Universal apparatus for use with electronic and/or mechanical access control devices

An apparatus for use with electronic and/or mechanical access control devices includes a holder which receives a removable insert which may include an electronic module with a cover member securing the insert to the holder. The holder may take various forms and may be in the form of a key ring, photo I.D. card, etc. The holder may be a key blank for forming a key that operates mechanical locks, in which case the insert may be a dummy insert or it may include electronic components for operating various types of electronic access control devices. A method of upgrading a key for operating a mechanical lock to a key for also operating an electronic access device is provided and involves replacing the insert in the key with an insert containing electronic components. The electronic components may utilize various technologies such as proximity-based access control.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to apparatus for use in operating 
electronic and/or mechanical access control devices. In particular, the 
invention relates to an apparatus having a removable insert which may 
include an electronic module for cooperating with the reader of an 
electronic access control device. 
2. Description of Relevant Art 
Keys for operating mechanical locks and for being inserted into a passage 
to communicate with the reader of an electronic access device are known in 
the art. For example, U.S. Pat. No. 4,998,952, assigned to the same 
assignee as the present application, discloses a hybrid key having a key 
blade and a key bow, the key bow having secured thereto a housing which 
contains a circuit board. The circuit board is molded in the housing and 
the housing is removably secured to the key bow by flanges formed thereon 
and a rivet that passes through aligned openings in the housing and key 
bow. The key blade may have bitting surfaces cut therein for operating the 
pin tumblers of a cylinder-type lock, or it may be uncut and used as a 
guide for guiding the key to permit contact of the electronic components 
thereof with the detector or reader of an electronic access control 
device. 
The Pat. No. 4,998,952 teaches replacement of the mechanical portion of the 
key, i.e., the key blade and bow, while permitting reuse of the more 
expensive housing and electronic component on a different key. Thus, for 
example, should someone in possession of the hybrid key lose that key, the 
mechanical locks operated by that key can be replaced or modified so that 
they are no longer operated by the lost key. As for the other keys which 
now do not operate the modified mechanical locks, the electronic component 
of such keys can be removed and positioned on new keys with bitted blades 
that operate the modified lock. In this manner, the security of the locks 
is maintained by replacing the key bow and blade while reusing the 
expensive electrical component of each key. 
The key disclosed in the Pat. No. 4,998,952 is an electronic key and may 
have a bitted blade for operating a mechanical lock or a smooth blade for 
engaging the reader of an electronic access device. 
This patent does not discuss the desirability of providing an apparatus for 
use in operating electronic access control devices which includes a 
removable insert secured to the apparatus by a separate housing, which 
insert may include an electronic component for cooperating with access 
control devices of varying types or levels of security, one such insert 
being replaceable with another insert which may contain different or 
additional electronic components. 
This patent also does not discuss the desirability of providing a key for 
operating a mechanical lock only, which key may be subsequently upgraded 
to include an electronic portion for cooperating with an electronic access 
control device. Thus, assume it is desired to install an electronic access 
device at the outer entrance of a building when the doors inside the 
building have already been provided with mechanical locks operated by cut 
keys. It would be necessary to form new keys according to the Pat. No. 
4,998,952, which keys would include a key blade and bow with an electronic 
housing (even though the cut blades of the new keys would correspond to 
the cut blades of the old keys). As such, installing an electronic access 
control device would result in increased key manufacturing costs. 
There is a need in the art for an improved apparatus for operating 
electronic access control devices which apparatus may contain one of many 
interchangeable inserts having various types of electronic components. 
There also is a need in the art for an improved key for operating a 
mechanical lock which can be upgraded to operate the mechanical lock and 
the reader of an access control device. 
SUMMARY OF THE INVENTION 
The present invention provides an apparatus for use with an electronic 
access control device which may be in the form of a holder for receiving 
an insert containing an electronic component which may be hermetically 
sealed in the insert and cooperates with the reader or detector of the 
electronic access control device. The insert is secured to the holder by a 
clamshell cover which engages the insert and the holder to securely fix 
the insert within a recess formed in the holder. The cover can be 
disengaged to permit removal of the insert and replacement thereof with 
another insert which may have the same or a similar configuration as that 
of the removed insert but may contain a different electronic component 
which, for example, is designed to cooperate with an electronic access 
control device that utilizes a different technology to provide a higher 
(or lower) level of security. 
