Vehicular lock apparatus and method

In some embodiments, lock assemblies are disclosed which have a housing, a barrel, and at least one tumbler. In some cases, the lock is codeable after the lock assembly has been assembled. Although not required, some embodiments can be re-coded to a new code with and without disassembling the lock assembly. The tumbler(s) can be pivotable, while in other embodiments the tumbler(s) move in a substantially linear fashion. The tumbler(s) can be comprised of two pieces or portions, wherein one piece/portion of the tumbler(s) either directly or indirectly engages the coded surface of a key while the other piece/portion is positionable to prevent rotation of the barrel with respect to the housing. In some embodiments, the tumblers are external to the barrel.

FIELD OF INVENTION

This invention relates generally to locks and methods of operating locks, and more particularly to codeable vehicular locks and methods for coding vehicular locks.

BACKGROUND OF THE INVENTION

Despite numerous developments in vehicular lock technology, several problems still exist with conventional vehicular locks. Among the most familiar to vehicle manufacturers are problems related to pre-coded lock sets. Vehicles are typically provided with a set of locks, such as multiple door locks, a trunk lock, a glove box lock and/or an ignition lock. In most cases, two or more of the locks for a vehicle are operated with a common key. Where multiple locks for a vehicle are coded to the same key, the commonly-coded locks are often sent to a vehicle manufacturer together as a set. During vehicle assembly, these lock sets must be carefully labeled and tracked to ensure that they are installed in the same vehicle—even after being sent to different assembly stations or otherwise being moved to different locations in preparation for installation. When a vehicle is being assembled, it is important that each lock in the set be installed in the same vehicle. If locks from different sets get interchanged during assembly, multiple vehicles would have to have new locks installed. This can involve the removal of such vehicles from an assembly line and/or can cause the assembly line to be temporarily stopped. Thus, the use of pre-coded lock sets can be very costly and time consuming to vehicle manufactures.

Generally, a codeable lock is a lock that can be coded to a key after the lock has been assembled and/or after the lock has been installed. Typically, conventional codeable locks employ two-piece tumblers. These two-piece tumblers often have a first member that “reads” the coded surface of a key inserted in the lock assembly and a second member that can releasably engage a housing of the lock assembly. In such lock assemblies, the two tumbler members are normally not connected or otherwise engaged to one another prior to coding of the lock assembly. However, the code of the lock is determined at least in part upon the relationship between these two tumbler members when they are joined together. To join the member of each tumbler together in order to code the lock assembly, a key is inserted into the lock assembly. In some cases, the positions of the tumbler members change according to the depth of the key cut at the locations of the tumblers. Next, with the key still inserted, the two members of each tumbler are forced together to set the code for the tumblers. The relationship between the two pieces can be held by serrated edges on the pieces joined together. Thus, with a codeable lock, there is little to no concern regarding mixing lock sets together. Unfortunately, this type of codeable lock design has a number of inherent limitations that limit its feasibility for use in many applications (such as vehicular applications).

One problem with conventional codeable locks is that they normally do not enable enough coding sequences. Generally, a pre-coded lock has multiple tumblers that read the key surface in a number of positions along a key. For example, many pre-coded locks read the key surface at seven places along the key. At each of these positions, a key can have a number of different depths. In many locks for example, the key has five depths that are read by locks. Thus, many pre-coded locks are potentially capable of a large number of different codings (in some cases, over 70,000 combinations). Many codeable locks, however, cannot be coded to a large number of different depths of a key, or at least can only be coded to a fraction of the number of possible key depths. For example, rather than having five different depth codings per tumbler, some codeable locks are only capable of having a maximum of three depth codings per tumbler. A number of key and lock design considerations limit the number of practical codes for a key. For example, it is normally desirable to avoid key codes in which all or substantially all of the notch depths are the same. However, larger numbers of potential codes for a lock normally result in larger numbers of practical codes for the same lock.

One of the reasons why only a limited number of coding sequences is possible in conventional codeable locks is due to the serrated edges often employed in multiple-piece (e.g., two-piece) tumblers. In order for a conventional codeable lock to be strong enough to withstand attempts at picking or overpowering the lock, the serrations retaining the engagement of the tumbler members to one another must be relatively large. Since the size of a vehicle lock's barrel is already predetermined by a number of esthetic standards and other design considerations, these large serrations permit fewer coding variations between the members of each tumbler. One way a conventional codeable lock with a fixed barrel size could have more coding variations is to employ smaller serrations for the tumbler members. Unfortunately, this also makes the lock more susceptible to picking and overpowering and to inadvertent shifting between the two tumbler pieces.

Another significant limitation in conventional codeable locks is related to the linear movement of the two-piece tumblers sometimes employed. Specifically, conventional two-piece tumblers employ tumbler members that move in a linear fashion during the coding process. In other words, the key-engaging member is limited to linear displacement in response to contact with the key notch steps of the key surface. In a number of applications (including automotive applications), the maximum size of the key and the distance between the deepest and shallowest key notches are largely determined by esthetic considerations. An advantage of using two-piece pivotable tumblers in a codeable lock rather than using linearly-moving tumblers in a codeable lock is that the pivoting tumbler is capable of magnifying the key notch depths read by the tumbler. This is due to the fact that the length of an arc traced by a pivoting tumbler increases as the distance from the pivot point of the tumbler increases.

Another problem with conventional codeable locks is that such locks have normally been designed for use in building doors. The design constraints for vehicle door locks can be significantly greater than those for building door locks. For example, building door locks can often be made larger without consequence, thereby enabling such locks to have more room for more coding sequences. To scale the barrel down to the customary size of a barrel on a vehicle (where lock size and weight are typically much greater concerns) would only magnify the problems discussed above. In light of the problems and limitations of the prior art described above, a need exists for a codeable lock assembly that is reliable, can be relatively small, is strong enough to resist picking and overpowering, can be manufactured and assembled at relatively low cost, can have a large number of coded states, is simple to operate for purposes of coding the lock assembly, and can employ tumbler elements that pivot during the coding process. Each embodiment of the present invention achieves one or more of these results.

SUMMARY OF THE INVENTION

The lock assembly according to some embodiments of the present invention has a housing, a barrel disposed within the housing and rotatable with respect thereto, and at least one pivotable tumbler. In some embodiments, the lock assembly has a plurality of pivotable tumblers. The pivotable tumblers can provide many advantages that many tumblers moving in a linear manner cannot. Comparing the path of an arc to a chord of the arc (which represents a linear path), it is clear that the arc can provide more movement within a confined space. Pivotable tumblers can therefore allow for more possible coding sequences than many linear-acting tumblers because the pivoting motion allows for more movement within the confined space of a lock assembly barrel.

In some embodiments of the present invention, the tumblers are two-piece rotatable tumblers, one piece of the two-piece tumblers engaging the coded surface of a key while the other piece engages the housing. These tumblers can provide many advantages when compared to conventional linear-acting two-piece tumblers. As discussed above, one advantage is the potential for an increased number of coding sequences for the tumblers. In some embodiments, this is due at least in part to the fact that pivoting motion creates a longer path of tumbler member motion within a confined space. In addition, more relative motion can be enabled by such a relationship between tumbler pieces, which allows for more coding sequences, if desired.

Alternatively or in addition, the pieces of a two-piece tumbler can be arranged to lie substantially in two different adjacent planes, thereby conserving valuable space that can be used to accommodate larger and stronger coding surfaces of the tumbler pieces. For example, if a serrated edge were used to lock the two elements of a tumbler together during tumbler coding, the serrations could be made larger (and in some cases, larger than those of conventional locks), which provides for greater tumbler strength. The serrations can be larger because more room is created for elements to move due to the pivoting movement (as discussed above) and/or due to the two tumbler pieces being located in different adjacent planes.

In some embodiments of the present invention, the tumblers are external to the barrel. These tumblers can be pivotable with respect to the barrel. However, because more room can be available for multiple coding sequences due to the external locations of the tumblers, the tumblers in such embodiments can instead move in a linear or substantially linear fashion. Additionally, these embodiments can utilize a sidebar to prevent rotation of the barrel with respect to the housing in the locked state.

Also, some embodiments of the present invention employ two piece tumblers that move linearly or substantially linearly, and move in an overlapping relationship to gain additional space within the barrel for added security and more coding sequences. In this regard, various combinations of male/female couplings can be employed to create overlap between the two pieces when they are placed in the coded condition. For example, in some embodiments one piece of the two piece tumbler is secured about a portion of the other piece in the coding process. In other examples, a pin or other projection on one piece mates with an aperture or other feature of the other piece.

In some cases, the codeable lock embodiments of the present invention are codeable after the lock assembly has been assembled (whether using pivotable two-piece tumblers or otherwise). This capability can provide one or more of the advantages discussed above. As also previously discussed, advantages can be achieved by employing pivotable two-piece tumblers in such embodiments, including the fact that more codings can be enabled by the use of an rotational tumbler path within the confined space of the lock assembly. Other advantages provided by some embodiments include the lack of need for lock sets, elimination of problems associated with tracking the location of locks within a set, and the reduction of costly vehicle assembly mistakes.

Although not required, the lock assembly according to some embodiments of the present invention can be re-coded to a new code, and in some cases can be re-coded without disassembling the lock assembly, thereby saving considerable cost in re-coding a vehicle if a key is lost or stolen.

Further objects and advantages of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings.

DETAILED DESCRIPTION OF THE EMBODIMENTS

One embodiment of a lock assembly according to the present invention is illustrated inFIGS. 1–13. With reference first toFIGS. 1–5, the illustrated lock assembly (indicated generally at29) includes a housing14, a barrel30located within and selectively rotatable with respect to the housing14, and tumblers23coupled for pivotable movement within the barrel30. By way of illustration, a lock and key set10of this nature operates by inserting a properly coded key1into a key slot26(seeFIG. 12) at the end of the barrel30. As the key1enters the barrel30, the coded surface of the key1engages the pivotable tumblers23, causing a part of each tumbler23to pivot. In other embodiments, entry of the key1into the barrel30causes each tumbler23to pivot in its entirety. As used herein, the term “pivotable tumbler” (in its various forms) refers to one-piece tumblers23that are pivotable within the lock assembly29as well as two-piece or multiple-piece tumblers23having one or more pieces that are pivotable within the lock assembly29.

When the properly-coded key1is fully inserted into the lock assembly29, the tumblers23are moved by surfaces of the key1from respective positions in which one or more tumblers23extend out of the barrel30(FIG. 3) to positions in which the tumblers23are retracted within the barrel30(FIG. 4). In some embodiments, all of the tumblers23are moved from extended positions to retracted positions upon insertion of the key1. The key1and the barrel30can then be rotated to unlock the mechanism to which the lock assembly29is connected. In this position, the lock assembly29is unlocked. The key1can then be rotated back to the original position and can be removed (or in some embodiments, can be removed without such rotation). In this position, the lock assembly29is in a locked state because the barrel30cannot rotate within the housing14. By removing the key1, the tumblers23can pivot back to their original positions in which at least one tumbler23extends from the barrel30toward the housing14. With reference toFIGS. 1,2, and5of the illustrated embodiment, the lock assembly29of this embodiment has a housing14. In some embodiments, the housing14is the interface between the lock assembly29and the element, assembly, or device being locked. The outer surfaces39and40of the housing14can be configured for mating to and retaining the lock assembly29in elements, assemblies, and devices of various applications, including but not limited to vehicle doors, deck lids, steering columns, dashboards, trunks, glove boxes, and other vehicular applications.

In some embodiments of the present invention, the housing14also supports various other working components of the lock assembly29. As shown inFIG. 2for example, the housing14can have a varying diameter along its length into which the barrel30is axially received. The inner surface of the barrel30can have stepped surfaces (34,35) as shown, can vary in any other manner, or can have a substantially constant diameter. The housing14of some embodiments has two internal axial grooves36,37that can receive portions52,63of the pivotable tumblers23(see FIGS.2and11A–E) extending from the barrel30in the locked state of the lock assembly29. The two internal axial grooves36,37can also receive portions32,33of the pivotable tumblers23which can extend from the barrel30when the wrong key is inserted into the barrel30. As mentioned above, when the tumblers23are moved to extend from the barrel30to the housing14, the tumblers23resist rotation of the barrel30within the housing14. Any number of grooves36,37or other recesses can be located in any portion of the barrel interior in order to receive the tumblers23for this purpose. Because the tumblers23in the embodiment illustrated inFIGS. 1–13are pivotable in two different directions about an axis as will be described in greater detail below, a minimum of two grooves in the housing14are employed with this embodiment. In some embodiments, the barrel30accepts and supports the pivotable tumblers23as well as one or more resilient biasing members (such as springs12) to bias some or all of the pivotable tumblers23in a direction extended from the barrel30toward the housing14. In this regard, the barrel30can have apertures24through which the tumbler ends52,63extend when they are pivoted to extended positions (i.e., locked positions) as shown inFIG. 3, and through which the tumbler ends52,63can extend when a wrong key is used. Alternatively, the barrel30can have any other shape permitting the tumbler ends52,63to extend toward the housing14for engagement therein or to be received within recesses, grooves, or other apertures in the housing14. In the unlocked position shown inFIG. 4, the tumbler ends52&63retract back within the periphery of the barrel30to permit the barrel30to rotate within the housing14.

As shown in FIGS.1and3–5, the barrel30can be constructed in two sections11,13joined together by rivets, welds, screws, bolts, snap-fit connections, adhesive or cohesive bonding material, bands, clips, pin and aperture connections, or in any other manner. The barrel30can instead be one element manufactured in any conventional manner (e.g., molded, machined, cast, and the like), or can be made of three or more sections connected together in any of the manners described above with reference to the two illustrated barrel sections11,13.

