Key and key blanks operable in vertically and horizontally oriented keyways

A key or key blank includes a key blade having a first edge, a second edge, and first and second opposed sides. The first edge has one or more edge bittings to elevate and/or rotate one or more tumbler pins of a lock with a vertically-oriented keyway, and one of the opposed sides has one or more side bittings to elevate and/or rotate one or more tumbler pins of a lock with a horizontally-oriented keyway. Side warding surfaces on the key blank are shaped and positioned to minimize the interference of peaks between the skewed bitting cuts on the key. A lock has a keyway configured for the key having edge bittings to elevate and/or rotate one or more tumbler pins of a vertical lock and side bittings to elevate and/or rotate one or more tumbler pins of a horizontal lock.

FIELD OF THE DISCLOSURE

This disclosure relates to improvements in keys and key blanks, particularly a key blank configured to receive bittings for both a lock with a horizontally-oriented keyway and a lock with a vertically-oriented keyway. In embodiments, the key blank may receive bittings only for a horizontally-oriented keyway, only for a vertically-oriented keyway, or for both horizontally- and vertically-oriented keyways.

BACKGROUND

Locks having a keyway with a horizontal orientation and locks having a keyway with a vertical orientation are known in the art. Examples of locks having vertically-oriented keyways include U.S. Pat. Nos. 3,499,302; 9,359,793; and 5,943,890, where the side faces of the key blade have a greater width than the top and bottom edges of the key blade. For an example of a horizontal keyway, U.S. Pat. No. 6,023,954 discloses a lock with a generally horizontal keyway and a key blade having large upper and lower surfaces connected by two short side edges or surfaces, providing the blade with a width greater than its thickness. The flat key blade has a plurality of bittings cut into the upper surface which extend across and through at least a portion of the upper surface from one side edge toward the other side edge. The bittings cut through a portion of the thickness of the blade so as to pass through one of the side edges, but preferably not the other side edge. Additional examples of locks with horizontally-oriented keyways include U.S. Pat. Nos. 9,416,561 and 9,771,738.

To introduce a new product line of cylinder locks having different complexities of locking mechanisms and security levels, it is important to have supporting locksmith and service centers to provide duplicate keys for the products. Techniques to reduce the inventory of key blanks that a service center must maintain are beneficial to product acceptance by the service personnel. Having many cylinder locks with the same keyway shape reduces the cost to produce the various types of cylinders and the cost of having to produce and stock many different key blanks to service the products for the end user.

A key blade has to be full height where the detainers, or tumbler pins, contact the key, but other portions of the blade are reduced to create unique key shapes. The shape of the key must be thinner than the keyway in a cylinder lock plug for the key to fit and operate. The shape of the key blade usually corresponds to the shape of the keyway in the cylinder lock. Bitting shapes require careful engineering to provide unique shapes that will support and position the tumbler pins at a correct location.

Where the tumbler pins contact the key blade, the bittings are cut into the blade to allow the key to position the tumbler pins at a location that allows the plug to rotate (i.e., at a shear line between the cylinder and the cylinder housing), thereby allowing the cylinder lock to open. Different locking mechanisms used in various cylinder locks have tumbler pins that contact the blade at various locations. These different locking mechanisms, such as levers, ward pins, common pins, and rotating pins, are formed with various techniques. For example, keys for the cylinder locks can be cut with rotary cutters, drilled with tapered holes, or formed with milling cutters to produce the necessary bittings to support and position these different tumbler pin types. In a certain cylinder locks, the tumbler pins must seat on the bitting in the key blade at a specific height, and the tumbler pins must also rotate to a correct angle for the lock to open. Skew cut bittings formed in the key blade cause the associated tumbler pins to rotate. Cutting the skew cut bittings that are necessary for rotating the tumbler pins produces vertices at the bitting peaks that often interfere with the rotation of the pins as the key is inserted. The key blank shapes must be carefully designed to eliminate these unwanted peaks.

SUMMARY

The following presents a simplified summary in order to provide a basic understanding of some aspects described herein. This summary is not an extensive overview of the claimed subject matter. It is intended to neither identify key or critical elements of the claimed subject matter nor delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

Aspects of this disclosure pertain to keys and key blanks that are designed to operate two different types of lock cylinders, vertically-oriented and horizontally-oriented lock cylinders.

Aspects of the disclosure are directed to a key blank adapted to be formed into a key for operating a cylinder lock with tumbler pins and a vertically-oriented keyway and a cylinder lock with tumbler pins and a horizontally-oriented keyway. The key blank may include a key blade having a first edge, a second edge, a first side surface extending between the first edge and the second edge, and an opposed, second side surface extending between the first edge and the second edge. The first edge is adapted to have formed thereon one or more edge bittings configured to elevate and rotate tumbler pins of a cylinder lock with a vertically-oriented keyway, and the first side surface is adapted to have formed thereon one or more side bittings configured to elevate and rotate tumbler pins of a cylinder lock with a horizontally-oriented keyway.

According to further aspects of the disclosure, the key blade includes warding grooves and ridges on at least one of the first side surface and the second side surface that match the vertically-oriented keyway and the horizontally-oriented keyway so that the key blade can be inserted into both the vertically-oriented keyway and the horizontally-oriented keyway.

According to further aspects of the disclosure, the key blank may include a longitudinal rib on the first side surface and extending along at least a portion of the blade, wherein the first side surface is adapted to receive the one or more side bittings in the longitudinal rib and a portion of the first side surface above the longitudinal rib.

According to further aspects of the disclosure, the first edge is adapted to receive one or more skewed edge bittings.

According to further aspects of the disclosure, the first side surface is adapted to receive one or more skewed side bittings.

According to further aspects of the disclosure, the first side surface is adapted to receive one or more side bittings extending to the second edge of the blade.

According to further aspects of the disclosure, the first side surface is adapted to receive one or more side bittings extending from the second edge of the blade to beyond a longitudinal axis of the blade.

According to further aspects of the disclosure, the key blade is divided into three segments between the first edge and the second edge, the segments comprising. A first segment may be encompassed by a first envelope defined by the first edge of the key blade, a first side boundary, a second side boundary, and a lower edge. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the blade from the first edge of the blade to the second edge of the blade. A second segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary, a second side boundary, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary, a second side boundary, and the second edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness.

According to further aspects of the disclosure, the first side surface is adapted to receive one or more side bittings in the first side boundary of the third segment.

According to further aspects of the disclosure, the key blade further includes a warding groove formed in at least one of the second segment and the third segment that extends to a depth beyond the centerline.

According to further aspects of the disclosure, the first side surface of the key blade and the second side surface of the key blade comprise horizontal warding surfaces, and the horizontal warding surfaces are perpendicular to a vertical axis extending from the first edge of the blade to the second edge of the blade.

According to further aspects of the disclosure, a portion of the key blade is symmetric with respect to a centerline extending from the first edge of the blade to the second edge of the blade and a portion of the key blade is asymmetric with respect to the centerline, the first edge of the blade adapted to receive the one or more edge bittings is part of the symmetric portion of the blade, and the first side surface adapted to receive the one or more side bittings is part of the asymmetric portion of the blade.

According to further aspects of the disclosure, the key blade further includes a warding groove formed in the first side surface or the second side surface that extends to a depth beyond a centerline extending from the first edge to the second edge.

According to further aspects of the disclosure, the key blade may include an edge bevel extending from a distal end of the blade to the first edge of the blade and configured to guide tumbler pins of a cylinder lock with a vertically-oriented keyway to the first edge of the key blade as the key blade is inserted into the vertically-oriented keyway and a side bevel extending from a distal end of the blade to the first side surface of the blade and configured to guide tumbler pins of a cylinder lock with a horizontally-oriented keyway to the first side surface of the key blade as the key blade is inserted into the horizontally-oriented keyway.

According to further aspects of the disclosure, the keyway corresponds to a shape of the key blade of the key blank of claim1.

According to further aspects of the disclosure, the keyway is a vertically-oriented keyway.

According to further aspects of the disclosure, the keyway is a horizontally-oriented keyway.

Aspects of the disclosure are directed to a key for a lock. The key may include a key blade having a top edge, a bottom edge, a first side surface, and an opposed second side surface. The first side surface may include one or more side bittings configured to elevate and rotate one or more tumbler pins of a horizontal lock. The blade may be divided into three segments between the top edge and the bottom edge, the segments comprising. A first segment is encompassed by a first envelope defined by the top edge of the key blade, a first side boundary, a second side boundary, and a lower boundary. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the blade from the top edge of the blade to the bottom edge of the blade. A second segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary, a second side boundary, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary, a second side boundary, and the bottom edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, and the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness.

According to further aspects of the disclosure, the key may include a longitudinal rib on the first side surface and extending along at least a portion of the blade, and the side bittings are formed in the longitudinal rib and a portion of the first side surface above the longitudinal rib.

According to further aspects of the disclosure, the top edge may include one or more edge bittings configured to elevate and rotate one or more vertically-oriented tumbler pins of a vertical lock.

According to further aspects of the disclosure, at least one the one or more side bittings extends to the bottom edge of the key blade.

According to further aspects of the disclosure, the side bittings do not extend through more than half of the thickness of the key blade.

According to further aspects of the disclosure, each side bitting has a base at an angle of 70-110 degrees with respect to a longitudinal axis of the blade.

According to further aspects of the disclosure, at least one of the one or more side bittings extends from the bottom edge of the key blade to beyond a longitudinal axis of the key blade.

According to further aspects of the disclosure, each side bitting has a base at an angle of 70-110 degrees with respect to the longitudinal axis of the blade.

According to further aspects of the disclosure, the thickness of first segment envelope is about 0.060 inch, the thickness of the second segment envelope is about 0.093 inch, and the thickness of third segment envelope is about 0.125 inch.