The holder which removably receives the insert may be any of various 
devices. In one embodiment, the holder is a key-shaped member with an 
elongated guide blade for insertion into the slot of the reader of the 
access control device. In another embodiment, the holder is in the form of 
a key ring tag-like device with a recess in which the insert is secured by 
the cover. In yet another embodiment, the holder is a card or card-shaped 
member, for example, a photo I.D. card, with a recess or cut-out section 
in which the insert is secured by the cover. These, of course, are merely 
exemplary of the many different holder devices with which the invention 
may be used and carried out. Also, the type of electronic component 
contained in the insert may utilize any of various technologies. 
The present invention also provides a key including a key bow with a 
portion thereof cut-out to form a recess, a key blade integral with and 
extending away from the key bow, and an insert removably disposed in the 
recess of the key bow. A clamshell housing is secured around the key bow 
so as to enclose the insert and secure the insert to the key. To modify 
the key, the insert is removed and replaced with an insert having an 
electronic component which, for example, operates a higher level access 
control device in a hierarchical system. The insert is designed to be 
removed only upon removal of the housing from the key bow, and the removal 
of the housing may be evident from tamper-indicating structure provided on 
the housing. 
The insert may be a dummy insert when used with a key for a mechanical lock 
to provide an upgrade path should the user desire to install a higher 
level of security, e.g., a reader operated electronic access control 
device. In that case, an insert which has an electronic module 
hermetically sealed therein may be positioned in the recess of the key bow 
in lieu of the dummy insert. For example, bitted keys for operating a 
system with mechanical locks may be provided with dummy inserts secured to 
the key bow by the clamshell housing. Should it subsequently be desired to 
upgrade the lock system to provide an additional level of security, such 
as a door secured by an electronic access control device, it is only 
necessary to replace the dummy inserts in the keys with inserts including 
suitable electronic components, thereby upgrading the keys to operate the 
mechanical lock and the electronic access control device.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
With reference to FIGS. 1A and 1B, a holder apparatus which forms part of 
the present invention is indicated generally by the reference numeral 10 
and is in the form of a key-shaped member that includes a bow portion 12 
in the form of a frame 14, and a blade portion 16. As seen in the Figures, 
the blade 16 is configured for use as a guide for insertion into the 
reader or detector of an electronic access control device. However, the 
blade 16 may be in the form of a key blank which is configured to fit 
within the keyway of a mechanical lock and adapted to be cut by a 
locksmith, for example, to provide bitting surfaces thereon for operating 
the tumbler pins of a cylinder-type lock as is known in the art. 
The bow 12 of the holder 10 includes a cut-out section or recess 18 which 
results in the bow having essentially the shape of a frame 14. The recess 
18 is preferably oval-shaped but it will be recognized that other shapes 
may be used as well. The shape of the recess 18 preferably corresponds to 
the shape of the insert 30 so that the insert is received in the recess in 
a relatively snug fashion. The bow 12 includes a first notched portion 20 
and a second notched portion 22 which cooperate with the insert 30 as will 
be described below. An opening 28 is provided on the bow at the end 
disposed away from the blade 16 which, upon placement of the insert 20 in 
the recess 18, forms an aperture for mounting the holder on a ring, chain, 
etc. 
FIGS. 2A-2C show an insert indicated generally by the reference numeral 30 
which is configured to be received in the recess 18 of the holder 10. The 
insert 30 may be a dummy insert that does not include an electronic module 
or the like therein which is preferably formed as a solid plastic molded 
member. That is, a dummy insert 30, although having an appearance which is 
the same as that of an insert containing electronic components for 
operating an electronic access control device, is electronically 
non-functional. As will be described below, according to one embodiment of 
the invention, the dummy insert is included with a key blank which is cut 
to form a key which operates a mechanical lock and, should the user 
subsequently desire to incorporate an electronic access control device and 
have the key also operate the access device, such structure provides an 
upgrade path in that the dummy insert 30 can be replaced with an insert 
containing various electronic components--depending on the level or type 
of security of the electronic access control device to be installed. 