In some embodiments, the barrel30has a shutter mechanism (not shown) at least partially covering or shielding the key slot26. The shutter can be mounted upon the end of the barrel30adjacent to the key slot26. Also, an output mechanism can be connected to an opposite end of the barrel30for transmitting force from the barrel30to one or more elements connected to the lock assembly29. The output mechanism can take a number of different forms, including without limitation a lever, drive shaft, coupling, cam, or other element mounted to the lock assembly29.

As previously mentioned, the pivotable tumblers23can be coupled to the barrel30for rotation with respect to the barrel30. The tumblers23can be pivotably mounted in any manner. However, in the illustrated embodiment shown inFIG. 3, the tumblers23are pivotably mounted upon a pivot8coupled to the barrel30.

As shown in the embodiment illustrated inFIG. 11, the tumblers23can engage the key1when the key1is inserted into the barrel30, and can engage the housing14when the key1is not inserted into the barrel30. The tumblers23can be made of any material sufficiently durable and strong to withstand attempts at picking the lock and unauthorized forced rotation of the barrel, and to resist wear from interfacing with the key1. The tumblers23can be sized to engage a key at various depths of the key's edge(s). Thus, by using a plurality of tumblers23that engage the key1with differing key depths, the lock29will only unlock with a properly coded key1. In some embodiments such as the embodiment illustrated inFIGS. 1–13, tumblers are located on opposite sides of the key1so that both coded edges49,50of the key1are engaged by tumblers23. The tumblers23in such embodiments can be arranged in any manner, and in some cases can be arranged in the lock assembly29in an alternating pattern. Also in such embodiments, the tumblers23can be positioned to pivot in substantially opposite directions responsive to insertion or removal of the key1.

Although each tumbler23of the present invention can be a single element, the tumblers in some embodiments are each defined by two or more elements. For example, the tumblers23can be two-piece tumblers as shown inFIGS. 5–9and11A–E. As illustrated, each pivotable two piece tumbler combination23is comprised of a housing-engaging element4or5and a key-engaging element6or7. In some embodiments, the housing-engaging elements4,5are movable to engage the housing14in a locked mode of the lock assembly29(in order to prevent rotation of the barrel30) and to disengage from the housing14in an unlocked mode (in order to permit rotation of the barrel30with respect to the housing14). Also, the key-engaging elements6and7can engage the coded surfaces49and50of the key1. In other embodiments, the key-engaging elements6and7can be positioned to engage only one of the coded surfaces49,50on one side of the key1as described above. In either case, the key-engaging elements6,7each can have one or more surfaces56which are contacted by the coded surface(s) of the key1when the key1is inserted into the lock assembly29. This contact causes the key-engaging elements6,7to move with respect to the housing-engaging elements4,5for purposes of coding the two-piece tumbler combination23as will be described in greater detail below.

In some embodiments, the housing-engaging elements4and5are pivotably independent of the key-engaging elements6and7when the lock assembly29is in an uncoded state. When the lock assembly29is in a coded state, such housing-engaging elements4and5are no longer pivotably independent of the key-engaging elements6and7.

The tumblers23(and in the case of multiple-part tumblers, an element of the tumblers23) can be pivotable within the barrel30in a number of different manners. In one embodiment for example, the housing-engaging elements4,5are pivotable about a pivot8. The housing-engaging elements4,5can be pivotable about the pivot8in any manner, such as by receiving the pivot8within apertures51in the housing-engaging elements4,5as illustrated in FIGS.5and11A–E. If desired, the pivot8can have a larger diameter section58at a location between the ends59,60of the pivot8to provide a location for additional support of the pivot8and tumblers23.

Although the housing-engaging element4,5can take any shape capable of moving into and out of engagement with the housing14as described above, the housing-engaging elements4,5in some embodiments have an aperture therein through which the key1can be received. The elements4and5of this embodiment also have at least one portion52,63(or two portions52,63in other embodiments) that engages the housing14in the locked state of the lock assembly29as described above.

In those embodiments of the present invention employing multiple-piece tumblers23, the pieces of the tumblers23can be movable with respect to one another and can engage one another in different relative positions. This engagement can be produced in a number of different manners. In the illustrated embodiment for example, each housing-engaging element4,5can engage a corresponding key-engaging element6,7by inter-engaging teeth on both elements4,5and6,7. In this manner of engagement, at least one projection or recess54on the housing-engaging element4,5can be engaged with at least one recess or projection57, respectively, on the key-engaging element6,7. In other embodiments, however, either the housing-engaging element4,5or the key-engaging element6,7have multiple recesses or projections to enable the elements4,5, and6,7to engage one another in at least two different relative positions. Yet in other embodiments, both elements4,5and6,7have multiple recesses or projections to provide for multiple relative engaged positions of the elements4,5,6,7.

Although inter-engaging projections and recesses54,57can be employed to engage the housing-engaging elements4,5and the key-engaging elements6,7, it should be noted that other types of elements can instead be employed for this purpose. By way of example only, the housing-engaging elements4,5can have one or more magnets thereon that attract one or more magnets on the key-engaging elements6,7to retain the housing-engaging elements4,5in position with respect to the key-engaging elements4,5,6,7. As another example, the housing-engaging elements4,5can have one or more surfaces that are pressed against by one or more surfaces of the key-engaging elements6,7with sufficient force to retain the housing-engaging elements4,5in a desired positional relationship with the key-engaging elements6,7. Still other elements and features of the housing and key-engaging elements4,5,6,7can be employed to retain the housing-engaging elements4,5in a desired positional relationship with respect to the key-engaging elements6,7. In still other embodiments, both elements4,5and6,7can be held together by a snap fit, a friction fit, and the like.

In some embodiments of the present invention (such as the embodiment illustrated inFIGS. 1–13), the housing and key-engaging elements4,5,6,7are generally flat in shape. In other embodiments, the housing and key-engaging elements4,5,6,7have any other shape desired. However, generally flat element shapes can be utilized for purposes of space conservation.

The projections and recesses54,57of the housing and key-engaging elements4,5,6,7can be located on any portion of the housing and key-engaging elements4,5,6,7which permits these elements to engage with one another as will be described in greater detail below. However, the inventors have discovered that space within the lock assembly29is better utilized and performance of the lock assembly29is improved when part of the housing-engaging element4,5and/or part of the key-engaging element6,7is located in a plane that is different than the remainder of the housing-engaging element4,5and key-engaging element6,7, respectively. More specifically, it is desirable in some embodiments for the engaging elements or features (e.g., projections or recesses54,57) of the housing and/or key-engaging elements4,5,6,7to be located out of plane with respect to the rest of the same elements4,5,6,7. For example, as illustrated in the embodiment shown inFIGS. 5–9and11, the projections and recesses54of each housing-engaging element4,5are located on a portion of the housing-engaging element4,5that is out of plane with respect to the rest of the housing-engaging element4,5. If desired, the key-engaging elements6,7can also or instead have offset recesses and projections57. In some embodiments, either the housing-engaging elements4,5or the key-engaging elements6,7(not both) have such offset engaging features or structure.

In those embodiments of the present invention employing tumblers having two or more elements (as described above), the tumbler elements moved into an engaged relationship with each other can remain in such a relationship during and after repeated use of the lock assembly. This can be accomplished in a number of different ways, depending at least in part upon the manner in which the tumbler elements are engaged. For example, if magnet sets retain the tumbler elements in an engaged relationship with one another, then the magnet sets may be sufficient to retain this relationship. Similarly, if a friction fit or snap fit is used to retain the engaged relationship with one another, then the friction fit or snap fit may be sufficient to retain this relationship. In other embodiments, the engaged relationship between tumbler elements is maintained by changing the point about which one (or more) of the tumbler elements pivots. The key-engaging elements6,7in the embodiment illustrated inFIGS. 1–13provide an example of such element control.

Specifically, as shown in the illustrated embodiment inFIGS. 5,7,9, and11, the pivot8can pass through an aperture55in the key-engaging elements6,7shaped to receive the pivot8in two different positions. The key-engaging elements6,7can pivot about the pivot8, and can be shifted with respect to the pivot8from one position to another. As illustrated, the aperture55is shaped to retain the pivot8in at least one of the two different positions so that the key-engaging elements6,7can be shifted with respect to the pivot8and can be retained in a position in which the key-engaging elements6,7are engaged with the housing-engaging elements4,5. In the embodiment illustrated inFIGS. 1–13for example, the key-engaging elements4,5have two-position apertures55that are hour-glass shaped. The hour-glass shape of these apertures55permits the pivot8to be moved within the apertures55(or the apertures55to be moved with respect to the pivot8) and to “snap” into place a position with respect to the pivot8in which the key-engaging elements6,7are engaged with the housing-engaging elements4,5as described above. In this regard, the apertures55can be deformable to produce a snap action between the two positions55a,55bof the key-engaging elements6,7on the support8. In some embodiments, hole deformability can be achieved by one or more slots, cuts, holes, or relief apertures65near the pivot apertures55, by providing relatively thin or otherwise flexible walls of the pivot apertures55, by employing one or more protrusions between the pivot aperture positions, and the like.

In some embodiments, the key-engaging elements6and7are placed on the pivot8in an uncoded position during assembly of the lock29. For example, in the illustrated embodiment, the pivot8passes through the inboard position55aof the two position aperture55, thereby positioning the projection(s)/recess(es)57of the key-engaging elements6,7so that they are disengaged from the mating projection(s)/recess(es) of the housing-engaging elements4,5. The tumbler combinations23can be retained on the pivot8by press on washers3, threaded on nuts, welds, clips, collars, or other like elements at either or both ends59and60of the pivot8. However, in some alternative embodiments (such as those in which tumbler coding by element movement with respect to the pivot8is not required), the pivot8can be formed as part of one element of the two piece tumbler23.

Although the tumblers23, pivot8, and other elements of the lock assembly29can be assembled in any manner, in some embodiments the uncoded tumbler element combinations (i.e., a housing-engaging element4matched up with a key-engaging element7or a housing-engaging element5matched up with a key-engaging element6) can be assembled on the pivot8and inserted within the barrel30as a unit subassembly.

The coding process of the present invention will now be described with reference to the embodiment illustrated inFIGS. 11A–11Eby way of example only. In this illustrated embodiment, the coding process of the lock assembly29begins with the insertion of the key1as shown inFIG. 11B. As the key1enters the barrel30, the key-engaging elements6and7pivot to an extent determined at least in part by the depth of the coding on the key surface49,50. Once the key1is fully inserted, the key-engaging elements6and7rest against the coded surfaces of the key49,50.

As shown in the sequence illustrated inFIGS. 11B–11D, the lock29is coded to the key1by rotating the barrel30with respect to the housing14in response to turning the key1. As the barrel30is turned, the key-engaging elements6and7are shifted upon the pivot8from the inboard pivot hole position55ato the outboard pivot hole position55b(seeFIGS. 11C and 11Din combination withFIGS. 7 and 9). This shift can be caused in a number of different manners, such as by a camming action of the key-engaging elements6,7against an interior surface of the housing14, by one or more springs directly or indirectly exerting force against the key-engaging elements6,7in at least one rotational position of the barrel30, and the like.

The shift of the key-engaging elements6and7on the pivot8from the inboard position55ato the outboard position55bcan cause the projection(s) and/or recess(es)57on the key-engaging elements6and7to engage the corresponding recess(es) and/or projection(s)54on the housing-engaging elements4and5. This engagement produces a tumbler combination23coded to the particular notch depth of the key1. Thus, in the coded state, the housing-engaging elements4,5and the key-engaging elements6,7can pivot together about the pivot8. As illustrated inFIG. 11E, once the key1is removed, at least one spring12(seeFIG. 5) can bias one or more of the tumblers23into engagement with the housing14and to thereby prevent rotation of the barrel30with respect to the housing14.

Once the tumblers23have been coded, the tumblers23can be maintained in their coded state in one or more manners. In the two-piece tumbler embodiment illustrated inFIGS. 1–13for example, the key-engaging elements6,7are maintained in their engaged coded relationship with the housing-engaging elements4,5in part by the relationship between the pivot8and two-position aperture55described above.

Another manner of maintaining the tumblers23in their coded state after coding is illustrated inFIGS. 1,5, and10–11. Specifically, the lock assembly29in the illustrated embodiment has a tumbler shifting mechanism31for shifting the key-engaging tumbler elements6and7from the uncoded positions to the coded positions within the barrel30. The tumbler shifting mechanism31is connected to or is integral with the housing14and is adaptable to include a moveable support15, a tumbler shifting plate/bar17, a tumbler shifting plate support16, one or more springs18, and a cover19. The cover19can be integrally formed with the housing14, and in other embodiments is connected thereto with one or more pins20,21(seeFIGS. 1,5and10), screws, rivets, clips, and other conventional fasteners, by adhesive or cohesive bonding material, by being snap fit to the housing14, and the like. If desired, the housing14can be provided with one or more elements or features to enable connection of the tumbler shifting mechanism31thereto and to facilitate movement of the tumbler shifting mechanism31in order to bias the tumblers23as will be described below. In the illustrated embodiment for example, the housing14has lugs41for mounting the tumbler shifting mechanism31(although any fastener apertures, bosses, clip receptacles, or other elements can instead be employed), a channel42to support and guide the moveable support15, and an aperture43through which the tumbler shifting plate/bar17can extend or otherwise be received to bias the tumblers23inside the housing14.