According to further aspects of the disclosure, the first side surface of the key blade and the second side surface of the key blade comprise horizontal warding surfaces between the top edge of the key blade and a maximum depth of a valley of the edge bitting, and the horizontal warding surfaces are perpendicular to a vertical axis extending from the top edge of the blade to the bottom edge of the blade.

According to further aspects of the disclosure, the first side surface of the key blade and the second side surface of the key blade comprise horizontal warding surfaces and outwardly-extending warding surfaces between the top edge of the key blade and a maximum depth of a valley of the edge bitting.

According to further aspects of the disclosure, the maximum depth of a valley of an edge bitting is not more than two-thirds the height of an unbitted key blade.

According to further aspects of the disclosure, the blade has only vertical warding surfaces cut into the first side surface.

According to further aspects of the disclosure, at least one of the first side surface and the second side surface of the key blade comprises at least one vertical warding surface and at least one horizontal warding surfaces.

Aspects of the disclosure are directed to a keyway having a shape corresponding to the shape of the keys describe herein.

Aspects of the disclosure ad directed to a key for a lock. The key may include a key blade having a top edge, a bottom edge, a first side surface, and an opposed second side surface, and edge bittings formed on the top edge of the key blade. The edge bittings may include at least two adjacent bitting cuts forming a bitting peak therebetween, and the two adjacent bitting cuts are formed at different angles with respect to a longitudinal axis of the key blade. The first side surface of the key blade and the second side surface of the key blade may include horizontal warding surfaces between a top edge of the bitting peak and a maximum depth of the at least two bitting cuts.

According to further aspects of the disclosure, the key may further include side bittings formed on the first or second side surface of the key blade, and the side bittings may include at least two adjacent bitting cuts forming a bitting peak therebetween, and the two adjacent bitting cuts are formed at different angles with respect to a longitudinal axis of the key blade.

Aspects of the disclosure to a lock system. The lock system may include a vertical cylinder lock including a housing, a cylinder rotatably disposed within the housing, and a vertically-oriented keyway within the cylinder. The vertically-oriented keyway has a height and a width that is less than the height, and wherein the vertically-oriented keyway is configured to receive a key blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape of the key blade. The cross sectional shape of a key blade of the vertically oriented keyway is configured to receive is divided into three blade segments between the first edge and the second edge, the segments. A first blade segment is encompassed by a first envelope defined by the first edge of the key blade, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the key blade from the first edge of the key blade to the second edge of the key blade. A second blade segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third blade segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and the second edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness. The vertically-oriented keyway is divided into first, second, and third keyway segments along its height. The first keyway segment corresponds to the first blade segment, the second keyway segment corresponds to the second blade segment, and the third keyway segment corresponds to the third blade segment. At least one twisting tumbler pin is oriented within the cylinder so as to be parallel to the height of the vertically-oriented keyway and configured to be elevated and rotated by a complementary bitting formed on a first edge of a key inserted into the keyway. The lock system also includes a horizontal cylinder lock including a housing, a cylinder rotatably disposed within the housing, and a horizontally-oriented keyway within the cylinder. The horizontally-oriented keyway has a height and a width that is greater than the height, and the horizontally-oriented keyway is configured to receive a key blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape of the key blade that is divided into the same first blade segment, second blade segment, and third blade segment as the cross sectional shape of the key blade the vertically-oriented keyway of the vertical cylinder lock is configured to receive. The horizontally-oriented keyway is divided into first, second, and third keyway segments along its width, and the second keyway segment corresponds to the second blade segment and the third keyway segment corresponds to the third blade segment. At least one twisting tumbler pin is oriented within the cylinder so as to be parallel to the height of the keyway and is configured to be elevated and rotated by a complementary bitting formed on a first side surface of a key inserted into the keyway, and the tumbler pin of the horizontal cylinder lock is primarily aligned with the third keyway segment of the horizontally-oriented keyway. The system further includes a key with a blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape such that the key can be inserted into both the vertically-oriented keyway of the vertical cylinder lock and the horizontally-oriented keyway of the horizontal cylinder lock. The cross sectional shape of the key may be defined by at least one blade segment corresponding to the third keyway segment of the vertically-oriented keyway of the vertical cylinder lock and the third keyway segment of the horizontally-oriented keyway of the horizontal cylinder lock, and the key has at least a bitting formed on the first side surface of the key and configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock.

According to further aspects of the disclosure, the key has a bitting formed on the first edge and configured to elevate and rotate the at least one tumbler of the vertical cylinder lock.

According to further aspects of the disclosure, the cross sectional shape of the key blade is defined by three blade segments. A first blade segment is encompassed by a first envelope defined by the first edge of the key blade, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the key blade from the first edge of the key blade to the second edge of the key blade. A second blade segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third blade segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and the second edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends to the second edge of the blade.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends from the second edge of the blade to beyond a longitudinal axis of the blade.

According to further aspects of the disclosure, the key blade further includes a warding groove formed in at least one of the second segment and the third segment that extends to a depth beyond the centerline.

According to further aspects of the disclosure, the key blade includes an edge bevel extending from a distal end of the blade to the first edge of the blade and configured to guide tumbler pins of a cylinder lock with a vertically-oriented keyway to the first edge of the key blade as the key blade is inserted into the vertically-oriented keyway and a side bevel extending from a distal end of the blade to the first side surface of the blade and configured to guide tumbler pins of a cylinder lock with a horizontally-oriented keyway to the first side surface of the key blade as the key blade is inserted into the horizontally-oriented keyway.

Aspects of the disclosure are directed key for a horizontal cylinder lock that includes a housing, a cylinder rotatably disposed within the housing, and a horizontally-oriented keyway within the cylinder. The horizontally-oriented keyway has a height and a width that is greater than the height, and the horizontally-oriented keyway is configured to receive a key blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape of the key blade, and the cross-sectional shape of the key blade the horizontally-oriented keyway is configured to receive is divided into three blade segments between the first edge and the second edge. A first blade segment is encompassed by a first envelope defined by the first edge of the key blade, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the key blade from the first edge of the key blade to the second edge of the key blade. A second blade segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third blade segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and the second edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness. The horizontally-oriented keyway is divided into first, second, and third keyway segments along its height, and the first keyway segment corresponds to the first blade segment, the second keyway segment corresponds to the second blade segment, and the third keyway segment corresponds to the third blade segment. The horizontal cylinder lock further includes at least one twisting tumbler pin oriented within the cylinder so as to be parallel to the height of the horizontally-oriented keyway and configured to be elevated and rotated by a complementary bitting formed on a first side of a key inserted into the keyway. The key may include a blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape such that the key can be inserted into the horizontally-oriented keyway of the horizontal cylinder lock. The cross sectional shape of the key may be defined by only one blade segment corresponding to the third keyway segment of the horizontally-oriented keyway of the horizontal cylinder lock and lacking any blade segment that corresponds to the first or second keyway segments of the horizontally-oriented keyway, or only two blade segments corresponding to the second and third keyway segments of the horizontally-oriented keyway of the horizontal cylinder lock and lacking any blade segment that corresponds to the first keyway segment of the horizontally-oriented keyway. The blade includes at least one bitting formed on the first side surface of the blade, and wherein the at least one bitting is configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends to the second edge of the blade.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends from the second edge of the blade to beyond a longitudinal axis of the blade.

Aspects of the disclosure are directed to a method for operating a horizontal cylinder lock. The horizontal cylinder lock includes a housing, a cylinder rotatably disposed within the housing, and a horizontally-oriented keyway within the cylinder. The horizontally-oriented keyway has a height and a width that is greater than the height, and the horizontally-oriented keyway is configured to receive a key blade having a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape of the key blade, and the cross-sectional shape of the blade the horizontally-oriented keyway is configured to receive is divided into three blade segments between the first edge and the second edge. A first blade segment is encompassed by a first envelope defined by the first edge of the key blade, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the first envelope have a first thickness therebetween, and the first side boundary and the second side boundary of the first envelope are equidistant from a centerline extending through the key blade from the first edge of the key blade to the second edge of the key blade. A second blade segment is encompassed by a second envelope defined by an upper boundary contiguous with the lower boundary of the first segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and a lower boundary. The first side boundary and the second side boundary of the second envelope have a second thickness therebetween, the first side boundary and the second side boundary of the second envelope are equidistant from the centerline, and the second thickness is greater than the first thickness. A third blade segment is encompassed by a third envelope defined by an upper boundary contiguous with the lower boundary of the second segment, a first side boundary contacting a portion of the first side surface of the key blade, a second side boundary contacting a portion of the second side surface of the key blade, and the second edge of the key blade. The first side boundary and the second side boundary of the third envelope have a third thickness therebetween, the distance from the centerline to the second side boundary of the third envelope is equal to the distance from the centerline to the second side boundary of the second envelope, and the third thickness is greater than the first thickness and the second thickness. The horizontally-oriented keyway is divided into first, second, and third keyway segments along its height. The first keyway segment corresponds to the first blade segment, the second keyway segment corresponds to the second blade segment, and the third keyway segment corresponds to the third blade segment. The horizontal cylinder lock further includes at least one twisting tumbler pin oriented within the cylinder so as to be parallel to the height of the horizontally-oriented keyway and configured to be elevated and rotated by a complementary bitting formed on a first side of a key inserted into the keyway. The method may include inserting a key blade into the horizontally-oriented keyway, wherein the key blade has a first edge, a second edge, a first side surface, and an opposed second side surface defining a cross sectional shape such that the key can be inserted into the horizontally-oriented keyway of the horizontal cylinder lock. The cross sectional shape of the key is defined by only one blade segment corresponding to the third keyway segment of the horizontally-oriented keyway of the horizontal cylinder lock and lacking any blade segment that corresponds to the first or second keyway segments of the horizontally-oriented keyway or only two blade segments corresponding to the second and third keyway segments of the horizontally-oriented keyway of the horizontal cylinder lock and lacking any blade segment that corresponds to the first keyway segment of the horizontally-oriented keyway. The blade includes at least one bitting formed on the first side surface of the blade, and the at least one bitting is configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock. Inserting the key blade into the horizontally-oriented keyway comprises inserting the segment of blade corresponding to the third keyway segment into the third segment of the keyway.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends to the second edge of the blade.