In a preferred embodiment, the electronic components are hermetically 
sealed in the body of the insert. This could be accomplished, e.g., by 
ultrasonically welding two insert halves together with the electronics 
module disposed and sealed therebetween. Alternatively, the electronics 
could be placed in a suitable mold and the insert then molded so as to 
completely enclose the electronics. Those skilled in the art will 
appreciate that other methods for forming the insert 30 may be used as 
well and those mentioned above are only non-limiting examples of preferred 
embodiments. 
The insert 30 comprises lower and upper halves with the lower half 
including thickened portions 32 on each side of the insert, and the upper 
half including a more narrow portion 36 defining flat faces on each side 
of the insert. The thickened portions 32 each include a depression 34 
configured to be engaged by the fingers of a person using the holder. See 
FIG. 2B. The portions 32 of the insert 30 provide an area for receiving 
indicia which may relate to the specific holder, advertising information, 
etc. For example, when the holder is a key blank and a dummy insert is 
used, this area on one side of the insert may carry a message regarding 
potential upgrading of the key for use in a hierarchical system. The area 
on the other side of the insert also may carry indicia. The indicia may be 
printed on a label or film that is suitably adhered to the outer surfaces 
of the insert 30, it may be molded into the insert, etc. At one end of the 
insert 30 a projection 38 is provided the shape of which is preferably 
rectangular and corresponds to the shape of the notch 20 formed in the bow 
12 of the holder 10. The opposite end of the insert 30 has a notched 
recess 40 which cooperates with a cover member 50 to secure the insert to 
the holder 10, as will be described below. 
Turning now to FIGS. 3A to 3C, a cover member for securing the insert 30 to 
the holder 10 is indicated generally at reference numeral 50 and is in the 
form of a clamshell member with two portions or halves 52 and 54. The 
cover 50 preferably is made of any suitable plastic material. The two 
halves 52, 54 are joined to each other by a semi-flexible connection 62, 
which may be a plastic hinge connection. The hinge preferably is flexible 
enough to permit folding of the cover 50 about the holder 10, yet rigid 
enough to securely lock against the insert 30 and holder 10. The cover 50 
is adapted to be closed around the bow 12 of holder 10 so as to sandwich 
the insert 30, which has been previously positioned in the recess 18 of 
holder 10, thereby locking the cover 50 to the insert and the holder, as 
will be described further below. 
Each of the portions 52, 54 includes a window or opening 56 passing 
therethrough in which are received the respective thickened portions 32 of 
insert 30. Surfaces 58, 60 are respectively disposed on portions 52, 54 
and are formed with a depression for receiving the fingers of a person 
using the holder. Upon assembly of the insert 30 and cover 50 on the 
holder 10, the surfaces 58, 60 of cover 50 preferably are flush with the 
thickened portions 32 of insert 30 and the depressions 34 thereof 
(disposed in windows 56) to form a continuous depression. The surfaces 58, 
60 may be used to receive various types of indicia 70 as seen in FIG. 3A, 
which indicia may be molded into the cover or applied to the surface 
thereof. Each of the portions 52, 54 includes an opening 80, and these 
openings 80 overlie each other and surround the aperture 28 of holder 10 
upon assembly of the components so as to form an opening for receiving a 
key ring or the like element. 