The tumbler shifting mechanism31can be activated (the tumbler shifting plate/bar17is biased to exert a force upon the tumblers23within the housing14and to shift the tumblers23as described above) by turning the barrel30with respect to the housing14. In the illustrated embodiment for example, a surface61on the movable support15(seeFIGS. 1 and 10) is cammed against by part of the barrel30when the barrel30is rotated during the coding process. More specifically, as the barrel30is rotated during the coding process, a cam surface66on the back of the barrel30(seeFIGS. 3 and 4) cams against the moveable support15of the tumbler shifting mechanism31. Referring again toFIGS. 1 and 10, the surface61of the movable support15thereby functions as a cam follower. As shown inFIGS. 10A and 10B, the moveable support15moves with respect to the rest of the tumbler shifting mechanism31due to the follower61riding the cammed surface66, thereby causing the tumbler shifting plate support16to release from the moveable support15and to permit the resiliently biased tumbler shifting plate/bar17to travel radially inward toward the barrel30. As illustrated inFIGS. 11C and 11D, this movement of the tumbler shifting plate/bar17brings the tumbler shifting plate into contact with the key-engaging tumbler elements6,7, and causes the key-engaging tumbler elements6,7to move from an uncoded state to a coded state as described in greater detail above.

Although the tumbler shifting mechanism31described above is one way of shifting the tumblers23to code the lock assembly29, it will be appreciated that the tumbler shifting mechanism31can take a number of other forms capable of performing this same function. By way of example only, a tumbler shifting mechanism such as that described above can be triggered to bias the tumbler shifting plate/bar17toward the tumblers23upon insertion of the key1into the barrel30. Specifically, the key1can directly or indirectly contact and move the movable support15(or like element or structure) upon insertion of the key1into the barrel30. Thereafter, rotation of the barrel30with respect to the housing14can align the biased tumbler shifting plate/bar17with the housing aperture43, permitting the tumbler shifting plate43to enter the tumbler aperture43and to bias the tumblers23as described above.

As another example, the tumbler shifting plate/bar17can be activated by user removal of the tumbler shifting plate support16retaining the tumbler shifting plate/bar17in a retracted position with respect to the tumblers23(in which case the movable support15or comparable element or structure would not be needed). In this regard, the tumbler shifting plate support16can take a number of different forms capable of being removed or otherwise released to activate the tumbler shifting plate/bar17. Still other mechanisms can be employed to bias a tumbler shifting plate/bar17or other element against the tumblers23within the housing14upon insertion of the key1into the barrel30or upon rotation of the barrel30with respect to the housing14. Each one of these alternative mechanisms falls within the spirit and scope of the present invention.

In some embodiments of the present invention, it is desirable to maintain the rotational position of the barrel30with respect to the housing14prior to coding the lock assembly29with a key1. For example, an element or device can be employed to prevent the barrel30from rotating with respect to the housing14during shipping or handling of the lock assembly. An example of such an element is illustrated inFIGS. 1,3–5,12, and13. In the illustrated embodiment, a shipping tumbler9maintains the position of the barrel30with respect to the housing14and thus, the orientation of the tumbler combinations before the lock assembly29is coded. In some embodiments, this shipping tumbler9or a similar mechanism (as described in greater detail in other embodiments) also prevents the coding process from beginning prematurely. For example, in the illustrated embodiment, the shipping tumbler is positioned and oriented to prevent barrel30rotation and coding of the lock until the key1is fully inserted.

With reference toFIG. 5, the shipping tumbler9can be formed in an “E” shape with three legs46,47, and48. As best shown inFIGS. 12 and 13, the uncoded lock assembly29can be assembled and shipped with the barrel30rotated an amount (e.g., 21° in the illustrated embodiment, although smaller or larger rotational amounts are possible) from the neutral position (key slot vertical) and fixed in this position by the shipping tumbler9. Referring to FIG.12A, the barrel30is in the uncoded position and retained in this position by an end38of one of the shipping tumbler legs38extending into an recess, groove, slot, or other aperture25in the housing14. Although the shipping tumbler9can be retained in this position by a snap or press-fit connection to the barrel30, by a light frictional engagement in the aperture25, or in another manner, the shipping tumbler9can also be biased into this position with at least one spring22.

With continued reference to the illustrated embodiment shown inFIGS. 12B and 13B, insertion of the key1can generate movement of the shipping tumbler9to retract the shipping tumbler9from the aperture25in the housing14. More specifically, when the selected key1is fully inserted into the barrel30during the coding process, a surface of the key1(e.g., at the tip of the key1) can contact a leg46of the shipping tumbler9, thereby camming the shipping tumbler9away from the housing aperture25against the biasing force of the shipping tumbler spring22. Thereafter, the barrel30is permitted to rotate.

It will be appreciated by one skilled in the art that the shipping tumbler9can take a number of different shapes capable of functioning to retract upon insertion of a key1during the coding process. The shipping tumbler shape9depends at least partially upon the shape of the barrel30, the shape of the housing14and the housing aperture25, and/or the position of the shipping tumbler9on the barrel30. Other shipping tumblers can be C or L-shaped, shaped similarly to the tumblers23in the illustrated embodiment, shaped in any conventional manner, and the like. In addition, it should be noted that the shipping tumbler23can be retracted from the housing aperture25manually by a user, if desired, and in some embodiments can even be removed from the lock assembly29.

For purposes of illustration,FIGS. 11A–11Eshow a coding operation performed upon the lock assembly29in the illustrated embodiment of the present invention. The assembled and uncoded lock29can be installed on or in a member to be locked (not shown) with the shipping tumbler extended in its shipping position, the tumbler elements4,5,6,7in their uncoded positions, and with no key in the key slot26of the barrel30as shown inFIG. 11A. Since the tumbler ends32and52contact the interior surfaces of the housing14and cannot enter the axial grooves of the housing due to the shipping orientation of the barrel30, the housing-engaging tumbler elements4,5are captured within the periphery of the barrel30in the shipping position. As a key1is inserted in the barrel30, the key-engaging tumbler elements6,7pivot about the pivot8due to the coded surface49of the key1contacting the tumbler surfaces56(seeFIG. 11B).

With continued reference to the illustrated embodiment, once the key1is fully inserted within the barrel30, the shipping tumbler9can be disengaged from the housing14(as shown inFIGS. 12 and 13), permitting the barrel30to rotate with respect to the housing14. Next, the key is turned to rotate the barrel30to the neutral position as shown inFIG. 11C, which causes the tumbler shifting mechanism31to activate (i.e., to release the tumbler shifting plate/bar17). The tumbler shifting plate/bar17is thereby biased towards the center of the barrel30, which causes the key-engaging elements6,7to be shifted to engage the corresponding housing-engaging elements4,5. Thus, the coding process is complete as shown inFIG. 11D, and the key1can be removed from the barrel30. When the key1is removed from the barrel30, the tumblers23can be biased about the pivot8to cause the housing-engaging tumbler element portions32,33,52,63to extend beyond the barrel30periphery into the axial grooves36of the housing14, thereby preventing rotation of the barrel30relative to the housing14(seeFIG. 11E). In the resulting locked state of the lock assembly29, the housing-engaging tumbler element portions32,33,52,63extend beyond opposite sides of the barrel30periphery in a substantially alternating pattern to prevent barrel rotation within the housing as shown inFIG. 3.

In some embodiments of the present invention having tumblers with two or more tumbler elements, the codeable lock assembly29is capable of being re-coded. Re-coding can be performed in a number of different manners, each one permitting the elements of one or more tumblers23to be disengaged for re-coding. In the illustrated embodiment ofFIGS. 1–13for example, the housing14can have one or more apertures44permitting entry of a tool for pushing the key-engaging elements6,7away from the housing-engaging elements4,5. Referring more particularly toFIG. 2, to recode a coded lock assembly29to a different key code, a key1already coded for the lock assembly29is inserted into the barrel30and the barrel30is rotated to the original shipping position. Then, a tool is inserted into each of the recoding holes44in the housing14to shift the key-engaging tumbler elements6,7back to the original uncoded position in which they are retracted from the housing-engaging tumbler elements4,5. After this has been completed, the key1can be withdrawn and the tumbler shifting mechanism31(if used) can be reset. In the illustrated embodiment ofFIGS. 1–13for example, the tumbler shifting plate/bar17is retracted from its extended state (removing the pins20,21, cover19, and springs18, if necessary) and the movable support15is returned to its shipping position. Another key with a new code can then be inserted into the barrel30to repeat the coding process.

In other embodiments, the tumbler shifting mechanism31can be partially or fully removed or opened to permit access to the key-engaging tumbler elements6,7(and/or housing-engaging elements4,5) for user manipulation of the key-engaging tumbler elements6,7. In still other embodiments, the pivot8can be user accessible and can be moved to move the tumblers for re-coding. By way of example only, the pivot8in the embodiment illustrated inFIGS. 1–13can be moved to disengage the key-engaging elements6,7from the housing-engaging elements4,5. In this case, a new key can then be inserted and the pivot8can be returned to its original position for the remainder of the coding process. Still other manners of re-coding keys in the lock assembly29of the present invention are possible, each one of which falls within the spirit and scope of the present invention.

Another embodiment of a pivotable tumbler lock assembly is illustrated inFIGS. 14A–14E, and is indicated generally at129. Like the tumbler lock assembly29in the embodiment illustrated inFIGS. 1–13, the embodiment illustrated inFIGS. 14A–14Eemploys pivotable tumblers123within a barrel130that is selectively rotatable with respect to a housing114. Also like the embodiment illustrated inFIGS. 1–13, this embodiment utilizes codeable pivotable tumblers23each defined by multiple elements that are movable with respect to one another. The illustrated embodiment ofFIGS. 14A–14Eemploys tumblers23each having two elements. The first element is a key-engaging element6that can engage the coded surface149of a key101. The second element can be a housing-engaging element104that can releasably engage the housing114in a locked position of the housing-engaging element104. Prior to coding, the key-engaging elements106may be pivotable independently of the housing-engaging elements104. Specifically, the key-engaging elements106can be pivotally connected to a bar shaped follower170inside the barrel130. The key-engaging tumbler elements106can also be biased by a spring112, if desired. Also, the housing-engaging elements104can be located within, guided by, and supported by the barrel130.

The key-engaging tumbler elements106can have at least one projection and/or recess157for selective engagement with one or more recesses and/or projections154, respectively, on the housing-engaging elements104to engage the housing-engaging elements104in the coded state. The projections and/or recesses157of the key-engaging tumbler elements106can be located anywhere in on the key-engaging tumbler elements106, but in some other embodiments they are located on ends of the key-engaging tumbler elements106opposite the pivot108. Although the barrel130of the lock assembly129can have tumblers123positioned to contact a coded surface on only one side of a key101, the barrel130of some embodiments has tumblers123that are positioned to contact coded surfaces on opposite sides of a key101(e.g., having alternating key-engaging tumbler elements106positioned to pivot in opposite directions upon contact with a key101). As illustrated in the embodiment shown inFIG. 14E, the housing-engaging elements104can be extendable into a groove, recess, or other aperture of the housing114, thereby engaging the housing114in a locked mode of the lock assembly129. For tumblers123having two or more elements, at least one of the tumbler elements is shaped to engage the housing114in this manner. With continued reference toFIGS. 14A–14Efor example, a portion of each housing-engaging tumbler element104can be shaped to be received within a recess, groove, or other aperture in the housing114.

The lock assembly129in the embodiment illustrated inFIGS. 14A–14Ecan be assembled in the uncoded condition as shown inFIGS. 14A and 14B, with the housing-engaging elements104contained within the barrel130by the housing114. As such, the follower170is received within a recess, groove, or other aperture171in an interior wall of the housing114.

To set the code for the lock assembly129shown inFIGS. 14A–14E, a key101is inserted into the barrel130and the key-engaging elements106pivot relative to the coded surfaces149,150of the key101as shown inFIG. 14B. Once the key101is fully inserted, the projection(s) and/or recess(es)157on the key-engaging elements106can align with corresponding projection(s) and/or recess(es)154on the housing-engaging elements104. As shown inFIGS. 14C and 14D, the key101is then rotated along with the barrel130inside the housing114, which causes the follower170to be radially driven into the barrel130by a cam surface on the housing114. The follower170causes the projection(s) and/or recess(es)157on the key-engaging elements106to become engaged with corresponding projection(s) and/or recess(es)154on the housing-engaging elements104for the corresponding key notch depths at each tumbler position in the barrel130. In the illustrated embodiment ofFIGS. 14A–14E, the barrel130is then rotated approximately 180° to a neutral locked state, although such a state can be located at smaller or larger angles in other embodiments. In some embodiments, the useable range of barrel rotation can be ±60° after coding. However, other ranges of rotation fall within the spirit and scope of the present invention. Thus, in other embodiments, this range is greater or smaller depending at least partially upon the positions of the housing apertures in which the tumblers123are received and the shape of the tumblers123. As shown inFIGS. 14D and 14E, after coding, the follower170remains in its radially inward position, retained in this position by the interior walls of the housing114. Therefore, the tumbler combinations123can remain engaged in their coded positions as the key101is inserted into and extracted from the barrel130.

To change the code of the lock assembly129, the correct key101can be used to unlock the lock and to permit the barrel130to be rotated to the original coding position. The key101is then extracted and a new key is inserted. The barrel130is then rotated to code the lock assembly129to the new key in a manner as described above.

Yet another embodiment of a codeable lock according to the present invention is illustrated inFIGS. 15–17. As with the other embodiments illustrated inFIGS. 1–14, this embodiment also uses pivotable two-piece tumblers223to provide for coding after assembly of the lock assembly229. Like the previous embodiments, the embodiment illustrated inFIGS. 15–17has a barrel230, a housing214, and pivotable tumblers223. However, unlike the previous embodiments described above and illustrated inFIGS. 1–14, the tumblers223can pivot during the coding process and translate during normal operation of the lock assembly229. Each pivotable two-piece tumbler223can include a housing-engaging element204,205and a key-engaging element206,207. In some embodiments, the key-engaging elements206,207are pivotable within the housing-engaging elements204and205prior to coding the lock assembly229.