According to further aspects of the disclosure, the at least one bitting formed on the first side surface extends from the second edge of the blade to beyond a longitudinal axis of the blade.

Other features and characteristics of the subject matter of this disclosure, as well as the methods of operation, functions of related elements of structure and the combination of parts, and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, and wherein like reference numerals designate corresponding parts in the various figures.

DETAILED DESCRIPTION

While aspects of the subject matter of the present disclosure may be embodied in a variety of forms, the following description and accompanying drawings are merely intended to disclose some of these forms as specific examples of the subject matter. Accordingly, the subject matter of this disclosure is not intended to be limited to the forms or embodiments so described and illustrated.

Unless otherwise indicated or the context suggests otherwise, as used herein, “a” or “an” means “at least one” or “one or more.”

This description may use various terms describing relative spatial arrangements and/or orientations or directions in describing the position and/or orientation of a component, apparatus, location, feature, or a portion thereof or direction of movement, force, or other dynamic action. Unless specifically stated, or otherwise dictated by the context of the description, such terms, including, without limitation, top, bottom, above, below, under, on top of, upper, lower, left, right, in front of, behind, beneath, next to, adjacent, between, horizontal, vertical, diagonal, longitudinal, transverse, radial, axial, clockwise, counter-clockwise, etc., are used for convenience in referring to such component, apparatus, location, feature, or a portion thereof or movement, force, or other dynamic action in the drawings and are not intended to be limiting.

Unless otherwise indicated, or the context suggests otherwise, terms used herein to describe a physical and/or spatial relationship between a first component, structure, or portion thereof and a second component, structure, or portion thereof, such as, attached, connected, fixed, joined, linked, coupled, or similar terms or variations of such terms, shall encompass both a direct relationship in which the first component, structure, or portion thereof is in direct contact with the second component, structure, or portion thereof or there are one or more intervening components, structures, or portions thereof between the first component, structure, or portion thereof and the second component, structure, or portion thereof.

Furthermore, unless otherwise stated, any specific dimensions mentioned in this description are merely representative of an exemplary implementation of a device embodying aspects of the disclosure and are not intended to be limiting.

To the extent used herein, the term “about” applies to all numeric values and terms indicating specific physical orientations or relationships such as horizontal, vertical, parallel, perpendicular, concentric, or similar terms, specified herein, whether or not explicitly indicated. This term generally refers to a range of numbers, orientations, and relationships that one of ordinary skill in the art would consider as a reasonable amount of deviation to the recited numeric values, orientations, and relationships (i.e., having the equivalent function or result) in the context of the present disclosure. For example, and not intended to be limiting, this term can be construed as including a deviation of +10 percent of the given numeric value, orientation, or relationship, provided such a deviation does not alter the end function or result of the stated value, orientation, or relationship. Therefore, under some circumstances as would be appreciated by one of ordinary skill in the art a value of about 1% can be construed to be a range from 0.9% to 1.1%.

The term “adjacent.” if used in the description or any claims, refers to being near or adjoining. Adjacent objects can be spaced apart from one another or can be in actual or direct contact with one another. In some instances, adjacent objects can be coupled to one another or can be formed integrally with one another.

The terms “substantially” and “substantial,” if used in the description or any claims, refer to a considerable degree or extent. When used in conjunction with, for example, an event, circumstance, characteristic, or property, the terms can refer to instances in which the event, circumstance, characteristic, or property occurs precisely as well as instances in which the event, circumstance, characteristic, or property occurs to a close approximation, such as accounting for typical tolerance levels or variability of the embodiments described herein.

All possible combinations of elements and components described in the specification or recited in the claims are contemplated and considered to be part of this disclosure. It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.

In the appended claims, the term “including” is used as the plain-English equivalent of the respective term “comprising.” The terms “comprising” and “including” are intended herein to be open-ended, including not only the recited elements, but further encompassing any additional elements. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as differentiating labels, and are not intended to impose numerical requirements on their objects.

FIG.1shows a lock4and key6in cross-section. Lock4has an outer housing with a cylinder or plug rotatably housed within the housing and a vertically-oriented, axially extending keyway2formed in the cylinder. Similarly,FIG.2shows a lock34and key36in cross-section. Lock34has an outer housing with a cylinder or plug rotatably housed within the housing and a horizontally-oriented, axially extending keyway32formed in the cylinder. Referring toFIG.1, the vertically-oriented keyway2has a top edge8, an open bottom10, and first12and second14opposed sides. The overall height16of the keyway is the distance from the top edge8to the open bottom10while the overall width18of the keyway2is the distance between first side12and second side14, which, as can be seen inFIG.1, may vary along the height of the keyway2. In the vertically-oriented keyway2, the height16of the keyway is greater than the maximum width18of the keyway. The key6for the vertically-oriented keyway2generally corresponds in shape (contour) to the vertically-oriented keyway2and has a height16greater than its maximum width18. For convenience, the reference numbers used for the height16and width18of the key6are the same as the reference numbers used for the height16and width18of the vertically-oriented keyway2. Notwithstanding, it will be appreciated by a person having ordinary skill in the art (POSA) that the height and width of the key6need to be smaller than the height and width of the keyway2in which the key6is to be inserted.

Referring toFIG.2, the horizontally-oriented keyway32has a top surface38, a bottom surface40, a first edge42, and second, open edge44. The overall width48of the keyway32is the distance between the first edge42and second edge44. The overall height46of the keyway is the distance between the top surface38and the bottom surface40, which, as can be seen inFIG.2, may vary along the width of the keyway32. In the horizontally-oriented keyway32, the width48of the keyway is greater than the maximum height46of the keyway. The key36for the horizontally-oriented keyway32generally corresponds in shape (contour) to the horizontal keyway32and has a width48greater than its maximum height46. For convenience, the reference numbers used for the height46and width48of the key36are the same as the reference numbers used for the height46and width48of the horizontally-oriented keyway32. Notwithstanding, it will be appreciated by a POSA that the height and width of the key36need to be smaller than the height and width of the keyway32in which the key36is to be inserted.

As shown inFIG.1, first side12and second side14of keyway2include various profile features conforming to ridges, plateaus, and grooves formed in key6. Similarly, as shown inFIG.2, top surface38and bottom surface40of horizontally oriented keyway32includes various profile features conforming to ridges, plateaus, and grooves formed in key36.

As used herein, a vertical lock, or vertical cylinder lock, refers to a lock with a vertically-oriented keyway (or, more generally, to a lock in which the long axis of the transverse keyway cross-section is oriented parallel to the axes of the tumbler pins, which may or may not be vertically-oriented, so that the tumbler pins contact an edge of the key blade inserted into the keyway), and a vertical key refers to a key configured to operate the vertical lock. Vertical tumbler pins or vertical pins refer to the tumbler pins (and, specifically, the tumbler pin orientation) of a vertical lock which, as explained above, may not actually be vertical. A horizontal lock, or horizontal cylinder lock, refers to a lock with a horizontally-oriented keyway (or, more generally, to a lock in which the long axis of the transverse keyway cross-section is oriented perpendicular to the axes of the tumbler pins, which may or may not be horizontally-oriented, so that the tumbler pins contact a side of the key blade inserted into the keyway), and a horizontal key refers to a key configured to operate a horizontal lock. Horizontal tumbler pins or horizontal pins refer to the tumbler pins (and, specifically, the tumbler pin orientation) of a horizontal lock which, as explained above, may not actually be horizontal.

FIGS.3a-3c, show an embodiment of a vertical key, or key6configured to operate vertical lock4(FIG.1).FIGS.4a-4cshow an embodiment of a horizontal key, or key36configured to operate horizontal lock34(FIG.2).FIG.5shows an embodiment of a key62configured to operate both vertical lock4and horizontal lock34.

In an embodiment, each key6,36,62includes a bow64and a shoulder or key stop66, with a blade63extending from the key stop66to a distal end85of the blade63. Each key6,36,62includes a primary top, or first, edge68having formed therein, or configured to have formed therein, bitting cuts for operating a vertical lock, a bottom, or second, edge76, a first side78having formed therein, or configured to have formed therein, bitting cuts for operating a horizontal lock, and an opposed second side79. The first side78includes a longitudinal rib80extending along some or all of the length of the blade63. The top edge68, bottom edge76, first side78, and second side79define a cross-sectional shape of the key blade63. In some embodiments, rib80is formed along a bottom end of first side78so that key blade63has a generally “L”-shaped cross section (which may be a backwards “L” in some embodiments). Each side may further include warding grooves and ridges as further discussed below (seeFIGS.6-13). Note that the designation of sides as first and second is arbitrary.

Referring toFIGS.3a-3c, the key6has edge bittings22(also referred to as vertical bittings), which are “V”-shaped bittings formed (e.g., cut, machined, ground, stamped, etc.) into primary top edge68of the key6to operate vertical lock4. In an embodiment, edge bittings22have angled or beveled surfaces that are configured to elevate and rotate tumbler pins of the vertical lock as is known in the art. See e.g. U.S. Pat. No. 3,499,302.