A pair of ridges 64, 65 are respectively formed along the upper ends of 
portions 52, 54 (FIGS. 3B and 3C) and extend across the cut-out portion of 
holder 10 to close off the border of recess 18 when the cover 50 is 
secured thereto. The specific configuration of the ridges 64, 65 is not 
critical as they form a seam along the upper end of the cover 50. The 
ridges may overlap each other, meet in an end-to-end manner, etc. The 
portions 52, 54 of cover 50 have semi-flexible tangs 66 formed at the ends 
thereof which are disposed away from the hinge 62. As seen in FIG. 3C, the 
tangs 66 are somewhat L-shaped and are located in notches 68 formed in the 
rear side of portions 52, 54. The notches 68 permit the tangs 66 to flex 
or move a limited amount when securing the cover 50 to the insert 30 and 
holder 10. 
When the cover 50 is closed around the bow 12 of holder 10 with the insert 
30 positioned in recess 18, the tangs 66 engage the notch 40 of the insert 
30 in a snap-fit fashion. In this position, the tangs 66 are held in the 
groove 40 of insert 30 by the holder 10, i.e., the groove 22 in holder 10 
forces the tangs 66 against the notch 40 of insert 30 to prevent 
disassembly of the apparatus. As seen in FIG. 5A, when assembled the tangs 
are hidden from view by the cover 50 and insert 30 which meet along a seam 
S. Thus, the tangs are not accessible after assembly of the apparatus. 
However, the cover may be removed by an authorized person using a tool or 
by an unauthorized person using sufficient force to fracture or tear the 
plastic cover. 
The invention preferably includes a tamper-indicating feature, which may be 
provided by the arrangement of the tangs 66 which are not accessible once 
the apparatus has been assembled. In particular, once assembled, the hinge 
62 of cover is cut to remove the cover 50 and replace the insert 30, e.g., 
to upgrade the apparatus such that it is capable of operating a different 
electronic access control device. Once the hinge 62 is cut, the portions 
52, 54 can be pivoted about the tangs 66 to release the latter from the 
notch 40 in insert 30 and the notch 22 in holder 10. It will be recognized 
that other tamper-indicating structure could be utilized, including, but 
not limited to, forming the cover of a plastic which becomes discolored 
when subjected to the stress arising during prying or other unauthorized 
attempts to disassemble the key. This feature indicates when the cover has 
been removed and ensures that only authorized individuals perform the 
conversion of the keys by replacing the inserts thereof. 
In another embodiment, the holder is a key blank adapted to be cut so as to 
operate a mechanical lock and having a dummy insert secured thereto. The 
key blank could be adapted to cooperate with any type of lock with means 
for being operated mechanically by inserting a key into the lock. For 
example, the lock could be a Medeco.RTM. type cylinder lock with rotatable 
pin tumblers which are engaged by bitting surfaces formed on the key 
blade. However, the invention is not limited to any specific type of 
mechanical lock in that the ability to upgrade a key for a mechanical lock 
to a key for operating an access control device does not depend on the 
particular mechanics of the lock but, rather, is facilitated by providing 
the key with structure for securing an insert thereto. 
In order to upgrade the key (formed from the key blank) for operating a 
mechanical lock so that it operates an electronic access control device, 
the dummy insert is removed from the key and replaced with an insert 
containing an electronic component which cooperates with and controls the 
reader or detector of said access control device. In a preferred 
embodiment, the dummy insert and the insert with an electronic component 
have a substantially identical outer appearance; however, persons skilled 
in the art will appreciate that such similarity in appearance is not 
necessary to practice the present invention. 
FIG. 4 shows the manner in which the apparatus is assembled. The insert 30 
is positioned within the holder recess 18 as indicated by arrows A. The 
cover 50 then is folded about the bow of holder 10 as indicated by arrows 
B. Upon closing together the cover portions 52, 54, the tangs 66 snap into 
the notch 40 of insert 30 and the inner surfaces of portions 52, 54 abut 
the outer side surfaces of the holder bow 12. The resulting structure 
provides a sturdy assembly with a sleek and smooth appearance. In 
addition, engagement of the cover 50 with the insert 30 and holder 10 
leaves a portion 24 of holder bow 12 exposed for receiving indicia 26 
which may relate to, e.g., customer specific advertising, information 
concerning potential upgrade if the holder is a key, etc. 