To code the lock assembly229of the embodiment illustrated inFIGS. 15–17, a key201is inserted into the uncoded lock assembly229. As the key201is inserted, it passes the tumblers223in the barrel230. In some embodiments such as that shown inFIGS. 15–17, the key201also passes through a bezel279or face plate prior to passing the tumblers223. If desired, spacer elements282can be positioned between tumblers223and can have apertures shaped to receive the key201therethrough. Once the key201is inserted into the lock assembly229, the tip of the key201can contact a clutch plate276. The clutch plate276can be spring loaded (by one or more springs278) against force exerted by the key201. The spring(s) can be of any type, including without limitation coil, leaf, torsion, and the like. For example, the spring278in the embodiment illustrated inFIGS. 15–17can be a leaf spring278extending from a base received within the housing214.The clutch plate276may be moved rearwardly by entry of the key201into the barrel, thereby compressing the spring278.

As illustrated in this embodiment, the clutch plate276can have an aperture277initially misaligned with respect to the tip of the key201. Specifically, the aperture277has a shape that can receive the tip of the key201when properly rotationally aligned therewith. In the illustrated embodiment for example, the aperture277is elongated and can receive the tip of the key201at a rotational angle of the key201. Other aperture shapes277can also be employed to match and receive the tip of a key201in a similar manner. The amount of misalignment between the tip of the key201and the aperture277in the clutch plate276may correspond to the amount of rotation of the key201during the coding process (described in greater detail below). In the illustrated embodiment for example, this amount of misalignment is approximately 130 degrees, although larger or smaller amounts of misalignment are possible.

As the key201is rotated within the barrel230of the illustrated embodiment ofFIGS. 15–17, the key201begins to contact the key-engaging elements206,207, which causes the key-engaging elements206,207to rotate with respect to the housing-engaging elements204,205. In some embodiments, the barrel230does not rotate with the key201in this stage of coding. Instead, the bezel279(if used), the key-engaging elements206,207, and the spacers282(if used) can rotate with the key201. In some embodiments, the barrel230can be prevented from rotating with respect to the housing214by a housing engagement assembly209. The housing engagement assembly209may be located on the barrel230, and can be employed to prevent the barrel230from rotating with respect to the housing214until the housing engagement assembly209has been moved. In the illustrated embodiment, the housing engagement assembly209is an elongated element which is received within a groove, slot, recess, or other aperture in the barrel230and can move axially therein.

The amount each key-engaging element206,207rotates, which determines the coding of the lock assembly229, is related to the depth of the cut in the key201at the location of that tumbler element206,207along the key201when the key201has been inserted within the barrel230. With reference toFIGS. 17A–17C, the greater the depth of the cut in the key201, the less the key-engaging element206,207rotates because the key201does not contact the key-engaging element206,207until later in the rotation of the key201. As the key-engaging elements206,207rotate within the housing-engaging elements204,205, projections57on the tails of the key-engaging elements206,207can engage recesses254in the housing-engaging elements204,205. This engagement can at least temporarily retains the key-engaging elements206,207in their coded positions with respect to the housing-engaging elements204,205.

After the key201has been rotated sufficiently to align the tip of the key1with the aperture277in the clutch plate276, the tip of the key201can enter the aperture277. In the illustrated embodiment, the spring278presses the clutch plate276toward the key201to create this engagement. As the clutch member276moves towards the key201, the clutch member276can push and move the housing-engaging assembly209with respect to the barrel230. In the illustrated embodiment, the housing-engaging assembly209moves within a groove, slot, recess, or other aperture in the barrel230away from the spring278. This movement can cause the housing-engaging assembly209to disengage from the barrel230, thereby permitting rotation of the barrel230with respect to the housing214. This movement can also cause a bezel-engaging element211to engage a shoulder or a notch, recess, groove, slot, or other aperture on the bezel279, thereby establishing a mechanical connection between the bezel279and the barrel230in order to turn the barrel230with the key201. This connection can also establish the bezel's orientation with respect to the barrel230. The bezel-engaging element211can be one or more spring-loaded pins, clips, fingers, and the like extending into engagement with the bezel279. Alternatively, the bezel-engaging element211can be a member (as shown inFIG. 15) that is spring-loaded (e.g., with one or more springs213) toward the bezel279and that is shaped to mate with the bezel279to transmit torque from the bezel279to the barrel230. Other shapes of the bezel-engaging element211are possible and fall within the spirit and scope of the present invention.

Further rotation of the key201may rotate the barrel230through another angle, which can generates a camming action between internal surfaces of the housing214and a plurality of keepers280located adjacent to the tumblers223. This camming action is similar to the relationship between the key-engaging elements6,7and the housing14in the embodiment of the present invention illustrated inFIGS. 1–13, and the relationship between the follower170and the housing114in the embodiment of the present invention illustrated inFIGS. 14A–14E. In particular, the keepers280can cam against the housing214and are thereby moved into spaces defined between the housing-engaging elements204,205and the key-engaging elements206,207. The keepers thereby secure the key-engaging elements206,207in position with respect to the housing-engaging elements204,205in order to code the tumblers223. Upon key removal, springs212or other resilient biasing members can bias the tumblers223to positions where they engage the housing214.

In operation of the lock assembly229illustrated inFIGS. 15–17, the key201is inserted into the barrel230. As the key201is inserted, the key201engages the key-engaging elements206,207, which causes the tumbler combinations223to translate with respect to the barrel230and housing214. After the key201has been inserted, the housing-engaging elements204,205of the tumbler combinations223are retracted into the barrel230, which allows the barrel230to rotate with the key201to unlock the lock assembly229.

The above-described lock assembly embodiments each employ one or more tumblers that pivot at some point during the process of coding the lock assembly. Other embodiments of the present invention employ codeable tumblers that move linearly or primarily linearly during coding. The embodiment shown inFIGS. 18A–18Eis one such embodiment. Like the illustrated embodiments described above, the lock assembly329illustrated inFIGS. 18A–18Ecan have a housing314, a barrel330, and one or more tumblers323within the barrel330. Each tumbler323can be defined by two or more elements movable with respect to one another for purposes of coding. In the illustrated embodiment for example, each codeable tumbler combination323includes a key-engaging element306,307and a housing-engaging element304,305. These elements can be guided and supported by the barrel330as shown.

The key-engaging elements306,307can each have at least one key-engaging surface356and one or more projections and/or recesses357to engage the housing-engaging elements304,305. Similarly, the housing-engaging elements304,305can each have at least one surface with one or more projections and/or recesses354to engage the key-engaging elements306,307during the coding process. Although the elements304,305,306,307can have any shape as described in greater detail above with reference to illustrated embodiment ofFIGS. 1–13, the engaging surfaces of the key-engaging elements306,307and the housing-engaging element304,305may be arc-shaped. In other words, the engaging surface of the key-engaging elements306,307can be concave or convex for engagement with a convex or concave surface of the housing-engaging elements304,305, respectively. One example of such tumbler element shapes is illustrated inFIGS. 18A–18E. The arc-shaped interface between these tumbler elements can provide larger engagement surfaces for the elements304,305,306,307for more possible codings and/or for improved engagement. In some embodiments, the housing-engaging elements304,305are movable to engage the housing315(e.g., each housing-engaging element304,305having a portion that can engage the housing315upon movement of the housing-engaging element305,305to a locked position).

As shown inFIG. 18A, the lock assembly329can be assembled with the tumbler combinations323in an uncoded condition. As such, the key-engaging elements306,307are movable with respect to the housing-engaging elements304,305. In some embodiments, the key-engaging elements306,307are biased by one or more coil springs312toward one position with respect to the housing-engaging elements304,305. Although one or more springs312may be employed for this purpose, various other biasing elements can be used, including without limitation leaf, torsion, and other types of springs, magnet sets, and the like. Prior to being coded, the housing-engaging elements304,305can be located entirely or substantially within the periphery of the barrel330, and are retained therein by the interior walls of the housing314.

To code the lock assembly329illustrated inFIGS. 18A–18E, a key301is inserted into the barrel330as shown inFIG. 18B. As the key301is inserted, the coded surfaces of the key301engage the key-engaging surfaces356of the key-engaging elements306,307. The key-engaging elements306,307react by translating and pivoting slightly under force exerted by the key301. Once the key301has been inserted, at least one projection or recess357on each key-engaging member306,307is aligned with a recess or projection354, respectively, on a corresponding housing-engaging member304,305. In some embodiments, more than one projection or recess357on each key-engaging member306,307is aligned with more than one recess or projection354on a corresponding housing-engaging member304,305. In still other embodiments, one or more projections or recesses357on the key-engaging members304,305are aligned with one or more projections or recesses354on corresponding housing-engaging members304,305, although in such embodiments at least one recess and projection pair is aligned in each tumbler in order to provide engagement between the tumbler elements304,306and305,307. Such an arrangement is illustrated by way of example inFIGS. 18A–18E, which show a projection357of a key-engaging element306,307in tip-to-tip contact with a projection of a housing-engaging element304,305, and another projection357of the key-engaging element306,307in tip-to-recess contact with a recess of the housing-engaging element304,305(although this can be a recess-to-tip relationship in other embodiments).

As described above, entry of the key301into the barrel330of the lock assembly329can cause the key-engaging surfaces356of the key-engaging elements306,307to move with respect to the housing-engaging elements304,305. The amount of movement of the key-engaging elements306,307may be dependent at least partially upon the key depth at each key-engaging element306,307. In some embodiments, the key-engaging elements306,307can be positioned in the barrel330to pivot in different directions upon entry of the key301. In these and other embodiments, some of the key-engaging elements306can be positioned in the barrel330to contact one side of the key301while other key-engaging elements307can be positioned in the barrel330to contact an opposite side of the key301. By arranging the tumbler elements in such a manner, more code sequences are possible compared to coding using only one side of the key301.

Although the key-engaging elements306,307in the embodiment illustrated inFIGS. 18A–18Ecan be urged into engagement with the housing-engaging elements304,305in any of the manners described above with respect to other multiple-piece tumblers, the key-engaging elements306,307can be engaged with the housing-engaging elements304,305by a camming arrangement between a follower and one or more surfaces of the housing314. With reference toFIGS. 18B and 18Cfor example, an inserted key301can be rotated to rotate the barrel330with respect to the housing314. As the barrel330rotates, a follower370may ride upon an inner surface of the housing314. As illustrated, the follower370can be in the shape of a bar. The inner surface is preferably shaped to inwardly cam the follower370. In this regard, the follower370can be received within a groove, recess, or other aperture371in the housing314prior to the coding process. As the follower370is moved in this manner, the follower370can force the key-engaging members306,307to engage the housing-engaging members304,305.

In some embodiments, the barrel330is rotated until the housing-engaging elements304,305are positioned with respect to the housing314to that they can be extended into engagement with the housing in order to prevent rotation of the barrel330with respect to the housing. In the embodiment illustrated inFIGS. 18A–18E, the barrel330is rotated approximately 180 degrees for this purpose, although larger or smaller rotations are possible depending at least partially upon the initial positional relationship between housing-engaging elements304,305and the housing314.

After the barrel330has been rotated as just described, the tumbler elements323remain engaged when the key301is extracted from the barrel330due to the inward position of the follower370(seeFIG. 18D). When the key301is removed, the spring312may bias the tumbler elements323, which then can cause the housing-engaging elements304,305to engage the housing314, such as by entering one or more grooves, recesses, or other apertures in the housing314. This engagement prevents the barrel330from rotating with respect to the housing314without the key301in the barrel330. The useable range of barrel rotation is approximately ±60° in the embodiment illustrated inFIGS. 18A–18E, although smaller or larger usable ranges of barrel rotation are possible in other embodiments of the present invention.

To change the code of the lock assembly329, the key301that the lock assembly329is coded to can be used to unlock the lock assembly329and to rotate the barrel30back to its coding position (see for example,FIGS. 18A and 18B). The key301can then be extracted and another key with a different code can be inserted. Next, the same steps discussed above can be followed to code the lock assembly329with the different key301. After rotation back to the useable range of barrel rotation, only the new key301will unlock the lock assembly329.

Another embodiment of a pivotable tumbler lock assembly according to the present invention is illustrated inFIGS. 19–21. Like the tumbler lock assembly29in the embodiments illustrated inFIGS. 1–18, the embodiment illustrated inFIGS. 19–21employs pivotable tumblers423. However, unlike the previous embodiments, the tumblers423are located substantially outside of the barrel430, and can have portions extending within the barrel430. The tumblers423in the illustrated embodiment ofFIGS. 19–21are located within the housing414, and are pivotable about locations external to the barrel430.

With reference first toFIG. 19, the lock assembly429of the present embodiment has a housing414that accommodates and supports various working components of the lock assembly. For example, the housing414can accommodate a barrel430selectively rotatable with respect to the housing414and one or more pivotable tumblers423. In the illustrated embodiment ofFIGS. 19–21, a sidebar484and an indexed pivot guide488is also located within the housing414. The sidebar484is movable to engage the barrel430in a locked state in which the barrel430is restricted from rotation with respect to the housing414. The housing414can have an aperture within which the barrel430is axially received, or can be otherwise shaped to receive the barrel430. In addition to housing the pivotable tumblers423, the housing414can also house one or more resilient biasing members (such as springs412) positioned to bias some or all of the pivotable tumblers423in a direction generally toward the barrel430. In some embodiments such as the embodiment illustrated inFIG. 19, the biasing members can be inserted within one or more apertures of the housing414and held in place by a housing plate414a. In some embodiments, the housing414has a plurality of internal grooves436,437that accept and receive portions of the pivotable tumblers423for maintaining the pivotable tumblers423in proper arrangement.

As shown inFIG. 19, the housing414can be constructed in two or more sections joined together in any manner, such as by rivets, stakes or crimps (whether using the parent material of the housing portions or not), welds, screws, bolts, snap-fit connections, adhesive or cohesive bonding material, bands, clips, pin and aperture connections, and the like. As illustrated inFIG. 19, the housing414of the exemplary embodiment is held together by two pins402The housing414can instead be defined by a single element manufactured in any conventional manner (e.g., molded, machined, cast, and the like).