The edge bittings22are cut into the top edge68through at least a portion of the blade height towards the bottom edge. The edge bittings22may extend to various depths relative to the top edge68, for example, as indicated by the dimension lines20shown inFIG.3c. A thalweg or base or root24is the lowest portion of each “V” cut, and dimension lines20represent the depths or potential depths of the bases24of the edge bittings22. In one embodiment, the depth20of the base extends no further than two-thirds of the dimension of the unbitted key blade63from the top edge68to the bottom edge76(which dimension may be referred to as the height of the key blade). A perpendicular top edge cut26is a “V” cut with a base24cut perpendicular to the length, or longitudinal axis57, of the key blade63(i.e., parallel to the width of the key blade63). Skewed top edge cut28is a “V” cut with a base24oriented at an angle relative to the base24of the perpendicular cut26and not perpendicular to the longitudinal axis57of the key blade. Skewed cuts can increase the number of unique key possibilities and allow increased security features to be included on the tumbler pins, for example notches that require the pin to be rotated to align with a sidebar. See e.g. U.S. Pat. No. 3,499,302.

The process of cutting skew cut bittings, however, may produce bitting peaks with interfering vertices as described in more detail below.

In various embodiments, the skewed top edge cuts28are oriented at an angle29no greater than 20° clockwise or counterclockwise relative to the perpendicular cut26(i.e., about 70°-110° relative to the length, or longitudinal axis57, of the blade63). In various embodiments, the key6may include only skewed top edge cuts28or a combination of skewed top edge cuts28with one or more perpendicular top edge cuts26.

The blade63may further include an edge bevel81extending from the distal end85of the blade63to the top edge68of the blade63. As the key blade63is inserted into the vertically-oriented keyway2of the vertical lock4, the edge bevel81guides the tumbler pins of the vertical lock to the top edge68of the key blade63.

Referring toFIGS.4a-4c, the key36has side bittings52(also referred to as horizontal bittings), which are “V”-shaped bittings formed (e.g., cut, machined, ground, stamped, etc.) into a first side78of the key36to operate horizontal lock34. The side bittings52are configured to elevate and rotate tumbler pins of the horizontal lock having angled or beveled ends (not shown in the figures).

The side bittings52are cut into the rib80(e.g., into the short leg of the “L”-shaped cross section) and partially into a portion of the first side78of the blade63above the rib80and extend across and through at least a portion of the blade63from the bottom edge76toward the top edge68. One or more of the side bitting52extend toward top edge68past a longitudinal axis57of the blade63. The bittings are cut into a portion of the thickness of the blade63so as to have a depth extending from the first side78towards the second side79of the blade63. The side bittings52may be cut into the thickness of the blade to various depths relative to the first side78, for example as shown by dimension lines50inFIG.4c. In some embodiments, the side bittings52do not extend to a depth more than half of the thickness of the key blade63. Additionally, the side bittings52may extend to various heights from the bottom edge76toward the top edge68, for example as shown by dimension lines51inFIG.4a. As the side bitting cuts are essentially flat, the height that a cut extends from the bottom edge76corresponds to the depth of the cut. The deeper the cut, the higher the cut extends from the bottom edge76of the blade63.

A thalweg or base or root54is the lowest portion of each “V” cut. A perpendicular side cut56is a “V” cut with a base54cut perpendicular to the length, or longitudinal axis57, of the key blade63(i.e., parallel to the height of the key blade63). A skewed side cut58is a “V” cut with a base54oriented at an angle relative to the horizontal perpendicular cut56and not perpendicular to the longitudinal axis57of the key blade. In various embodiments, the skewed side cut58is oriented at an angle no greater than 20° clockwise or counterclockwise relative to the horizontal perpendicular cut56(i.e., about 70°-110° relative to the length, or longitudinal axis57, of the blade). In various embodiments, the key36may include only skewed side cuts58or a combination of skewed side cuts58with one or more perpendicular side cuts56.

The blade63may further include a side bevel83extending from the distal end85of the blade63to the first side surface78of the blade63. As the key blade63is inserted into the horizontally-oriented keyway32of the horizontal lock34, the side bevel83guides the tumbler pins of the horizontal lock34to the first side surface78of the key blade63.

In some embodiment, key6and key36have the same cross-sectional profile, and both keys6and36can be inserted into keyway2and both keys6and36can be inserted into keyway32.

As shown inFIG.5, embodiments of the disclosure have both edge bitting cuts70for operating a vertical lock and side bitting cuts82for operating a horizontal lock. One or more of the edge bitting cuts70may be vertical skewed cuts72, and one or more of the side bitting cuts82may be horizontal skewed cuts84. In various embodiments, the key blade63may have one or more vertical perpendicular cuts74and one or more horizontal perpendicular cuts86. The blade63may further include an edge bevel81and/or a side bevel83.

FIG.6depicts a cross-sectional shape of an embodiment of the blade63of a key blank configured to receive edge bitting cuts and/or side bitting cuts so that a key formed from the blank may be operable in a vertical and/or a horizontal lock, as applicable. The cross-sectional shape of the blade63includes three distinct segments98,106,114between the top edge68and the bottom edge76.

First segment98is encompassed by a rectangular envelope99defined by top edge68(corresponding with the top edge68of the blade63), a first side boundary100, a second side boundary104, and a lower boundary130. First side boundary100and second side boundary104correspond to physical side surfaces of blade63within segment98, but lower boundary130is not a physical edge of the blade63but represents a boundary between first segment98and second segment106. The top edge68is configured to receive edge bitting cuts as described above. First side boundary100and second side boundary104of the first segment98have a first thickness102therebetween, with the first side boundary100and the second side boundary104equidistant from a centerline96extending through the blade from the top edge68to the bottom edge76. The side boundaries100,104of envelope99correspond to portions of the segment98furthest distant from the centerline96. In the illustrated embodiment, side boundaries100,104of envelope99correspond to opposed, parallel sides of the blade63within segment98. Lower boundary130of the envelope99is defined as the point at which the opposed sides of the blade63are no longer parallel and begin to flare outwardly from the centerline96.

First segment98may or may not include warding grooves and/or ridges.

Second segment106is encompassed by a rectangular envelope107defined by upper boundary132(corresponding to lower boundary130of envelope99), a first side boundary108, a second side boundary112, and a lower boundary134. Upper boundary132and lower boundary134are not physical edges of the blade63, but represent boundaries between first segment98and second segment106and between second segment106and third segment114, respectively. The second segment106may be further characterized by various warding features that fall within the envelope107. The side boundaries108,112of envelope107correspond to portions of the segment106furthest distant from the centerline96. In the illustrated embodiment,FIG.6depicts the right side of segment106having a groove138between two peaks, or plateaus,140,142and the left side of segment106having a groove144between two ridges defining peaks146,148. First side boundary108of envelope107corresponds to the peaks140,142, being equal and maximum distances from the centerline96. Second side boundary112of envelope107corresponds to the peaks146,148, being equal and maximum distances from the centerline96. First side boundary108and second side boundary112are equal distant from the centerline96, and the maximum width110of segment106is defined as the distance from first side boundary108to second side boundary112, or the distance from peak140or142to peak146or148.

Maximum width110of segment106(envelope107) is greater than maximum width102of segment98(envelope99).

Lower boundary134of the envelope107is defined as the point at which the right side of the blade63begins to flare outwardly from the centerline96and is no longer equidistant from centerline96as second side boundary112of envelope107.

The third segment114is encompassed by a rectangular envelope115defined by an upper boundary136(corresponding to lower boundary134of envelope107), a first side boundary116, a second side boundary120, and the bottom edge76. Upper boundary136is not a physical edge of blade63, but represents a boundary between second segment106and third segment114. Third segment114includes a longitudinal rib128within the envelope115and is configured to receive side bitting cuts that may extend from bottom edge76into the right-hand side of segment106.

The side boundaries116,120of envelope115correspond to portions of the segment114furthest distant from the centerline96. In the illustrated embodiment,FIG.6depicts the right side of segment114having longitudinal rib128and the left side of segment114having a groove, or undercut,152and a lobe154. First side boundary116of envelope115corresponds to the outer edge of rib128(i.e., portion furthest from centerline96), and second side boundary120of envelope115corresponds to the outer edge of lobe154(i.e., portion furthest from centerline96). The maximum width118of segment114is defined as the distance from first side boundary116to second side boundary120, or the distance from rib128to lobe154.

In some embodiments, the maximum thickness118of segment114is greater than the maximum thickness102of segment98and the maximum thickness110of segment106, and the first side boundary116and second side boundary120are not equidistant from the centerline96. Rather, a distance122between the centerline96and the first side boundary116of the envelope115is greater than a distance124from the centerline96to the second side boundary120of envelope115. The distance124between the centerline96and the second side boundary120of envelope115is equal to a distance126between the centerline96and the second side boundary112of envelope107, so that the second side boundary120of envelope115is coplanar with the second side boundary112of envelope107. Thus, while first segment98and second segment106are symmetric with respect to centerline96, third segment114is asymmetric with respect to centerline96.

In an embodiment, edge bittings22,70for operating tumbler pins of a cylinder lock with a vertically-oriented keyway (as inFIG.1) may be formed in top edge68of blade98in the portion corresponding to first segment98, Side bitting52,82for operating tumbler pins of a cylinder lock with a horizontally-oriented keyway (as inFIG.2) may be formed in segment114, and may extend into segment106, and may be formed on the thicker side of segment114corresponding to thickness122.

In various, non-limiting embodiments, to maintain a sufficient strength in the key62having both edge bittings70and side bittings82, the thickness102of first segment98(envelope99) is about 0.060 inch, the thickness110of the second segment106(envelope107) is about 0.093 inch, and the thickness118of third segment114(envelope115) is about 0.125 inch.