FIG. 6 shows an embodiment of the present invention which includes a key 
blank 100, an insert 300, and a cover 500. The insert 300 has embedded 
therein an electronic module which may contain different electronic 
components for cooperating with the circuit connectors or contacts 420 of 
the reader 410 of an electronic access control device when the blade of 
the key blank (or key after the blank is cut) is inserted into the passage 
430 of reader 410. The insert 300 may contain a solid state memory, 
transmitter, receiver, microprocessor, etc., the specific components 
depending on the technology being utilized. In the embodiment of FIG. 6, 
the key may simply have data which is read by the detector to determine 
whether operation of the access control device is authorized. Many 
different technologies may be used to provide the additional level of 
access control. The cover 500 includes an enlarged portion 510 with 
electronic contacts indicated at 520 that engage contacts 420 provided on 
the reader or detector 410 of the electronic access control device upon 
insertion of key blade 16 into passage 430. The contacts 420, 520 may be 
electronic, optical, etc. 
For example, in further embodiments the insert may have means for 
cooperating with the reader of the access control device to provide 
proximity based control such that moving the key within a preselected 
distance activates the access control device (and thus it is not necessary 
to position a guide blade in the passage of a reader such as 430). The 
insert may have a transmitter to indicate the location of the key to 
monitor the key's location and prevent the key from leaving a certain 
area. Those skilled in the art will recognize that various technologies 
may be utilized depending on the desired application of the present 
invention. 
It should be recognized that the shape of the cover of the apparatus of the 
present invention is not limited to those shapes disclosed herein but, on 
the contrary, can be varied to accommodate different reader or detector 
configurations, or to accommodate inserts having a shape different than 
those of inserts 30 or 300. Also, the inserts could be color-coded to 
indicate a particular type or level of security, a particular insert or 
cover configuration, or other characteristics of the apparatus. 
FIG. 7A depicts another embodiment of the apparatus of the present 
invention in which the holder is in the form of a card-like member 700. 
The card 700 includes a flat body 710 with a recess 718 configured to the 
receive the insert containing the electronic component in a manner similar 
to that described above with respect to the previous embodiments. The 
holder 700 includes first and second notched portions 720, 722 as well as 
an opening 728 which serve a purpose as described in the previous 
embodiments. The holder 720 has a portion 724 which may receive a 
photograph, for example, if the holder is used as photo I.D. The portion 
or area 724 may also be used to carry indicia if desired. The insert is 
secured to the holder 700 by a cover as discussed in connection with the 
previous embodiments. 
FIG. 7B depicts yet another embodiment 600 of the apparatus of the present 
invention in which the holder is in the form of a key ring tag-like member 
614 which includes a recess 618 for receiving an insert secured thereto by 
a cover as in the above-described embodiments. The holder 600 also 
includes first and second notched portions 620, 622, opening 628, and 
frame area 624, which may function as in the previous embodiments and, 
therefore, will not be described in detail here. The holders shown in 
FIGS. 7A and 7B are but two examples of many different possible 
configurations of the present invention. 
It is apparent that the present invention provides an apparatus for use 
with electronic access control devices which includes a holder for 
receiving a removable insert that contains an electronic component(s) for 
cooperating with and operating the access control device. Further, the 
invention provides a key blank or key for use with mechanical locks and 
electronic access control devices in which the key blade and bow are 
combined with a removable, reusable insert which may be a dummy insert or 
may have incorporated therein an electronic module. It is further apparent 
that the invention provides a method of upgrading a key for operating a 
mechanical lock to a key which also operates an electronic access control 
device, e.g., a reader located at an outer entrance of a building, by 
substituting an insert with electronic components for the dummy insert. It 
will be appreciated that the invention is not limited for use with any 
particular type of holder or key blank and, as such, may be used with many 
types of holders as well as key blanks and keys sold by various 
manufacturers. 
Other features and advantages of the present invention will readily occur 
to those skilled in the art, as will many modifications and alterations in 
the preferred embodiments of the invention described herein, all of which 
may be achieved without departing from the spirit and the scope of the 
invention as defined by the appended claims.