As illustrated inFIGS. 19–21, the housing rotatably supports a barrel430. The barrel430can also have one or more grooves424through which key-engaging surfaces of the tumbler423extend as shown. If desired, the key-engaging surfaces of the tumblers423can be biased into these grooves424in the locked condition by springs412. Although the tumblers423in the illustrated embodiment are received within grooves424of the barrel430in order to contact a key401inserted therein, any other barrel shape enabling contact between the tumblers423and a key401inserted in the barrel is possible (e.g., through a slot running along the barrel430, a series of holes in the barrel430through which extensions of the tumblers423are received to contact a key401therein, and the like). In this regard, the tumblers423need not necessarily contact the barrel430. However, the key401does not necessarily have to directly contact the tumblers423of this embodiment or any other embodiment of the present invention. Rather, indirect contact through an intermediate element can be sufficient. For example, the key401can have contact with a follower or other member, which in turn contacts and moves the tumblers423.

Although the tumblers423are biased toward the barrel430in the illustrated embodiment ofFIGS. 19–21C, the contact (if any) between the barrel430and the tumblers423does not necessarily prevent the barrel430from rotating. However, it should be noted that the tumblers423can be shaped and oriented to contact and engage the barrel430in the locked state of the assembly429such that rotational movement of the barrel430is restricted or prevented in the locked condition. As will described in greater detail below, a sidebar484can be employed to prevent the barrel430from rotating with respect to the housing414. The sidebar484can prevent the barrel430from rotating by being received within a groove, recess, or other aperture or feature of the barrel430. In some embodiments, it is the engagement between the sidebar484and the barrel430that prevents barrel rotation in the locked state of the assembly429.

With reference now toFIGS. 21A–21C, each tumbler423in the illustrated embodiment has a trunion portion408, a sidebar-engaging portion457, and key-engaging portion456. In some embodiments, the key-engaging portion456of each tumbler423extends between the trunion portion408of the tumbler423and the sidebar-engaging portion457. The key-engaging portions456of the tumblers423can be received within the barrel grooves424as discussed above. The key-engaging portion456of each tumbler423has a surface that contacts the coded portion of a key inserted in the barrel430.

A portion of the illustrated tumbler423has a trunion408which can help set the code of the lock assembly in some embodiments and serve as a pivot in other embodiments. As shown in the illustrated embodiment ofFIGS. 19–21, the trunion408can be located at one end of the tumbler423. However, the trunion408can be located in other positions on the tumbler423if desired. In some codeable embodiments as illustrated and described in greater detail below, the trunion408aligns with and engages a pivot guide488to determine the code of the lock. Once the lock is in the coded condition, the tumblers423in the illustrated embodiment ofFIGS. 19–21pivot about the trunion408which is pivotally supported in a groove488aof the pivot guide488.

The pivot guide488is best shown inFIGS. 19,20A, and21. As illustrated in this embodiment, the pivot guide488can have one or more grooves488afor receiving the trunion408of each tumbler423in different positions with respect to the pivot guide488. The locations of the grooves in the pivot guide can determine the code of each tumbler. In some embodiments, multiple indexed grooves488aare provided to allow for a number of different coding possibilities. These multiple indexed grooves488acan be used both in pre-coded embodiments and in codeable embodiments. Regardless of the embodiment, multiple grooves488aallow the trunions408to be movable to different locations with respect to the indexed pivot guide488prior to coding without having to add or remove materials (tumblers or pivot guides) from the lock.

The interaction of the pivot guide488and the trunions408will now be briefly discussed with reference to the illustrated codeable embodiment ofFIGS. 19–21. As will be discussed in greater detail below, when a key401is inserted into the barrel430during the coding process, the tumblers423pivot and the trunions408move with respect to the indexed pivot guide488. Once the key401is fully inserted, each trunion408is positioned with respect to a groove488aon the indexed pivot guide488corresponding to the code of the key401. The trunions408and the indexed pivot guide488can then be brought into engagement with one another. In some embodiments, the pivot guide488is biased into engagement with the tumblers423. For example, as illustrated inFIG. 19, one or more springs418contained within the housing by enclosure plate419can bias the pivot guide488into engagement with the tumblers423. When the lock is coded in this manner, the pivot guide488and the tumblers423are held in engagement even after the key401is removed.

Although the description regarding the engagement between the tumblers and the pivot guide of the illustrated embodiment ofFIGS. 19–21have been described with reference to trunions and grooves, other embodiments of the present invention use other arrangements and structures for this engagement between the key-engaging portion456and sidebar-engaging portion457of the tumblers423. By way of example only, one or more grooves can be provided on each tumbler423which is engagable with a pin or other pivot element on pivot guide488(e.g., a structure that is the reverse of what is illustrated inFIGS. 19–21). As another example, other embodiments can utilize inter-engaging teeth on the tumbler portions456,457, a friction fit between these elements, or any other manner of engagement enabling pivoting motion between these elements.

As mentioned above, yet another portion of each tumbler423in the illustrated embodiment ofFIGS. 19–21interacts with a sidebar484. The sidebar484is similar to most conventional sidebars in many respects. Therefore, the operation of the sidebar484will not be discussed in great detail. Like most conventional sidebar locks, each tumbler423can have a portion that mates with the sidebar484in a male-female relationship in the unlocked state. By way of example only, a notch457with a mating projection484ais employed in the illustrated embodiment ofFIGS. 21A–21C. However, the structure can be reversed so that the notch is on the sidebar484and the mating projection is on the tumbler423. When the proper key is inserted into the lock, the notch457and projection484aare in a mating relationship and the sidebar484can be biased into an unlocked condition (i.e., out of engagement with the barrel430). However, as the proper key401is removed from the barrel430, each tumbler423is biased to a locked position. As the tumblers423pivot to their locked positions, the mating relationship between the notch457on the sidebar-engaging portion of the tumbler423and the projection484aon the sidebar484is disrupted. This disruption occurs because the notch457cams past the projection484a. The forces generated by the notches457camming out of alignment with the projection484aof the sidebar484cause the sidebar484to move to a locked condition. The sidebar moves to the locked condition because the biasing force of the tumblers423into the locked condition is greater than the biasing force of sidebar484into the unlocked position. Thus, in the locked condition, the notch457in the sidebar-engaging portion of the tumbler423is out of alignment with a projection484aof the sidebar484.

Unlike conventional sidebar locks which bias the sidebar radially outward into engagement with the housing from within the barrel, the sidebar484in the illustrated embodiment is biased radially inwardly into engagement with the barrel430from within the housing414. Accordingly, in the locked state of the lock assembly429, the sides of the sidebar484cooperate with the sides of the barrel groove427to prevent the lock barrel430from rotating relative to the housing414. When a properly coded key401is installed, the notches457on the tumblers423become aligned (or substantially aligned) with the projection484aof the sidebar484, allowing the projection484aof the sidebar484to be received in the notches457and for the sidebar484to retract from the barrel430. With the sidebar484retracted, the lock barrel430can be rotated within the housing414to actuate the output mechanism.

The operation of the coded lock illustrated in this embodiment will now be discussed by way of example only. Assuming that the lock assembly is already coded, operation of the lock begins with the insertion of a properly coded key401. As the key401is being inserted into the barrel430, the coded surface of the key401begins to contact and interact with the key-engaging surfaces456of the tumblers423. This interaction forces the tumblers423to pivot about the trunions408engaged with the indexed pivot guide488, thereby moving at least part of each tumbler423in a radial direction with respect to the barrel430. This motion in turn causes the sidebar-engaging surfaces of the tumblers423to cam against the sidebar484. Once the properly coded key401is fully inserted, the notch457on the sidebar-engaging portion of each tumbler423becomes aligned (or substantially aligned) with the protrusion484aon the sidebar484, thereby enabling the sidebar484to move out of engagement with the barrel430until the protrusion484aon the sidebar484rests in the notch457of each tumbler423. Accordingly, the sides of the sidebar484are no longer received within the barrel groove427, and the barrel430is free to rotate with respect to the housing414to cause actuation of an output mechanism.

To once again restrict relative motion between the barrel430and the housing414(i.e., place the assembly429in a locked state), the key401is rotated back to the original locked position and is removed. As the key401is removed, it causes the coded portion of the key401to no longer contact the key-engaging surfaces456of the tumblers423. This allows the tumblers423to pivot about their trunions408and move toward the barrel430under biasing force of the tumbler springs412. This pivoting further causes the sidebar-engaging surface of the tumblers423to interact with and cam the sidebar484in a radially-inward direction (toward the barrel430) due to the misalignment between the mating surfaces of the sidebar-engaging portion and the sidebar484. Specifically, the projection484aof the sidebar484is forced out of the notches457of the tumblers423by the movement of the tumblers423. Having been forced from the notches457of the tumblers, the sidebar484is biased radially towards the barrel430and engages the barrel groove427to prevent relative motion between the barrel430and the housing414.

If a key401other than a properly coded key is inserted into the barrel430in the illustrated embodiment ofFIGS. 19–21, the lock assembly429will not unlock because the sidebar484will not disengage the barrel430. The sidebar484will not disengage the barrel430because the mating surfaces of the sidebar484(e.g., the projection484aof the sidebar484) and the sidebar-engaging portion of each tumbler423(e.g., the notches457of the tumblers423) will not align. This misalignment forces the sidebar484to remain engaged with the barrel430as described above. Thus, since the sidebar484will not disengage the barrel430, the barrel430cannot rotate with respect to the housing414.

As shown inFIGS. 19–21, the tumblers423are only illustrated on one side of the barrel430, and only engage one side of the key401. However, this lock assembly429is shown with such a tumbler arrangement by way of example and illustration only. The tumblers423can be positioned on opposite sides of the barrel430so that the tumblers423engage opposite sides of the key401in an alternating or substantially alternating fashion.

As discussed above, one of the many advantages of this embodiment is that it is codeable. Therefore, the lock assembly429of the present invention can be assembled in the uncoded condition. In the uncoded condition of some embodiments, the mating surfaces of the sidebar-engaging portion of each tumbler423and the sidebar484are aligned, thereby permitting the sidebar484to be biased out of engagement with the barrel430. When the sidebar484is moved out of engagement with the barrel430and the tumblers423are aligned with the sidebar projection484a, the interface between the tumblers423and the sidebar484at the mating surface can provide a pivot point for the tumblers423in the uncoded state. In the illustrated embodiment, the tumblers423are therefore capable of pivoting about the sidebar484because the trunions408are not seated in the indexed pivot guide488in the uncoded condition. However, the tumblers423in some embodiments are prevented from pivoting on their own or from other forces in the uncoded condition due to the bias members412forcing the tumblers423radially toward the barrel430. In such embodiments, the bias members412can be oriented to force the key-engaging surface of the tumblers423against the barrel430.

As previously mentioned, when the tumblers423in the illustrated embodiment ofFIGS. 19–21are in their uncoded states, the tumblers423are able to pivot about the sidebar484because the trunions408are not seated in the pivot guide488. The pivot guide488is held in the uncoded state, disengaged from the trunions by a lever or bar415shown inFIGS. 19 and 20. In some embodiments, an end of the lever415is positioned in an aperture489of the pivot guide488. The aperture489can be a recess, groove, two position aperture, L-shaped aperture, and the like. When the lever415is in the aperture489or is otherwise in a select portion or range of positions in the aperture, the pivot guide488is held in a disengaged position with respect to the tumblers423. Once the lever415is removed from the aperture489or a portion of the aperture489, the pivot guide488is moveable to an engaged position with respect to the tumblers423. In the illustrated embodiment ofFIGS. 19–21, the lever415is engaged with a first portion of the aperture489ato prevent the pivot guide488from engaging the tumblers423and is moveable to a second position to allow the pivot guide488to engage the tumblers423. As illustrated, the lever415pivots about pivot pin416to allow the pivot guide488to engage the tumblers423. Once the lever415pivots out of engagement with the aperture489a, springs418bias the pivot guide488towards the tumblers423.

As illustrated inFIGS. 19–21, the lever415can also be used to prevent rotation of the barrel430in the uncoded condition. As illustrated, an end of the lever415can be received within a recess, groove, slot, or other aperture in the barrel430that intersects the key slot to prevent the barrel430from rotating. Due to this arrangement, the key401can be used to move the lever415out of engagement with the barrel430during the coding process. As illustrated inFIG. 20A, the lever can be equipped with a finger that extends in an axial direction. When the lever415engages the barrel430, the finger abuts a portion of the barrel430to prevent rotation of the barrel. This finger can take many shapes not illustrated. For example, the finger can also extend radially into a hole to prevent rotation of the barrel430. Furthermore, the finger can be serrated and the barrel can have a mating serration to prevent rotation of the barrel430until it is coded. Still other manners of releasable engagement with the barrel430to prevent barrel rotation are possible, and fall within the spirit and scope of the present invention.

An exemplary manner in which the lever415can be moved in order to move the pivot guide488(or to allow the pivot guide488to move) is illustrated inFIGS. 19–21. With particular reference toFIG. 20, the lever415is moved by the key401as it is inserted into the barrel430. In the illustrated embodiment, the lever415is not moved out of engagement with the barrel430until the key401is fully inserted. This ensures that the lock will be coded to the entire key401. However, in other embodiments, it may be desirable to code only a portion of the key401, in which case a length of the key401would be inserted into the lock in order to permit barrel rotation and to unlock the lock. In such embodiments, the position of the lever415with respect to the barrel430can be different so that the lever415is tripped at a different insertion point of the key401in the barrel430. In still other embodiments, the lever415(or other mechanism by key insertion or rotation) is moved at a time other than upon partial or full insertion of the key401.