A POSA would understand that the various warding segments may have various shapes, sizes/proportions, quantities, angles, and other configurations.

Returning toFIG.1, vertically-oriented keyway2may be divided into three segments45,47,49of relative widths and symmetry corresponding to segments98,106,114, respectively, of key blade63. Returning toFIG.2, horizontally-oriented keyway32may be divided into three segments, with two segments53,55of relative widths and symmetry corresponding to second and third segments106,114, respectively, of key blade36.

As noted above, the process of cutting skew cut bittings on the top edge and on the side edge or rib produces bitting peaks with vertices that can interfere with the rotation of tumbler pins of a lock as the key blade is inserted into the keyway. The interference of the vertices can be minimized by carefully designing the warding shapes, bitting angles, and bitting depths as further described below.

FIGS.7and8depict a key blade segment178for a vertical cylinder lock having a top edge160, bottom edge162, first side166, and opposing second side168, with angled warding surfaces164on the first side166and second side168of the key blade segment178and forming angled longitudinal warding grooves. The angled warding surfaces164are oriented at acute angles relative to an axis161perpendicular to the bottom edge162, extending through the centroid of the key blade segment178, and connecting the top edge160and the bottom edge162, as shown inFIG.8.

Referring toFIG.7. “V”-shaped vertical bittings forming the top edge160of the key blade segment178include alternating peaks185,186,187,188and valleys156,157,158. Each valley156,157,158defines a thalweg or base182,183,184. Valleys formed in the vertical bittings, such as valleys156,157,158, may have the same or varying depths and slopes (angles of the opposed sides of the valley). The depth of valleys156,157,158is related to the height of the adjacent peak185,186,187,188and the angle of the slopes of the valleys156,157,158. A deeper valley will result in a shorter peak (i.e., a peak positioned closer to the bottom edge162) if the slope connecting the valley to the peak remains unchanged. Alternatively, a deeper valley with a steeper (i.e., more vertical) slope causes the height of the adjacent peak to remain unchanged. In various embodiments, however, the maximum depth of any valley should be such that the remaining material under the cut (i.e., the material between the thalweg, or base, of the valley and the bottom edge162of the key blade) is not less than one-third of the height of the original, unbitted key blank blade.

The “V”-shaped valleys156,157,158of the vertical bittings may be cut in an unskewed orientation (i.e., perpendicular to a longitudinal axis of the blade) or at a skewed orientation (i.e., at a non-perpendicular angle with respect to the longitudinal axis of the blade). Details of a bitting peak are described with reference to peak186and peak187. Peak186is defined by a first vertex167on the first side166of the key blade segment178and a second vertex169on the second side168of the key blade segment178with a top lateral edge176extending between the first vertex167and the second vertex169. Peak187is defined by a first vertex171on the first side166of the key blade segment178and a second vertex172on the second side168of the key blade segment178with a top lateral edge177extending between the first vertex171and the second vertex172. Differential skew angles of the adjacent valleys156and157forming peak186(i.e., the skew angle of valley156with respect to the longitudinal axis of the blade as compared to the skew angle of valley157with respect to the longitudinal axis of the blade) result in a vertical offset between the first vertex167and the second vertex169, and differential skew angles of the adjacent valleys157and158forming peak187result in a vertical offset between the first vertex171and the second vertex172. That is, because the skew angle of valley156with respect to the longitudinal axis of the blade is different from the skew angle of valley157with respect to the longitudinal axis of the blade, a vertical offset is created between first vertex167and the second vertex169. On the other hand, if the skew angle of valley156with respect to the longitudinal axis of the blade is the same as the skew angle of valley157with respect to the longitudinal axis of the blade, no vertical offset would be created between first vertex167and the second vertex169. Similarly, because the skew angle of valley157with respect to the longitudinal axis of the blade is different from the skew angle of valley158with respect to the longitudinal axis of the blade, a vertical offset is created between first vertex171and the second vertex172. If the skew angle of valley157with respect to the longitudinal axis of the blade were the same as the skew angle of valley158with respect to the longitudinal axis of the blade, no vertical offset would be created between first vertex171and the second vertex172. This is further illustrated inFIGS.9-10as described below.

Referring toFIG.7, the positions of vertex167and vertex169along the key blade segment178is governed by the nature of the warding surfaces164, the depth of adjacent valleys156,157, the slopes of the “V” cuts (e.g., the cuts of valley156and valley157), and the skew angles of valleys156and157. As described above, the skew angles of valleys156and157impact the vertical offset between vertex167and the vertex169. Similarly, the positions of first vertex171and second vertex172along the key blade segment178is governed by the nature of the warding surfaces164, the depth of adjacent valleys157,158, the slope of the “V” cuts (e.g., the cuts of valley157and valley158), and skew angle of valleys157and158(creating an offset between first vertex171and second vertex172). For example, modifying valley156to extend deeper (i.e., closer to the bottom edge162of the key blade178) while maintaining the same slope of the “V” cut of valley156will reduce the height of peak186and reposition vertex169, top lateral edge176, and vertex167to a lower position (i.e., closer to the bottom edge162) and closer to peak187.

To further illustrate the effect of the depth of the valley, the nature of the warding surface, the slope of the “V” cuts, and the skew angles of the valleys,FIG.8depicts lateral edge176of peak186having vertex167and vertex169, and lateral edge160of peak185having vertex260and vertex262. Axis161represents the approximate center line of the key blade segment178which is also the general path that a tumbler pin of a lock (not shown) would pass over when the key blade178is inserted into the lock (i.e., vertical pin axis). Vertices167,169,260, and262are each positioned in a different location (height) relative to the bottom edge162of the key blade segment178and the vertical pin axis161. Vertex167and vertex169are positioned at a higher or a further distance from bottom edge162than vertex260and vertex262because peak186is higher, or at a further distance from bottom edge162, than peak185. Vertex167and vertex169are positioned to the right of vertical pin axis161because the warding surface164at the height of peak186extends to the right of vertical pin axis161. Due to the warding shape at the height of peak185, vertex262is positioned to the left of vertical pin axis161and vertex260is positioned to the right of vertical pin axis161at a distance greater than vertex169but less than vertex167. When blade178is inserted into a lock having tumbler pins, the pins are more likely to become caught on vertex169or vertex262because vertex169and vertex262are closer to the pathway of the tumbler pin than vertex167or vertex260.

FIG.9is a partial cross-sectional view of peak186through and parallel to top lateral edge176(i.e., the cross section is not perpendicular to the longitudinal axis of the blade). Peak186has a first side230and second side232. As shown inFIG.9, vertex167on the first side230of peak186is offset at a lower position (relative to horizontal) than vertex169on the second side232of peak186so that top lateral edge176is tilted in a clockwise direction by an angle154between the top lateral edge176and an axis195parallel to the bottom edge162(horizontal inFIG.9). Side230corresponds to the angled warding surface164on the first side166of the key blade segment, and side232corresponds to the angled warding surface164on the second side168of the key blade segment. Side230extends inward relative to vertex167(i.e., beneath vertex167) and top lateral edge176, thereby forming a first vertex angle236between top lateral edge176and side230. Side232extends outward and away from vertex169and top lateral edge176, thereby forming a second vertex angle238between top lateral edge176and side232. Vertex angle236and vertex angle238vary in degree based on the shape of the warding surfaces164and the angle154of the top lateral edge176, which in turn is determined by the differential skew angles forming valleys156and157as described above. Side230, angled inward relative to vertex167, forms a vertex angle236that is smaller than vertex angle238, whereas side232is angled outward relative to vertex169. Thus, the key segment has a more severe “point” at vertex167than at vertex169. Vertex169is positioned closer to the path of a tumbler pin, (i.e., closer to vertical pin axis161) when the key is inserted into a lock (not shown) than vertex167and is more likely to contact the tumbler pin. However, since side232extends outward and vertex angle238is less acute, the tumbler pin is less likely to become caught on vertex169. If the tumbler pin contacts vertex167, the pin is more likely to become caught on vertex167than vertex169because vertex angle236is more acute than vertex angle238, and side230extends inwardly relative to vertex167and top lateral edge176rather than outwardly. Thus, the angle and orientation of warding surface164on second side232results a less acute, or even obtuse, angle238at vertex169, so that a tumbler pin, which has greater contact with vertex169than vertex167, is less likely to get caught on vertex169.

FIG.10is a partial cross-sectional view of peak187through and parallel to top lateral edge177(i.e., the cross section is not perpendicular to the longitudinal axis of the blade). Peak187has a first side240and a second side242. As shown inFIG.10, first vertex171on the first side240of peak187is offset at a higher position (relative to horizontal) than second vertex172on the second side242of peak187so that top lateral edge177is tilted in a counterclockwise direction by an angle155between the top lateral edge177and an axis201parallel to the bottom edge162(horizontal inFIG.10). Side240corresponds to the angled warding surface164on the first side166of the key blade segment, and side242corresponds to the angled warding surface164on the second side168of the key blade segment. Side240extends inward relative to first vertex171and top lateral edge177, thereby forming a first vertex angle246between top lateral edge177and side240. Side242extends outward and away from second vertex172and top lateral edge177, thereby forming a second vertex angle248between top lateral edge177and side242. First vertex angle246and second vertex angle248vary in degree based on the shape of the warding surfaces164and the angle155of the top lateral edge177, which in turn is determined by the differential skew angles forming valleys157and158as described above. Side240angled inward relative to first vertex171forms a first vertex angle246that is smaller than second vertex angle248, where side242is angled outward relative to vertex172. Thus, the key segment has a more severe “point” at first vertex171than at second vertex172. If first vertex171or second vertex172is positioned closer to the path of a tumbler pin (i.e., closer to vertical pin axis161) when the key is inserted into a lock (not shown), the pin may become caught on first vertex171or second vertex172. The pin is more likely to become caught on first vertex171than second vertex172because first vertex angle246is more acute than second vertex angle248and side240extends inward relative to first vertex171and top lateral edge177rather than outward.

