to the base, the stylus, and the cutting element, the carriage including a first clamp dimensioned and arranged to receive and retain a key blank and a second clamp dimensioned and arranged to receive and retain an original key; unthreading and removing the threaded cap; inserting the non-rotatable threaded tip portion through the aperture and securing a locking nut around the non-rotatable threaded tip portion to thereby retain the rotary tool in a fixed orientation relative to a working zone of the key duplicating system; securing a cutting element to the rotatable threaded tip portion; inserting a key blank into the first clamp and inserting an original key to be duplicated into the second clamp alignable; energizing the rotary tool; and angularly and linearly translating the carriage so as to bring the original key and key blank into contact with the stylus and cutting element, respectively and to thereby remove sufficient material from the key blank as to create a duplicate key.