As the lever415moves, it releases the pivot guide488, allowing the pivot guide488to be moved towards the tumblers423and to engage the trunions408. As the pivot guide488moves, the lever415moves to the second position of the aperture489. In the second position as shown inFIG. 20C, the lever415engages a side wall490of the aperture489, which prevents the lever415from moving back into the first position, and also prevents the end of the lever415nearest the barrel430from interfering with rotation of the barrel430.

Although the same lever415is used in the illustrated embodiment to prevent the barrel430from rotating in the uncoded condition and to hold the pivot guide488in the disengaged position, other embodiments can use separate levers or other mechanisms for each function. For example, although the illustrated embodiment utilizes a lever415engaged with an aperture489to control the coding process, a number of other elements and assemblies can be employed to release the pivot guide488into engagement with the tumblers423in order to secure them in place. These elements and assemblies can be cammed by the key401, rolled or pivoted off of the key401, shifted by the key401, tripped by the key401, or can be moved in any other manner to release the pivot guide488. In addition, these alternative elements and assemblies can move to permit the pivot guide488to engage the tumblers423by spring-loaded action, by pushing or pulling action upon the pivot guide488(e.g., by causing the pivot guide488to shift in the lock assembly), by only permitting the pivot guide488to move toward the barrel by another element or assembly (e.g., by later rotation of the barrel), and the like.

To code the exemplary lock assembly429illustrated inFIGS. 19–21, a key401is inserted into the barrel430of the lock assembly429as shown inFIGS. 20B and 21B. As the key401is inserted, the coded surfaces of the key401interact with the key-engaging surfaces456of the tumblers423. This interaction causes the tumblers423to pivot about the notches457of the tumblers423engaging the sidebar484. Once the key401is fully inserted, the key-engaging surface456of the tumblers423engage and rest against a portion of the coded surface of the key401. Depending upon the code of the key401, some of the tumblers423will rest in a greater radially extended position (with respect to the barrel430) than others. This in turn causes the trunion408of each tumbler423to align with one of the many grooves in the indexed pivot guide488, or otherwise be positioned in one of two or more different positions in which the trunion408can be secured. After the key401has been inserted in the illustrated embodiment, the lever415releases the barrel430for rotation and the pivot guide488for movement. As illustrated, the indexed pivot guide488can then move to engage the aligned trunions408. Once the key401is removed from the barrel430, the lock assembly429will remain coded. However, as the key401is being the removed, the lock assembly429transitions from the unlocked condition to the locked condition as discussed above.

In some embodiments, the lock assembly illustrated inFIGS. 19–21can be uncoded and re-coded to a different key. By way of example only, one such way to uncode the lock assembly429would by to retract the pivot guide488in any suitable manner (e.g., by one or more levers connected thereto or pivotable to retract the pivot guide488, by one or more pins, fingers, or other elements extending to the pivot guide488and movable to retract the pivot guide488, by a modified aperture in which the lever415extends and which enables actuation of the lever415to cause retraction of the pivot guide488, and the like). This would allow the coding process to start over with a new key.

Yet another embodiment of the present invention is illustrated inFIGS. 22–25. This embodiment utilizes a housing514, a barrel530, tumblers523, and a sidebar584. Much of the structure of the embodiment illustrated inFIGS. 22–25is similar to those described above with reference to previous embodiments. With the exception of the structure and features described below, additional information regarding the lock assembly illustrated inFIGS. 22–25can be found in the previously-described embodiments of the present invention.

The tumblers523in the embodiment of the present invention illustrated inFIGS. 22–25are located in the barrel530and consist of two elements. The first element is a key-engaging element506,507and the second element is a sidebar-engaging element583. In the uncoded condition of the lock assembly, these elements506,507,583are disengaged from each other. In the coded state, however, the key-engaging tumbler elements506,507and the sidebar-engaging tumbler elements583are secured to each other in a particular relative position corresponding to the code of the key501.

As illustrated, the key-engaging elements506,507can have a structure similar to a plate tumbler with an aperture positioned to allow the key501to pass through it when inserted into the barrel530. Although a substantially O-shaped tumbler is illustrated, other types and shapes of tumblers523are possible. For example, the tumblers523can each have an L-shape, C-shape, T-shape, I-shape, and the like. Regardless of the shape of the tumbler, a portion of the key-engaging element506,507contacts the coded surface of the key501when the key501is inserted into the barrel530. The key-engaging elements506,507also have a portion that can be engaged by the sidebar-engaging tumbler elements583. In some embodiments (such as that shown inFIGS. 24 and 25), this portion is serrated, ribbed, embossed, dimpled, or is otherwise shaped to provide a robust fit between the two elements506,507and583.

The key-engaging element506,507can also have a portion for engaging a spring or other bias member. This portion for engaging a bias member can be located anywhere on the key-engaging elements506,507. The bias members (not shown) bias the tumbler elements506,507to locked positions when the key501is removed from the keyhole. The key-engaging elements506,507can be biased in substantially opposite directions in a substantially alternating fashion in a conventional manner. However, in some embodiments, the key-engaging elements506,507can be biased in the same direction (also in a conventional manner).

The sidebar-engaging element583in the illustrated embodiment ofFIGS. 22–25has a channel583athat engages the sides of the key-engaging element506,507during the coding process. The sidebar-engaging elements583can be held in an engaged position with the key-engaging elements506,507by a friction fit, an interference fit, an interlocking fit, a snap fit, and the like. Additionally, although the channel583aengages the sides of the key-engaging element506,507in the exemplary embodiment ofFIGS. 22–25, the channel583acan engage any other portion of the key-engaging elements506,507. In alternative embodiments, the engaging structure can be reversed such that the channel is located on the key-engaging elements506,507for engagement with any portion of the sidebar-engaging elements583.

As shown inFIGS. 25A and 25B, the two tumbler elements506,507,583are independent of each other prior to coding. However, once coded, the channel583aof the sidebar-engaging elements583straddle the side of the key-engaging tumbler elements506,507and are fixed to the key-engaging tumbler elements506,507in the coded state by a friction fit. In some embodiments, this friction fit connection between the two tumbler elements506,507,583enables exact placement of the tumbler elements506,507,583with respect to one another, and can reduce or eliminate manufacturing tolerance problems associated with the tumblers523and tumbler location in the lock assembly529. To robustly retain the code defined by the relative positions of the tumbler elements506,507,583and to provide resistance to tampering or misuse, the mating surfaces of the key-engaging tumbler elements506,507can be serrated while the mating edges of the sidebar-engaging tumbler583can have a stamping burr and/or be turned slightly. Thus, the edges of the sidebar-engaging tumbler elements583can positively engage the key-engaging elements506,507and can resist any alterations to the code setting.

The coding process of the embodiment illustrated inFIGS. 22–25will now be described in further detail. Referring toFIGS. 25A–25C, the coding process of the lock assembly529begins with the insertion of the key501. As the key501enters the barrel530, the key-engaging elements506,507shift to an extent determined at least in part by the depth of the coding on the key surface. Once the key501is fully inserted, the key-engaging elements506,507can rest against the coded surfaces of the key. As will be described below, a code setting mechanism is then utilized to cause the tumblers elements506,507,583to engage each other.

The lock assembly529illustrated inFIGS. 22–25is coded to the key501by rotating the barrel530with respect to the housing514in response to turning the key501. As the barrel530is turned, the sidebar-engaging elements583are shifted towards the key-engaging elements506,507by camming action of the sidebar584against the inside surface of the housing514in a manner similar to that described above with regard to the follower170,370in the first and third embodiments. This shift can be caused in a number of other manners, such as by a camming action of the sidebar-engaging elements583against an interior surface of the housing514, by one or more springs directly or indirectly exerting force against the sidebar-engaging elements583in at least one rotational position of the barrel530, and the like. In other embodiments, however, the barrel does not need to rotated to code the lock. Rather, the code setting mechanisms described in any of the embodiments described and illustrated herein can be used. For example, the code setting mechanisms disclosed inFIGS. 1–13and19–21are adaptable to be utilized in the present embodiment.

As illustrated in several embodiments and as mentioned above, the shift of the sidebar-engaging elements583can be caused by the sidebar584camming against an interior portion of the housing514, which in turn exerts a force upon the sidebar-engaging elements583to move the sidebar-engaging elements583into engagement with the key-engaging elements506,507. In the uncoded condition, the sidebar584extends from the barrel530into a recess in the housing514. The inside surface of the housing514is shaped to cause the sidebar584to be pushed toward the barrel530as the barrel530is being rotated with respect to the housing514(e.g., such as by a ramped or other cam surface defined in the inside of the housing514). As discussed in greater detail below, as the sidebar584is forced to retract within the barrel530by the inside surface of the housing514, the sidebar584forces the sidebar-engaging elements583to engage the key-engaging elements506,507.

As shown inFIG. 25C, shifting of the sidebar-engaging elements583towards the key-engaging elements506,507allows the elements506,507,583to engage each other via a friction fit. However, other manners of engagement are possible, such as having projection(s) and/or recess(es) on the key-engaging elements506,507engage corresponding recess(es) and/or projection(s) on the sidebar-engaging elements583. This engagement produces a tumbler combination523coded to the particular notch depth of the key501. Thus, in the coded state, the sidebar-engaging elements583and the key-engaging elements506,507are capable of moving together in response to forces exerted on either element.

Once the key501is removed, at least one spring or other bias member (not shown) can bias one or more of the tumbler combinations523into the locked state. As discussed in greater detail with regard to the embodiment illustrated inFIGS. 19–21, this biasing in turn can cause the sidebar-engaging element583to exert a force on the sidebar584. As such, the sidebar584is forced radially into engagement with the housing514, which prevents rotation of the barrel530with respect to the housing514in a manner well known in the art. The sidebar584and the tumbler combinations523can engage in any conventional manner or in the manner discussed above in regard to the embodiment disclosed inFIGS. 19–21. For example, the sidebar584and the tumbler combinations523can engage in any male-female engagement, such as a projection and recess engagement of the elements523,584. In some embodiments such as that shown in the embodiment ofFIGS. 22–25, the sidebar-engaging elements583have a pair of projections583bthat form a recess583cwithin which the sidebar584engages. When the recesses583cformed by the projections583bare aligned with the projection on the sidebar584, the sidebar584is biased into engagement with the recesses583c. This movement of the sidebar584causes the sidebar584to retract within the barrel530and disengage the housing514.

In other embodiments, the sidebar584does not have a projection. Rather, the projections583con the sidebar-engaging tumbler elements583are configured to rest on either side of the sidebar584in the unlocked condition. Therefore, the recesses583con the sidebar-engaging tumbler elements can align with the sidebar584once the properly coded key is inserted. When the recesses583con the sidebar-engaging tumbler elements583align with the sidebar584, the projections583bof the sidebar-engaging tumbler elements583are positioned on either side of the sidebar584. As such, the sidebar584is able to be biased towards the recess583cof the sidebar-engaging tumbler element583. Thus, the sidebar584retracts from engagement with the housing514to allow rotation of the barrel530with respect to the housing514.

Other embodiments also utilize a sidebar584with an anti-pick feature584b. The exemplary anti-pick feature illustrated inFIGS. 22–24utilizes a recess584bon the sidebar584rather than a projection to engage the tumbler combinations523. This recess584bcan work as an anti-pick feature due to the configuration of the sidebar-engaging tumbler elements583. The projections583bon the sidebar-engaging tumbler elements583can align with and engage the recess584bon the sidebar584when one is attempting to pick the lock. When this occurs, the person attempting to pick the lock may assume that the tumbler combination523is properly aligned with the sidebar584due to the engagement of the projection583cwith the recess584b. However, the sidebar-engaging tumbler elements583are instead improperly aligned with the sidebar584to enable the sidebar584to retract from the housing514as described above. Thus, the sidebar584will not disengage from the housing514.

In some embodiments, the sidebar-engaging elements583can be contained within a carrier586as illustrated inFIG. 24prior to coding. The sidebar-engaging tumbler elements583can be contained within an apertured wall of the carrier586prior to coding. In some embodiments, the sidebar-engaging tumbler elements583are held within the apertured wall via a friction fit prior to coding. However, in other embodiments, the sidebar-engaging tumbler elements583merely rest against the apertured wall prior to coding. In either embodiment, an interference fit or frictional engagement can keep the sidebar-engaging elements contained in desired positions within the carrier586until the lock is coded. In still other embodiments, the sidebar-engaging tumbler elements583are retained in place in the carrier586by one or more bosses, lugs, recesses, walls, pins, fingers, or other elements on or defined by the carrier586for registration of the sidebar-engaging tumbler elements583. Regardless of how the sidebar-engaging tumbler elements583are retained within the carrier586, each of the sidebar-engaging tumbler elements583can be held in position substantially aligned with a key engaging tumbler element506,507(in a manner permitting the sidebar584to retract from the housing514). Such an arrangement can result in a lock assembly in which less motion is necessary to code the lock.

As shown in the illustrated embodiment, the carrier586can be part of a larger subassembly containing the sidebar, such as a sidebar cartridge585as shown inFIGS. 23 and 24. The sidebar cartridge585can facilitate easier assembly of the lock assembly529. The sidebar cartridge585can be comprised of the carrier586, the sidebar-engaging elements583, and the sidebar584, and in some cases can further include a sidebar spring or other bias member518and/or a cover519. As assembled, the sidebar-engaging elements583can rest in or be aligned with apertures of the carrier586or can otherwise be retained in the carrier586as described above. Additionally, the sidebar584can rest against or adjacent to the sidebar-engaging elements583. In some embodiments where the sidebar-engaging tumbler elements583are retained in apertures in the carrier586, the sidebar584can have a portion that engages and forces the sidebar-engaging tumbler elements583through the carrier wall during the coding process. If employed, the sidebar bias member(s)518can rest against the sidebar584and can be held in place by the cover519.