As the key is inserted into a lock, tumbler pins with beveled ends slide over the “V” cut vertical bittings. Pushing the key into the lock forces the pins to rotate. A pin contacts and travels up a first side of a peak of the bitting. The pin rotates to align its beveled end with the skew angle of the first side of the peak. When the pin slides down a second side of the peak, a spring pushes the pin down and the pin rotates to align its beveled end with the skew angle of the second side of the peak. Before the pin slides down the second side of the peak, if a vertex of a peak is positioned near the path of the beveled end of the pin, the pin may become caught on the vertex and not rotate correctly. The pin is more likely to become caught on an inward extending warding surface, particularly if the inward extending warding surface forms a vertex having a more severe angle between the side of the peak and the top lateral edge. Interference of the bitting peak vertex with rotation of the pin is exacerbated if the pin includes a longitudinal slot that extends through the beveled end of the pin, and the vertex may become caught in the edge of this slot.

The interference of the vertices can be minimized by providing straight warding surfaces that are oriented perpendicular to a tumbler pin axis where the top lateral edges of the bitting peaks are formed. As further described below, horizontal warding surfaces, that are perpendicular to the vertical pin axis, minimize the interference of vertices formed by skew cut bittings on the top edge of a key blade segment for a vertical cylinder lock. Vertical warding surfaces that are perpendicular to a horizontal pin axis minimize the interference of vertices formed by skew cut bittings on the side edge or rib of a key blade segment for a horizontal cylinder lock.

FIGS.11and12depict a key blade segment208having a top edge190, bottom edge192, first side196, and opposing second side198, with horizontal warding surfaces194on the first side196and second side198of the key blade segment208and forming longitudinal warding grooves with horizontal upper and lower surfaces. The horizontal warding surfaces194are substantially parallel to the bottom edge192and perpendicular to a vertical tumbler pin axis254. In this regard, the surfaces194are actually horizontally-oriented only when the key blade is oriented as shown inFIG.12. In addition, as shown inFIG.12, the warding grooves and ridges forming the horizontal warding surfaces194include peaks and valleys that are curved, and thus, the horizontal warding surfaces194constitute only portions of those grooves and ridges.

Vertical pin axis254represents the approximate center line of the key blade segment208, which is also the general path that a vertical tumbler pin (not shown) would pass over when the key blade is inserted into a lock (not shown). In the embodiment shown inFIGS.11and12, side196is offset from vertical pin axis254, and horizontal bittings may be formed on side196as described above.

“V”-shaped vertical bittings are cut into the top edge190, forming alternating peaks191,213,215,217,219, and valleys193,214,216,218,220. The lowest portion of each valley defines a thalweg or base or root, such as valley216defining thalweg or base212or valley218defining thalweg or base227. Valleys formed in the vertical bittings, such as valleys193,214,216,218,220, may have the same or varying depths. In various embodiments, however, the maximum depth of any valley should be such that remaining material under the cut (i.e., the material between the thalweg or base of the valley and the bottom edge of the key blade) is not less than one-third of the height of the original, unbitted key blank blade in order to maintain the structural integrity of key blade.

The “V”-shaped valleys193,214,216,218,220of the vertical bittings may be cut in an unskewed orientation (i.e., perpendicular to a longitudinal axis of the blade) or at a skewed orientation (i.e., at a non-perpendicular angle with respect to the longitudinal axis of the blade). Details of a bitting peak are described with reference to peak215and peak219. Peak215is defined by a first vertex221on the first side196of the key blade segment208and a second vertex222on the second side198of the key blade segment208with a top lateral edge223extending between the first vertex221and the second vertex222. Peak219is defined by a first vertex224on the first side196of the key blade segment208and a second vertex225on the second side198of the key blade segment208with a top lateral edge226extending between the first vertex224and the second vertex225. The differential skew angles of the adjacent valleys214and216forming peak215(i.e., the skew angle of valley214with respect to the longitudinal axis of the blade as compared to the skew angle of valley216with respect to the longitudinal axis of the blade) result in a vertical offset between the first vertex221and the second vertex222. Similarly, the differential skew angles of the adjacent valleys218and220forming peak219result in a vertical offset between the first vertex224and the second vertex225. The offset between the first vertex221and the second vertex222of peak215is less than (i.e., top lateral edge223is more horizontal) than the offset between the first vertex224and the second vertex225of peak219. This is because the skew angles of the adjacent valleys214and216forming peak215are at a greater differential angle relative to the longitudinal axis of the blade compared to the skew angles of the adjacent valleys218and220forming peak219.

FIG.13is a partial cross-sectional view of peak215through and parallel to top lateral edge223(i.e., the cross section is not perpendicular to the longitudinal axis of the blade). Peak215has a first side250and a second side252. As shown inFIG.13, vertex221on the first side250of peak215is offset at a lower position (relative to horizontal) than vertex222on the second side252of peak215so that top lateral edge223is tilted in a counterclockwise direction by an angle251between the top lateral edge223and an axis253parallel to the bottom edge192(horizontal inFIG.13). Side250corresponds to the horizontal warding surface194on the first side196of the key blade segment, and side252corresponds to the horizontal warding surface194on the second side198of the key blade segment. Side250extends outward relative to vertex221and top lateral edge223, thereby forming a first vertex angle256between top lateral edge223and side250. Side252extends outward relative to vertex222and top lateral edge223, thereby forming a second vertex angle258between top lateral edge223and side252. Vertex angle256does not form a severe “point” at vertex221because of the shape of the warding surface194on side250and the angle251of the top lateral edge223, which in turn is determined by the differential skew angles forming peak215. Vertex angle258does not form a severe “point” at vertex222because of the shape of the warding surface194on side252of the key blade and the angle251of the top lateral edge223, which in turn is determined by the differential skew angles forming peak215. Vertex222is positioned closer to the path of a tumbler pin, (i.e., closer to vertical pin axis254) when the key is inserted into a lock (not shown) than vertex221and is more likely to contact the vertical tumbler pin. However, since side252extends outward relative to vertex222and top lateral edge223, and vertex angle258does not form a severe “point” at vertex222, the tumbler pin is less likely to become caught on vertex222. If the tumbler pin contacts vertex221, the pin is unlikely to become caught on vertex221because side250extends outward relative to vertex221and top lateral edge223, and vertex angle256does not form a severe “point” at vertex221.

To illustrate the effects of angled or horizontal warding surfaces on the severity of the vertex angle formed on bitting peaks, dashed lines A and B superimposed onFIG.13illustrate angled warding surfaces. As can be appreciated, while vertex angle258would be larger (less acute, more obtuse) on an angled warding surface represented by line B, vertex angle256would be smaller (more acute) forming a more “severe” point at vertex221on an angled warding surface represented by line A. Consequently, if the tumbler pin contacts vertex221on an angled warding surface as illustrated by line A and line B, the pin would be more likely to become caught on vertex221because line A extends inward relative to vertex221and top lateral edge223, and vertex angle258forms the severe “point” at vertex221.

In some embodiments, the key blade contains only horizontal warding surfaces between the top edge and the maximum bitting depth. In other embodiments, the key blade contains outward angled warding surfaces between the top edge and the maximum bitting depth. The warding shape below the maximum bitting depth will not impact the formation of interfering vertices because no top lateral edge will extend beyond this point. In some embodiments, the maximum bitting depth is not less than one-third of the height of the blade from the bottom edge.

A POSA would appreciate that the shape or contour of a keyway of a lock may correspond to the shape or contour of the key blade configured to be inserted into the keyway to operate the lock. In some embodiments, a keyway corresponding to the key blade described above contains only horizontal warding surfaces between a top edge of the keyway and a maximum bitting depth of the corresponding key blade. In other embodiments, the keyway corresponding to the key blade described above contains outward angled warding surfaces between the top edge of the keyway and the maximum bitting depth of the corresponding key blade.

The process of cutting skew cut bittings on the side edge of a key blade for a horizontal cylinder lock may similarly produce vertices which can interfere with the rotation of tumbler pins of a horizontal lock. As described above in connection with the vertically-oriented key blade for a vertical lock, the interference of vertices in connection with a horizontally-oriented key blade for a horizontal lock can be minimized by orienting vertical warding surfaces perpendicular to a horizontal pin axis where top lateral edges of the bitting peaks are formed.

FIG.14, depicts an embodiment of a cross-sectional shape of a key blade270of a key blank configured to receive edge bitting cuts and/or side bitting cuts so that a key formed from the blank may be operable in a vertical and/or a horizontal lock. The cross-sectional shape of the key blade270is defined by a primary top edge272having formed therein, or configured to have formed therein, bitting cuts for operating a vertical lock (e.g., elevating (positioning) and rotating the tumbler pins when the key blade is inserted into a keyway that is oriented parallel to the tumbler pins), a bottom edge274, a first side276having formed therein, or configured to have formed therein, bitting cuts for operating a horizontal lock (e.g., elevating (positioning) and rotating the tumbler pins when the key blade is inserted into a keyway that is oriented perpendicular to the tumbler pins), and an opposed second side278. The first side276includes a longitudinal rib280extending along some or all of the length of the blade270. Vertical pin axis282represents the approximate center line of the key blade segment270which is also the general path that a tumbler pin (not shown) configured for the vertical bittings would pass over when the key blade270is inserted into a keyway of a lock (not shown) that is oriented parallel to the pin axis282. Horizontal warding surfaces286perpendicular to the vertical pin axis282are formed on the first side276and the second side278of the key blade and minimize the interference of vertices in connection with bitting cuts for operating the vertical lock as described above with respect toFIGS.11-13.

Horizontal pin axis284represents the approximate center line of a tumbler pin (not shown) configured for the horizontal bittings. The horizontal pin axis284may be positioned at any point along the path the horizontal tumbler pin would pass over when the key blade is inserted into a keyway of a lock (not shown) that is oriented perpendicular to the pin axis284. Vertical warding surfaces288perpendicular to the horizontal pin axis284are formed on the rib280and minimize the interference of vertices in connection with bitting cuts for operating the horizontal lock. In other embodiments, the vertical warding surfaces288may be positioned at any point where top lateral edges of the horizontal bitting peaks (not shown) are formed.

FIGS.15,16, and17depict a cross-section of an embodiment of a blade298of a key blank having a top, or first, edge296, a first side342, a second side344and a bottom, or second, edge294. Top edge296is configured to receive edge bitting cuts and first side342is configure to receive side bitting cuts so that a key formed from the blank may be operable in a vertical and/or a horizontal lock, as applicable, similar toFIG.6described above.

Referring toFIG.15, the cross-sectional shape of the blade298includes three distinct keyway segments300,302,304between the top edge296and bottom edge294. First segment300is encompassed by a rectangular envelope306defined by top edge296(corresponding with the top edge296of the blade298) a first side boundary308, a second side boundary310, and a lower boundary312. First side boundary308and second side boundary310correspond to physical side surfaces of blade298within segment300, but lower boundary312is not a physical edge of the blade298but represents a boundary between first segment300and second segment302. The top edge296is configured to receive edge bitting cuts as described above. The edge bittings may extend to various depths relative to the top edge296, for example, as indicated by dimension lines1A-4A. In the embodiment shown inFIG.15, the edge bittings will not extend to a depth greater than the dimension shown by line4A to maintain the integrity of the blade. First side boundary308and second side boundary310of the first segment300have a first thickness314therebetween, with the first side boundary308and the second side boundary310equidistant from a centerline316extending through the blade from the top edge296to the bottom edge294. The side boundaries308,310of envelope306correspond to portions of the segment300furthest distant from the centerline316. In the illustrated embodiment, side boundaries308,310of envelope306correspond to opposed, parallel sides of the blade298within segment300. Lower boundary312of the envelope306is defined as the point at which the opposed sides of the blade298are no longer parallel and begin to flare outwardly from the centerline316.

In the embodiment shown inFIG.15, first segment300does not include warding grooves and/or ridges.

Second segment302is encompassed by a rectangular envelope318defined by upper boundary320(corresponding to lower boundary312of envelope306), a first side boundary322, a second side boundary324, and a lower boundary326. Upper boundary320and lower boundary326are not physical edges of the blade298, but represent boundaries between first segment300and second segment302and between second segment302and third segment304, respectively. The second segment302may be further characterized by various warding features that fall within the envelope318. The side boundaries322,324of envelope318correspond to portions of the segment302furthest distant from the centerline316. In the illustrated embodiment,FIG.15depicts the right side of segment302having a peak or plateau328and a paracentric groove330, which extends beyond the centerline316from the first side boundary322in the direction of the second side boundary324. The paracentric groove330is positioned at a transition between the second segment302and the third segment304. In other embodiments the paracentric groove330may be located at any position in the second segment302below the deepest bitting cut (e.g. as shown by dimension line4A) or any position in the third segment304. The left side of segment302has a plateau332which extends the length of the second segment302and continues into the third segment304. First side boundary322of envelope318corresponds to the peak328being the maximum distance from the centerline316. Second side boundary324of envelope318corresponds to the plateau332, being the maximum distance from the centerline316. First side boundary322and second side boundary324are equal distant from the centerline316, and a maximum width336of segment302is defined as the distance from first side boundary322to second side boundary324, or the distance from peak328to peak332.

Maximum width336of segment302(envelope318) is greater than maximum width314of segment300(envelope306).

Lower boundary326of the envelope318is defined as the point at which the right side of the blade298extends outwardly from groove330and is no longer equidistant from centerline316as second side boundary324of envelope318.

The third segment304is encompassed by a rectangular envelope338defined by an upper boundary340(corresponding to lower boundary326of envelope318), a first side boundary342, a second side boundary344, and the bottom edge294. Upper boundary340is not a physical edge of blade298, but represents a boundary between second segment302and third segment304. Third segment304includes a longitudinal rib346within the envelope338and is configured to receive side bitting cuts that may extend from bottom edge294into the right-hand side of segment302. The side bittings may be cut to various depths relative to the first side342, for example as shown by dimension lines1B-3B.

The side boundaries342,344of envelope338correspond to portions of the segment304furthest distant from the centerline316. In the illustrated embodiment,FIG.15depicts the right side of segment304having longitudinal rib346with a warding groove348bisecting the rib346into an upper rib portion346aand lower rib portion346b, and the left side of segment304having a peak349between two grooves defining valleys350,352as well as a lobe354. First side boundary342of envelope338corresponds to the outer edge of rib346(i.e., portion furthest from centerline316), and second side boundary344of envelope338corresponds to the outer edge of peak349or lobe354(i.e., portions equally furthest from centerline316). The maximum width356of segment304is defined as the distance from first side boundary342to second side boundary344, or the distance from rib346to peak349.

The maximum thickness356of segment304is greater than the maximum thickness314of segment300and the maximum thickness336of segment302, and the first side boundary342and second side boundary344are not equidistant from the centerline316. Rather, a distance358between the centerline316and the first side boundary342of the envelope338is greater than a distance360from the centerline316to the second side boundary344of envelope338. The distance360between the centerline316and the second side boundary344of envelope338is equal to a distance362between the centerline316and the second side boundary324of envelope318, so that the second side boundary344of envelope338is coplanar with the second side boundary324of envelope318. Thus, while first segment300and second segment302are symmetric with respect to centerline316, third segment304is asymmetric with respect to centerline316.

FIG.16depicts a cross-sectional view of a horizontal lock364, a tumbler pin366having a beveled end367, and blade298having one or more side bittings. The horizontal lock364has an outer housing with a cylinder or plug rotatably housed within the housing and a horizontally-oriented, axially a keyway368profile between an open first side370and an enclosed second side372corresponding to the shape or contour of the key blade298. Keyway368includes features corresponding to contour features of first side342of key298, such as a ridge corresponding to paracentric groove330, grooves corresponding to upper rib portion346aand lower rib portion346b, and a ridge corresponding to warding grove348. In addition, keyway368includes features corresponding to contour features of second side344of key298, such as a groove conforming to lobe354, a ridge corresponding to valley352, a groove corresponding to peak349, and a ridge corresponding to valley350.

As the key blade298is inserted into the keyway368, the tumbler pin366contacts the upper portion346aand lower portion346bof the rib346in the third segment304and the beveled end367extends into the warding groove348. As the key blade298moves through the keyway368to a fully inserted position as shown inFIG.16, the beveled end367of the tumbler pin366contacts a corresponding side cut which elevates and rotates the tumbler pin366into an unlocked position.

FIG.17depicts a cross-sectional view of a vertical lock363, a tumbler pin365having a beveled end369, and blade298having one or more edge bittings. The vertical lock363has an outer housing with a cylinder or plug rotatably housed within the housing and a vertically-oriented, axially a keyway375profile between an open first side371and an enclosed second side373corresponding to the shape or contour of the key blade298. Keyway375, which is configured to receive key298, includes features corresponding to paracentric groove330, upper rib portion346aand lower rib portion346b, warding grove348, lobe354, valley352, peak349, and valley350.

As the key blade298is inserted into the keyway375, the beveled end369of the tumbler pin365contacts the top edge296of the key blade298in the first segment300. As the key blade298moves through the keyway375to a fully inserted position as shown inFIG.17, the beveled end369of the tumbler pin365contacts a corresponding edge bitting which elevates and rotates the tumbler pin365into an unlocked position.

In some embodiments, the key blade contains only vertical warding surfaces. In other embodiments, the key blade contains vertical warding surfaces and horizontal warding surfaces.

Referring toFIG.17, vertically-oriented keyway375may be divided into first380, second382, and third384keyway segments of relative widths and symmetry corresponding to segments300,302,304, respectively, of key blade298. Referring toFIG.16, horizontally-oriented keyway368may be divided into first386, second388, and third390keyway segments, with second and third388,390keyway segments of relative widths and symmetry corresponding to second and third segments302,304, respectively, of key blade298.

A POSA would appreciate that the shape or contour of a keyway of a lock may correspond to the shape or contour of the key blade configured to be inserted into the keyway to operate the lock. In some embodiments, a keyway of a horizontal cylinder lock corresponds to a key blade having only vertical warding surfaces (such as vertical warding surfaces288). In other embodiments, a cylinder lock configured to receive edge bitting cuts and side bitting cuts so that a key formed from the blank may be operable in a vertical and/or a horizontal lock corresponds to a key blade having vertical warding surfaces (such as vertical warding surfaces288) and horizontal warding surfaces (such as horizontal warding surfaces286).

Further, it could be appreciated that a key made from a modified key blank having a key blade with a cross-sectional shape encompassing only the third segment304(i.e., including only warding groove348, upper rib portion346a, lower rib portion346b, a peak349, valleys350,352, and lobe354and not including any portion of the key blade298corresponding to first segment300or second segment302), or a cross-sectional shape encompassing only the second segment302and third segment304(and not including any portion of the key blade corresponding to first segment300) and having appropriate side bittings that are complementary to tumbler pin(s)366could operate the horizontal lock364ofFIG.16. Such a modified key could not, however, operate the vertical lock363ofFIG.17.