In other embodiments, much of the structure described in the previous paragraph can be eliminated. For example, the sidebar-engaging elements583can be releasably seated upon or connected to the sidebar584(or another element adjacent to the sidebar) and can be transferred to the tumblers506,507by frictional engagement therewith as described above (thereby avoiding the need for the carrier586). Alternatively, the sidebar584can be eliminated in its entirety. In such an embodiment, the sidebar-engaging tumbler elements583can be forced into engagement in any manner discussed in other embodiments of the present invention. Specifically, a code setting mechanism such as that described with regard to the embodiments disclosed inFIGS. 1–21can be used.

In those embodiments employing a sidebar cartridge585, the sidebar cartridge585can be installed adjacent the barrel530and key-engaging tumbler elements506,507after assembly of the sidebar cartridge585, or can alternatively be assembled in the lock assembly529. Also, in those embodiments in which rotation of the barrel530causes the sidebar584to be forced toward the barrel530by the inside surface of the housing514(as described above), the sidebar584may extend a greater distance from the cover519of the cartridge585in the uncoded state than in the locked and coded state. This greater extension is due to the position of the sidebar-engaging elements583in the uncoded state. In the uncoded state, the sidebar engagement elements583are retained within the cartridge585, while in the coded state they are mated to the key-engaging elements506,507. While retained with the cartridge585, the sidebar engagement elements583can take up space within the cartridge585, which forces the sidebar584to extend a greater distance from the cover519than in the coded state. During the coding process, the sidebar584forces the sidebar-engaging elements583through the carrier wall of the cartridge585to mate with the key-engaging elements506,507. This creates more room in the cartridge585for the sidebar584. Thus, the sidebar584does not extend as far from the cartridge585in the coded condition. In some embodiments, the sidebar584extends about one millimeter less in the coded and locked state than in the uncoded state.

Yet another embodiment of a codeable lock according to the present invention is illustrated inFIGS. 26–32, and is similar in many respects to the previous embodiment. For example, both embodiments have similar housings, barrels, and sidebars. A substantial difference between the embodiment illustrated inFIGS. 26–32and that illustrated inFIGS. 22–25is the manner in which engagement is established between the key-engaging tumbler elements and the sidebar-engaging tumbler elements. With the exception of the structure and features described below, additional information regarding the lock assembly illustrated inFIGS. 26–32can be found in the previously-described embodiments of the present invention.

Like the illustrated embodiment ofFIGS. 22–25described above, the embodiment of the present invention illustrated inFIGS. 26–32has a housing614, a barrel630, and one or more tumblers623within the barrel630. Each tumbler623can be defined by two or more elements movable with respect to one another for purposes of coding. In this illustrated embodiment for example, each codeable tumbler combination623can include a key-engaging element606,607and a sidebar-engaging element683. In the uncoded state, the key-engaging tumblers elements606,607are movable independent of the sidebar-engaging elements683. In the coded state, these elements606,607,683are coupled to each other in a position relative to the code of the key.

Much like the previous embodiment, the key-engaging tumbler elements606,607can have an illustrated structure similar to a plate tumbler with an aperture positioned to allow a key to pass therethrough when inserted into the barrel630. Although a substantially O-shaped tumbler623is illustrated inFIGS. 29,30, and32, other types and shapes of tumblers623are possible. For example, the tumbler623can have an L-shape, C-shape, T-shape, I-shape, and the like. Regardless of the shape of the tumbler623, in some embodiments a portion of the key-engaging element606,607is able to contact the coded surface of the key when inserted into the barrel630.

The key-engaging element606,607can also have a portion for engaging a spring or other bias member. This portion for engaging a bias member can be located anywhere on the element606,607. The bias members (not shown) bias the tumbler elements606,607to locked positions when the key is removed from the keyhole. The key-engaging elements606,607can be biased in substantially opposite directions in a substantially alternating fashion. However, in other embodiments, the key-engaging elements606,607are biased in the same direction.

As illustrated, the key-engaging elements606,607and the sidebar-engaging elements683can engage each other with a coupling. This coupling can take a variety of forms, such as a force fit, a friction fit, an interference fit, a snap fit, a mating fit, and the like. For example, the key-engaging elements606,607can have one or more projections and/or recesses657to engage the sidebar-engaging elements683. Similarly, the sidebar-engaging tumbler elements683can have at least one surface with one or more projections and/or recesses654to engage the key-engaging elements606,607during the coding process.

With reference to the exemplary embodiment illustrated inFIGS. 26–32, the key-engaging tumbler elements606,607have at least one projection657that engages an aperture654of the sidebar-engaging tumbler element. As shown inFIGS. 31 and 32, the projection657can have a serrated or notched periphery, while the sidebar-engaging element can have a matching profile along the interior of the aperture654. Furthermore, the aperture654is longer than the projection,657to allow for many potential engagement positions with the key-engaging element683during the coding process. Once the projection657is inserted into the aperture654, the serrations align and interlock to prevent relative motion between the two pieces in the directions that the tumblers are biased.

Although a serrated projection657and recess654are employed to join the key and sidebar-engaging tumbler elements683,606and607illustrated inFIGS. 26–32, the projection657and recess654(if used) do not need to be serrated. For example, some embodiments of the present invention utilize a simple projection and recess engagement that is not serrated, while other embodiments utilize one or more projections and recesses that have other mating shapes. A non-limiting list of such mating periphery shapes can include circular, square, triangular, polygonal, and the like. Additionally, some other embodiments can utilize multiple projections and/or recesses by which the tumbler elements606,607,683can be releasably engaged in two or more relative positions.

Since the sidebar-engaging tumbler elements683are not engaged with the key-engaging tumbler elements606,607in the uncoded state, the lock assembly illustrated inFIGS. 26–32can employ a number of different elements and features to control the location and orientation of the sidebar-engaging tumbler elements683prior to and during the coding process. By way of example only, (and as will be described in greater detail below), one of the features provided in the illustrated embodiment controls the location and orientation of the sidebar-engaging tumbler elements683in the uncoded condition, while another feature controls the location and orientation of the sidebar-engaging tumbler elements683during the coding process. Although two separate features are used in the illustrated embodiment, they can be combined in various other embodiments.

Each sidebar-engaging tumbler element683can have one or more apertures683dadjacent the barrel630as shown inFIG. 31B. These apertures can engage one or more projections630eon the barrel630(see barrel portion630ainFIG. 28) or another feature of the lock in the uncoded condition to control the location and orientation of the sidebar-engaging element prior to coding. For example, in the illustrated embodiment ofFIGS. 26–32, the apertures683dengage projections630eon the barrel630,630a. The sidebar-engaging tumbler elements683can be held in positions engaged with the projections630evia a friction fit, a force fit, an interference fit, adhesive, a bias member, and the like. Also, in some embodiments one or more ribs683e(or other projections) can extend from the interior wall of the aperture683dto enhance or cause a friction fit with the projection630eon the barrel630,630a. One way of engaging the sidebar-engaging tumbler elements683with the barrel630,630ais to assemble the lock with the apertures683dengaged with the projections630eon the barrel630,630a. However, various triggering mechanisms discussed herein can instead be utilized to generate engagement after the lock has been fully or partially assembled. This engagement of the sidebar-engaging tumbler elements with the barrel630,630a(via the apertures683d) can hold the sidebar-engaging tumbler elements683in an aligned position with the key-engaging tumbler elements606,607to facilitate quicker and easier coding. It will be appreciated that the projections630eof the barrel630,630aand the apertures683din the sidebar-engaging tumbler elements683can be reversed in location, and can also be replaced by a number of alternative structures and elements providing releasable engagement and retention of the sidebar-engaging tumbler elements683with respect to the barrel630,630a.

After the coding process has begun, the sidebar-engaging tumbler elements683in the exemplary illustrated embodiment ofFIGS. 26–32are drawn away from the barrel630,630a. This causes disengagement between the apertures683don the sidebar-engaging elements683and the projections630eon the barrel630,630a. To maintain the orientation of the sidebar-engaging elements683in this period of transition between the uncoded state and the coded state, a push plate687can be utilized. Among other attributes, the push plate687prevents the sidebar-engaging elements683from translating or substantially pivoting while moving toward the key-engaging tumbler elements623. Thus, the push plate687helps to facilitate a quick, clean engagement between elements606,607,683. As illustrated, the push plate687has a generally open frame structure, although any structure performing the same function just described can instead be employed. The frame controls the position and orientation of the sidebar engaging tumbler elements683during the coding process, while the opening in the frame allows the sidebar684to engage and interact with the sidebar-engaging elements683both during the coding process and afterwards.

The coding process of the exemplary embodiment illustrated inFIGS. 26–32will now be described. In this embodiment, the coding process of the lock assembly629begins with the insertion of the key601. As the key601enters the barrel630, the key-engaging elements606,607may move to an extent determined at least in part by the depth of the coding on the key surface. When the key601is fully inserted, the key-engaging elements606,607can rest against the coded surfaces of the key. A code setting mechanism can then be used to couple the key-engaging tumbler elements606,607to the sidebar engaging tumbler elements683, such as any of the structures described elsewhere herein for moving sidebar-engaging tumbler elements with respect to key-engaging tumbler elements.

The lock assembly629illustrated inFIGS. 26–32is coded to the key601by rotating the barrel630with respect to the housing614in response to turning the key601. As the barrel630is turned, the sidebar-engaging elements683are shifted towards the key-engaging elements606,607. As indicated above, this shift can be caused in a number of different manners, such as by a camming action of the sidebar-engaging elements683against an interior surface of the housing614, by one or more springs directly or indirectly exerting force against the sidebar-engaging elements683in at least one rotational position of the barrel630, and the like. In other embodiments, however, the barrel does not need to rotated to code the lock. Rather, the non-rotating code setting mechanisms described above can instead be used as desired. For example, the code setting mechanisms disclosed with reference to the embodiments ofFIGS. 1–13and19–21are adaptable to be utilized in the present embodiment.

As illustrated in several embodiments, the above-described shift of the sidebar-engaging elements683can be caused by the sidebar684camming against an interior portion of the housing614, which in turn exerts a force upon the sidebar-engaging elements683to move the sidebar-engaging elements683into engagement with the key-engaging elements606,607. In the uncoded condition, the sidebar684extends from the barrel630into a recess in the housing. The inside surface of the housing614can be shaped to cause the sidebar684to be pushed toward the barrel630as the barrel630is being rotated with respect to the housing614(e.g., such as by a ramped or other cam surface defined in the inside of the housing614). As discussed in greater detail below, as the sidebar684is forced to retract within the barrel630by the inside surface of the housing614, the sidebar684forces the sidebar-engaging elements683to engage the key-engaging elements606,607.

As illustrated, shifting of the sidebar-engaging elements683towards the key-engaging elements606,607allows the projections of the key-engaging tumbler elements606,607to engage the sidebar-engaging tumbler elements683. In some embodiments, the elements606,607,683are held together with a friction and/or mating fit between the two elements as discussed above. However, other manners of engagement are possible, such as any type of male-female fit. This engagement produces a tumbler combination623coded to the particular notch depth of the key601. Thus, in the coded state, the sidebar-engaging elements683and the key-engaging elements606,607are able to move together in response to forces exerted on either element.

Once the key601is removed, at least one spring (not shown) can move one or more of the tumblers623into the locked state. As discussed above, moving the tumblers623in this manner causes the sidebar684to be cammed into engagement with the housing614to thereby prevent rotation of the barrel630with respect to the housing614. The sidebar684and the tumbler combinations623can engage in any conventional manner or in the manner discussed above in regard to the embodiment of the present invention disclosed inFIGS. 19–21. For example, the sidebar684and the tumbler combinations623can engage in any male-female engagement, such as a projection and recess engagement of the elements623,684. As illustrated inFIG. 31A and 31B, the sidebar-engaging elements683have a recess683cwithin which can be received a projection of the sidebar684. When the recesses683care aligned with the projection on the sidebar684, the sidebar684is biased into engagement with the recess683c(such as by one or more springs or other biasing elements, not shown). This movement of the sidebar684causes the sidebar684to retract within the barrel630and to disengage the housing614.

When a correctly coded key is removed from the lock illustrated inFIGS. 26–32, the spring-biased tumbler combinations623are forced by springs (positioned in a conventional manner to bias the tumbler combinations623) into their locked positions. By virtue of the shape of the recess683cand mating sidebar projection683c, this movement of the tumbler combinations623forces the sidebar684radially outward to engage the sidebar684with the housing614, thereby preventing rotation of the barrel630with respect to the housing614(and locking the lock).

As mentioned above, the locks of the present invention generally interact with another device or other components, including but not limited to a latch or various ignition components. Since these devices may not have a range of motion comparable to that of the lock as it is coded, these devices may need to be initially isolated from the motion of the lock during the coding process. For example, certain automobile door locks only have a rotational range of motion between plus or minus forty-five degrees. In other words, the door latch has a limited range of motion that cannot be exceeded. Since in some embodiments of the present invention the barrel can be rotated during the coding process through a greater range of motion than a device (e.g., a latch) connected thereto, it may be necessary to isolate the device from the lock during at least part of the coding process. Therefore, some embodiments of the lock according to the present invention are equipped with a clutch or other motion isolation element to prevent rotation of the lock from transferring to the connected device for a range of motion during the coding process. Thus, in these embodiments, as the coding process begins, the barrel is rotated but the lock output mechanism (e.g., a lever connected to the device) does not rotate. As the coding process continues, the clutch member (or other isolation element) drivingly engages the barrel and thereafter causes motion and force to be transferred to the lock output mechanism. Accordingly, further rotation of the barrel generates motion of the latch or other device.