FIG.18depicts an embodiment of a modified key blank having a key blade298awith a cross-sectional shape encompassing only the third segment304, including only warding groove348, upper rib portion346a, lower rib portion346b, a peak349, valleys350,352, and lobe354and not including any portion of the key blade298corresponding to first segment300or second segment302.FIG.22shows a cross-sectional view of modified key blade298ainserted into horizontal lock364with horizontally-oriented keyway368.FIG.23shows a cross-sectional view of modified key blade298ainserted into vertical lock363with vertically-oriented keyway375.

FIG.19depicts an embodiment of a modified key blank having a key blade298bwith a cross-sectional shape encompassing only the second segment302and third segment304(and not including any portion of the key blade298corresponding to first segment300).FIG.24shows a cross-sectional view of modified key blade298binserted into horizontal lock364with horizontally-oriented keyway368.FIG.25shows a cross-sectional view of modified key blade298binserted into vertical lock363with vertically-oriented keyway375.

FIG.20depicts an embodiment of a modified key blank having a key blade63awith a first edge68, a second edge76, a first side surface78, and an opposed second side surface79defining a cross-sectional shape encompassing only the third segment114, including only longitudinal rib128, undercut152, lobe154, and not including any portion of the key blade63corresponding to first segment98or second segment106.

FIG.21depicts an embodiment of a modified key blank having a key blade63bwith a first edge68, a second edge76, a first side surface78, and an opposed second side surface79defining a cross-sectional shape encompassing only the second segment106and third segment114(and not including any portion of the key blade63corresponding to first segment98).

In various embodiments, a key blank or modified key blank may be formed into a key and used in a lock system comprising a vertical cylinder lock, such as vertical cylinder lock4inFIG.1and vertical cylinder lock363inFIG.17, and a horizontal cylinder lock, such as horizontal cylinder lock34inFIG.2and horizontal cylinder lock364shown inFIG.16.

In one embodiment, the vertical cylinder lock4or363comprises a housing, a cylinder rotatably disposed within the housing, and a vertically-oriented keyway2or375within the cylinder, as shown inFIGS.1and17. The vertically-oriented keyway2has a height and a width that is less than the height. The vertically-oriented keyway2is configured to receive a key blade, for example blade63shown inFIG.6or key blade298shown inFIG.15.

Referring toFIGS.1and17, the vertically-oriented keyway2,375is divided into first keyway segment45,380, second keyway segment47,382, and third keyway segment49,384along its height. The first keyway segments45,380correspond to first blade segments98,300, respectively, second keyway segments47,382correspond to second blade segments106,302, respectively, and third keyway segments49,384correspond to third blade segments114,304, respectively. The vertically-oriented keyway2,375further includes least one twisting tumbler pin, e.g., pin365ofFIG.17, oriented within the cylinder so as to be parallel to the height of the vertically-oriented keyway2,375and configured to be elevated and rotated by a complementary bitting formed on a first edge68,296of a key inserted into the keyway2,375.

Referring toFIGS.2and16, the horizontal cylinder lock34,364comprises a housing, a cylinder rotatably disposed within the housing, a horizontally-oriented keyway32,368within the cylinder. The horizontally-oriented keyway32,368has a height and a width that is greater than the height. Like the vertically-oriented keyway2and375, horizontally-oriented keyway32,368is configured to receive a key blade, for example key blade63as shown inFIG.6and key blade298shown inFIG.15

As shown inFIGS.2and16, the horizontally-oriented keyway32,368is divided into first keyway segment59,386, second keyway segment53,388, and third keyway segment55,390along its width. The second keyway segments53,388correspond to second blade segments106,302, respectively, and third keyway segments55,390correspond to the third blade segment114,304, respectively. The horizontally-oriented keyway32,368further includes at least one twisting tumbler pin, e.g., pin366ofFIG.16, oriented within the cylinder so as to be parallel to the height of the keyway32,368and configured to be elevated and rotated by a complementary bitting formed on a first side surface78,342of a key inserted into the keyway32,368. The tumbler pin of the horizontal cylinder lock34,364is aligned primarily with the third keyway segment55,390of the horizontally-oriented keyway32,368.

The lock system may further include a key having a key blade, such as such as blades63,63a,63b,270,298,298a, or298bshown inFIGS.3-6,14-15,18-21, wherein the blade has a cross sectional shape such that the key can be inserted into both the vertically-oriented keyways2,375of the vertical cylinder locks4,363and the horizontally-oriented keyways32,368of the horizontal cylinder locks34,364. The cross sectional shape of the key is defined by at least one blade segment114or304corresponding to the third keyway segment49,384of the vertically-oriented keyway2,375of the vertical cylinder lock4,363and the third keyway segment55,390of the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364. The key has at least a bitting formed on the first side surface78,342of the key and configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock34,364.

In various embodiments, a key blank or modified key blank may be formed into a key for a horizontal cylinder lock, such as horizontal cylinder lock34inFIG.2and horizontal cylinder lock364shown inFIG.16. The horizontal cylinder lock34,364includes a housing, a cylinder rotatably disposed within the housing, and a horizontally-oriented keyway32,368within the cylinder. The horizontally-oriented keyway32,368has a height and a width that is greater than the height. The horizontally-oriented keyway32,368is configured to receive a key blade, for example blade63as shown inFIG.6and key blade298shown inFIG.15.

Referring toFIGS.2and16, the horizontally-oriented keyway32,368is divided into first keyway segment59,386, second keyway segment53,388, and third keyway segment55,390along its width. The first keyway segment59,386corresponds to the first blade segment98,300, the second keyway segment53,388corresponds to the second blade segment106,302, and the third keyway segment55,390corresponds to the third blade segment114,304. The horizontal cylinder lock34,364further includes at least one twisting tumbler pin, e.g., pin366ofFIG.16, oriented within the cylinder so as to be parallel to the height of the horizontally-oriented keyway32,368and configured to be elevated and rotated by a complementary bitting formed on a first side surface78,342of a key inserted into the keyway32,368.

A key includes a blade, such as such as blades63,63a,63b,270,298,298a, or298bshown inFIGS.3-6,14-15,18-21wherein the blade has a cross sectional shape such that the key can be inserted into the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364. The cross sectional shape of the key is defined by only one blade segment114,304corresponding to the third keyway segment55,390of the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364and lacking any blade segment that corresponds to the first59,386or second53,388keyway segments of the horizontally-oriented keyway32,368as shown inFIG.18or20. Alternatively, the cross sectional shape of the key is defined by only two blade segments corresponding to the second53,388and third55,390keyway segments of the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364and lacking any blade segment that corresponds to the first keyway segment59,389of the horizontally-oriented keyway32,368as shown inFIG.19or21.

The blade includes at least one bitting formed on the first side surface of the blade, and wherein the bitting is configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock34,364.

In various embodiments, a key blank or modified key blank may be formed into a key to be used in a method for operating a horizontal cylinder lock, such as horizontal cylinder lock34inFIG.2and horizontal cylinder lock364shown inFIG.16. The horizontal cylinder lock34,364includes a housing, a cylinder rotatably disposed within the housing, and a horizontally-oriented keyway32,368within the cylinder. The horizontally-oriented keyway32,368has a height and a width that is greater than the height. The horizontally-oriented keyway32,368is configured to receive a key blade, for example blade63as shown inFIG.6and key blade298shown inFIG.15.

Referring toFIGS.2and16, the horizontally-oriented keyway32,368is divided into first keyway segment59,386, second keyway segment53,388, and third keyway segment55,390along its width. The first keyway segment59,386corresponds to the first blade segment98,300, the second keyway segment53,388corresponds to the second blade segment106,302, and the third keyway segment55,390corresponds to the third blade segment114,304. The horizontal cylinder lock34,364further includes at least one twisting tumbler pin, e.g., pin366ofFIG.16, oriented within the cylinder so as to be parallel to the height of the horizontally-oriented keyway32,368and configured to be elevated and rotated by a complementary bitting formed on a first edge68first side surface78,342of a key inserted into the keyway32,368.

The method comprises inserting a key blade, such as such as blades63,63a,63b,270,298,298a, or298bshown inFIGS.3-6,14-15,18-21, into the horizontally-oriented keyway32,368, wherein the blade has a cross sectional shape such that the key can be inserted into the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364. The cross sectional shape of the key is defined by only one blade segment114, corresponding to the third keyway segment55,390of the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364and lacking any blade segment that corresponds to the first59,386or second53,388keyway segments of the horizontally-oriented keyway32,368as shown inFIG.18or20. Alternatively, the cross sectional shape of the key is defined by only two blade segments corresponding to the second53,388and third55,390keyway segments of the horizontally-oriented keyway32,368of the horizontal cylinder lock34,364and lacking any blade segment that corresponds to the first keyway segment59,389of the horizontally-oriented keyway32,368as shown inFIG.19or21. The blade includes at least one bitting formed on the first side surface78,342of the blade, and the bitting is configured to elevate and rotate the at least one tumbler pin of the horizontal cylinder lock34,364. Inserting the key blade into the horizontally-oriented keyway32,368comprises inserting the segment of blade114,304corresponding to the third keyway segment49,384into the third segment49,384of the keyway.

While the subject matter of this disclosure has been described and shown in considerable detail with reference to certain illustrative embodiments, including various combinations and sub-combinations of features, those skilled in the art will readily appreciate other embodiments and variations and modifications thereof as encompassed within the scope of the present disclosure. Moreover, the descriptions of such embodiments, combinations, and sub-combinations is not intended to convey that the claimed subject matter requires features or combinations of features other than those expressly recited in the claims. Accordingly, the scope of this disclosure is intended to include all modifications and variations encompassed within the scope of the following appended claims.