An example of an isolation element and a lock output mechanism is illustrated inFIGS. 22 and 23. In this embodiment, a spring loaded clutch593is located between the barrel530and the output mechanism594, and has two projections593a,593bthat engages two recesses530a,530brespectively on the barrel530as the barrel530is rotated with respect to the clutch member593. The projection593ais similarly shaped to recess530a, but has a different shape than recess593b. Also, the projection593bis similarly shaped to recess530b, but has a different shape than recess593a. Therefore, the clutch593only engage the barrel530when these elements are correctly aligned.

The projections593a,593bof the clutch member593are initially not aligned with the recesses530a,530bon the barrel530, thereby allowing the barrel530to rotate without transferring motion to the output mechanism594. Due to the shape of these elements, they can be out of alignment by 180 degrees or more. However, after a predetermined amount of barrel530rotation, the recesses530a,530bon the barrel530align with the projections593a,593bon the clutch593. The spring595biases the clutch593into engagement with the barrel530. After the clutch593engages the barrel530, further movement of the barrel530is transferred to the output mechanism594.

Also, as illustrated inFIGS. 22 and 23, the clutch member593can also have a tail member593ccapable of engaging the housing514in the uncoded condition. Without this tail593c, the clutch593may be able to rotate with the barrel530in the uncoded state due to frictional engagement between the clutch593and the barrel530. Since the tail593cengages the housing514in the uncoded state and the housing514does not rotate, the clutch593does not rotate with the barrel530. The clutch593, however, does rotate with the barrel530once the projections593a,593band recesses530a,530bon the two elements engage.

It will be appreciated that the recesses530a,530bon the barrel530and the projections593a,593bon the clutch member593can be reversed, or can be replaced by any other clutch mechanism well-known in the art, or any other inter-engaging structure or elements that engage to drive the output mechanism after a desired amount of rotation of the barrel530. Furthermore, the number and shape of the engaging elements can vary. For example, the barrel530can be provided with a clutch engagement element or projection and the output mechanism (or other intermediate element) can be provided with a clutch plate or recess. In other embodiments, such clutch mechanisms, structures, and elements include without limitation pins or dogs on the clutch or barrel rotatable into recesses or apertures in the barrel or clutch, respectively, inter-engaging teeth on the clutch and barrel, and the like. Such alternative clutch mechanisms, structures, and elements fall within the spirit and scope of the present invention.

Yet another embodiment of a codeable lock according to the present invention is illustrated inFIGS. 33–34. This embodiment is similar to the previous embodiment in many respects. For example, the embodiment illustrated inFIGS. 33–34is similar to the embodiment illustrated inFIGS. 26–32in that both embodiments can employ similar housings, barrels, and sidebars. Accordingly, with the exception of the structure and features described below, additional information regarding the lock assembly illustrated inFIGS. 33–34can be found in the previously-described embodiment of the present invention.

Like the previous illustrated embodiment described above, the tumbler combinations723in the embodiment of the present invention illustrated inFIGS. 22–24is employed in a housing and barrel similar to the housing614and barrel630illustrated inFIGS. 26–28. Each tumbler723can be defined by two or more elements movable with respect to one another for purposes of coding. In the illustrated embodiment ofFIGS. 33–34for example, each codeable tumbler combination723includes a key-engaging element706,707and a sidebar-engaging element783. In the uncoded state, the key-engaging tumblers elements706,707are independent of the sidebar-engaging elements783. In the coded state, these elements706,707,783are coupled to each other in a position relative to the code of the key.

Much like the embodiment of the present invention illustrated inFIGS. 26–32, the key-engaging tumbler elements706,707have an illustrated structure similar to a plate tumbler with an aperture positioned to allow the key to pass through it when inserted into the barrel730. Although a substantially O-shaped tumbler is illustrated, other types and shapes of tumblers are possible. For example, the tumbler can have an L-shape, C-shape, T-shape, I-shape, and the like. Regardless of the shape of the tumbler, a portion of the key-engaging element706,707should be able to contact the coded surface of the key701when the key is inserted into the barrel (not shown inFIGS. 33–34).

The key-engaging tumbler element706,707can also have a portion for engaging a spring or other bias member in a conventional manner. This portion for engaging a spring or bias member can be located anywhere on the element706,707(such as on a ledge or projection as illustrated inFIGS. 33 and 34. The bias members (not shown) bias the tumbler elements706,707to locked positions when the key is removed from the keyhole.

The key-engaging tumbler elements706,707of the embodiment illustrated inFIGS. 33–34engage a second tumbler element783in the coded condition. The key-engaging elements706,707can each have at least one key-engaging surface756and one or more projections and/or recesses757to engage the sidebar-engaging elements783. As shown inFIGS. 34A–34Cby way of example only, the key-engaging tumbler elements706,707have apertures757, such as indentations, recesses, notches, grooves and the like, that engage one or more projections from the sidebar-engaging tumbler elements783. In some embodiments, each key-engaging tumbler element706,707has multiple apertures757as shown inFIGS. 33 and 34. These apertures757can have any arrangement or spacing as desired. However, in some embodiments, the apertures757that are substantially equidistant from each other. Although the illustrated embodiment shows the key-engaging elements706,707having apertures757for engagement with projections754on the sidebar-engaging elements783(as will be described in greater detail below), this engagement structure can instead be reversed to perform the same functions.

As stated above, the lock assembly729illustrated inFIGS. 33–34also has sidebar-engaging tumbler elements783. As shown inFIG. 33, the sidebar-engaging tumbler elements783have a portion that engages the sidebar784and a portion that selectively engages the key-engaging tumbler elements706,707. In some embodiments, the projections of the sidebar-engaging tumbler elements783take the form of pins754capable of engaging one or more of the apertures757of the key-engaging tumbler elements706,707. The pins754can have any shape desired, and in the illustrated embodiment have a substantially round cross-sectional shape. In some cases, the pins754are retractable. Although the pins754can be arranged in any manner on the sidebar-engaging tumbler elements783, the pins754in some embodiments are spaced non-equidistantly, and/or do not have the same spacing as the apertures757on the key-engaging tumbler elements706,707. Such pin spacing can allow for more potential coding positions for each tumbler723as well as more robust pins754.

In some embodiments, and as will be described in greater detail below, only one of the pins754engage a corresponding aperture757in the key-engaging element706,707during the coding process, while the other pins754are pushed by the key-engaging elements706,707into the body of the sidebar-engaging tumbler element783. In other embodiments, two or more of the pins (or other projections754) engage a corresponding aperture757in the key-engaging element706,707.

The coding process of the embodiment illustrated inFIGS. 33–34will now be briefly described. In this embodiment, the coding process of the lock assembly729begins with the insertion of the key (not shown). As the key enters the barrel (in the same manner as that described and illustrated with reference to the previous embodiment), the key-engaging elements706,707can shift to an extent determined at least in part by the depth of the coding on the key surface. When the key is fully inserted, the key-engaging elements706,707can rest against the coded surfaces of the key.

The lock assembly is coded to the key by rotating the barrel with respect to the housing in response to turning the key. As the barrel is turned, the sidebar-engaging elements783are shifted towards the key-engaging elements706,707. This shift can be caused in a number of different manners, such as by a camming action of the sidebar-engaging elements783against an interior surface of the housing, by one or more springs directly or indirectly exerting force against the sidebar-engaging elements783in at least one rotational position of the barrel, and the like. In other embodiments, however, the barrel does not need to be rotated to code the lock. Rather, the alternative code setting mechanisms described in any of the other embodiments described herein can instead be used. For example, the code setting mechanisms described with reference toFIGS. 1–13and19–21can be adapted to be utilized in the present embodiment.

In some embodiments, the above-described shift of the sidebar-engaging elements783is caused by the sidebar784camming against an interior portion of the housing, which in turn exerts a force upon the sidebar-engaging elements783to move the sidebar-engaging elements783into engagement with the key-engaging elements706,707. In the uncoded condition, the sidebar784extends from the barrel into a recess in the housing. As in the embodiment illustrated inFIGS. 26–32, the inside surface of the housing is shaped to cause the sidebar784to be pushed toward the barrel as the barrel is rotated with respect to the housing (e.g., such as by a ramped or other cam surface defined in the inside of the housing). As discussed in greater detail below, as the sidebar784is forced to retract within the barrel by the inside surface of the housing, the sidebar784forces the sidebar-engaging elements783to engage the key-engaging elements706,707.

As illustrated, shifting of the sidebar-engaging elements783towards the key-engaging elements706,707allows the pins754of the sidebar-engaging tumbler element783to approach and engage the key-engaging tumbler elements706,707. As shown inFIG. 34C, one of the pins754of each sidebar-engaging element783is aligned with an aperture757in a corresponding key-engaging element706,707as the sidebar-engaging elements783approach the key-engaging elements706,707. However, more than one pin and aperture engagement per tumbler723is possible in other embodiments. Therefore, as the two tumbler elements engage each other, only the pin(s)754aligned with the aperture(s)757will remain extended, while the other pins754, which are misaligned with the remaining apertures757, will be forced to retract into the sidebar-engaging element783. Thus, the sidebar-engaging elements783and the key-engaging elements706,707can be held together with a friction fit between engaged pins754and apertures757. However, other manners of engagement are possible, such as any other type of male-female fit. By way of example only, some other embodiments utilize the reaction force of a spring-loaded sidebar784to hold the pins754in the engaged position. Engagement between the tumbler portions783,706,707produces a tumbler combination723coded to the particular notch depth of the key. Thus, in the coded state, the sidebar-engaging elements783and the key-engaging elements706,707can move together in response to forces exerted on either element.

Once the key is removed, at least one spring (not shown) can bias one or more of the tumblers723into the locked state. As discussed above with reference to the embodiment of the present invention illustrated inFIGS. 26–32, this biasing in turn causes the sidebar784to be cammed radially into engagement with the housing to thereby prevent rotation of the barrel with respect to the housing. The action of the sidebar784as illustrated is similar in nature to the sidebar action described in the previous embodiments. Therefore, any of the sidebar structures described above can be employed to generate sidebar784disengagement from the tumblers723upon key removal.

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention. For example, various alternatives to the features and elements of the lock assemblies29,129,229,329,429,529,629,729are described with reference to each lock assembly29,129,229,329,429,529,629,729. With the exception of features, elements, and manners of operation that are mutually exclusive of or are inconsistent each illustrated embodiment described above, it should be noted that the alternative features, elements, and manners of operation described with reference to each of the lock assemblies29,129,229,329,429,529,629,729are applicable to the other embodiments. Many variations of certain structural features have been disclosed throughout the embodiments discussed above. Merely because certain variations were not disclosed with respect to one or more embodiments does not mean that those variations are not applicable to those embodiments. For example, any of the code setting mechanisms can be altered to work with each embodiment disclosed. As another example, the anti-pick mechanism disclosed with regard to the sidebar in one embodiment can also be utilized in any of the other embodiments with slight variations made to those embodiments.

In some embodiments, some or all of the tumblers6,106,206,306,406,506,606,706can be turned over and/or rotated to be employed as a second or different set of tumblers7,107,207,307,407,507,607,707. In such embodiments, the tumblers in both sets can be identical in shape and in structure, thereby reducing the number of different parts employed in the lock assembly and the manufacturing costs of the lock assembly.

Yet another example of the various changes that fall within the spirit and scope of the present invention relates to the tumblers. Although various embodiments of the present invention discussed herein refer to portions of the tumblers in terms of key-engaging elements, housing-engaging elements, sidebar-engaging elements, and the like, these terms are not limiting upon the scope of the appended claims not referring to such engagement or contact between the tumblers and the key, sidebar, and housing. The tumbler elements of the present invention can engage other elements and serve other functions. For example, some of the embodiments of the present invention employ tumbler elements for reading the coding of a key, and tumbler elements for performing a locking function by bridging a shear line between the barrel and the housing. However, neither of these functions are limited to a particular tumbler portion. Rather, as will be discussed briefly below, the “key-engaging elements” can perform many of the same functions as the “sidebar-engaging elements” and the “housing-engaging elements.” Similarly, the other tumbler elements described herein can be adapted to perform one or more of the other tumbler element functions also described herein.

By way of example only, and with reference toFIG. 11E, the key-engaging element7can be altered to also engage the housing in a manner similar to the housing-engaging element4. One such modification could include attaching the curved arm52of the housing-engaging element4(which is shown out of the plane of the cross-section) to the key-engaging element7rather than or in addition to the housing-engaging element4. Thus, the “key-engaging element” would engage the coded surface of the key and engage the housing in the locked position, while the “housing-engaging element” could serve a primary purpose of holding the code of the lock. However, the “housing-engaging element” could still engage the housing even without curved arm52when an incorrect key is inserted in the lock. In such a case, the portion of the housing-engaging element labeled32(inFIG. 11A) would extend into the housing to prevent rotation of the barrel.

Another example of the possible modified functions of the tumbler elements described herein will be discussed with regard toFIG. 18. The key-engaging element306of this embodiment can also be modified to prevent rotation of the barrel with respect to the housing. As illustrated, the key-engaging element306has a generally U-shaped configuration. Either of the ends of the U-shape could be extended to engage the housing in the locked position. Alternatively, the bar370could be replaced with a conventional sidebar. As such, the sidebar and the “key-engaging element”306could have projection/recess engagement discussed above to control the position of the sidebar. In such an arrangement, the “key-engaging element” would also be a “sidebar-engaging element.”

The tumbler element variations just described are but a few of the many possible variations of the illustrated embodiments that fall within the spirit and scope of the present invention. For example, a limited number of alternatives are provided above with regard to certain embodiments of the present invention. However, the variations discussed above have applications in the other embodiments of the present invention presented herein.

Although the embodiments of the present invention illustrated inFIGS. 1–34are described above with reference to their use in vehicular applications, it will be appreciated that such lock assemblies can be employed in a number of other applications. By way of example only, lock assemblies according to the present invention can be employed to lock building or house doors, enclosures, cabinets, safes, and the like.