Abstract:
A recodeable lock includes a housing, a cylinder plug, a plurality of wafer tumblers, and a sidebar coupled with the cylinder plug. The sidebar is assembled with a plurality of code blocks and a codebar releasably securing the code blocks to the sidebar. A liftbar is disposed in the housing radially outward of the cylinder plug and is configured to selectively engage a radially outward extending appendage of the codebar when the cylinder plug and sidebar are rotated to a recoding orientation, to release the code blocks from the sidebar. The housing includes a circumferential track axially positioned to receive the appendage of the codebar to permit greater than 180 degree rotation of the cylinder plug and sidebar with respect to the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/022,083, entitled “KEY CYLINDER LOCK ARRANGEMENTS” and filed Jan. 18, 2008, the entire contents of which are incorporated herein by reference, to the extent that they are not conflicting with the present application. 
     
    
     BACKGROUND  
       [0002]    Key cylinder lock sets are well known and commonly used in many applications, including, for example, padlocks, residential and commercial entry doors, and vehicle door applications. It is often desirable to change or “re-key” a lock to prevent access to a locked structure or enclosure by the holder of an authorized key, for example, when a key is lost or stolen, or when access (such as by a former employee or resident) is no longer necessary or desirable. While re-keying some key cylinder locks requires disassembly of the lock and removal of the cylinder plug from the cylinder body to replace or rearrange tumblers, other key cylinder lock sets have been developed to include recoding or re-keying mechanisms that allow a user to alter the locking mechanism to accept a different authorized key. For example, a recodeable key cylinder lock arrangement may be configured such that, upon insertion of an authorized key and selective movement of the locking mechanism to a recoding condition (such as by rotation of the key to a recoding orientation and/or insertion of a tool into the lock cylinder), insertion of a different key may cause the locking mechanism to become configured to be unlocked by the different key. 
         [0003]    In one embodiment, a recodeable key cylinder lock may include a sidebar configured to be movable from a locked condition to an unlocked condition to disengage a locking portion of the sidebar from a corresponding locking portion of the housing for rotation of the cylinder plug. Insertion of an authorized key moves a series of wafer tumblers to unlocking positions, in which code blocks (disposed in corresponding unlocking positions) assembled with the sidebar engage notches in the wafer tumblers to allow the sidebar to move to the unlocked condition. Rotation of the cylinder plug to a recoding orientation allows a liftbar to engage an appendage of a codebar for release of the code blocks from the sidebar, such that the code blocks may be moved to new unlocking positions corresponding to a coded surface of a new authorized key. 
         [0004]    One such exemplary embodiment of a key cylinder lock set configured to allow for this type of recoding operation is described in U.S. patent application Ser. No. 11/244,881 (Publication No. 2006/0117822) (the “&#39;881 application”), entitled LOCK APPARATUS AND METHOD, the entire disclosure of which is incorporated herein by reference, to the extent that it is not conflicting with the present application. In the exemplary embodiment (illustrated in FIGS. 36A-36I of the &#39;881 application, and corresponding Figures A-I herein), a recodeable lock  929  includes a cylinder plug  930  configured to receive an authorized key  901  (Figure A) for engaging a series of slidable wafer tumblers  923  (Figures B, C, and I) to align notches  935  disposed on the wafer tumblers  923  with corresponding protrusions  910  (Figure G) associated with a sidebar  984  (Figures B and C). Upon alignment of the notches  935  and protrusions  910 , the sidebar  984  becomes movable (by flexible arm  976  on sleeve  920 ) to disengage from a notch  916  (Figure B) of the housing  914 , thereby allowing the cylinder plug  930  to be rotated to an unlocked orientation. The protrusions  910  are disposed on a series of code blocks  908  (Figures B and G-I) positioned in channels  983  of the sidebar  984  and are each secured at a fixed distance from the key axis by serrations  909  on the code blocks  908  that interlock with corresponding serrations  951  on posts  950  of a codebar  946  (Figures D and G) that is received in apertures  977  of the sidebar  984  (Figure C). 
         [0005]    To modify or “recode” the locking mechanism to accept a different key for unlocking the lock, an authorized key is inserted into the key cylinder plug  930  to align the wafer notches  935  with the code block protrusions  910  to allow the sidebar  984  to disengage the notch  916  in the cylinder housing  914  to permit rotation of the plug  930  and sidebar  984  about the key axis (by turning the key). When the cylinder plug  930  and sidebar  984  are rotated to a recoding orientation (Figure D), an appendage  945  of the codebar  946  engages a catch  995  of a liftbar  985 . A tool  905  may then be inserted into an access hole  919  of the housing  914  to move a pivot lever  991  engaged with the liftbar  985  (Figure E), such that the liftbar  985  moves the codebar posts  950  out of engagement with the code blocks  908 , allowing the code blocks  908  to move radially with respect to the key axis (along channels  983  in the sidebar  984 ). Upon insertion of a new key (which the user intends to use as the new authorized key), the coded surface of the new key moves each of the code blocks  908  (which are still engaged with corresponding wafer tumblers  923 ) against corresponding springs  924 . Subsequent withdrawal of the tool  905  allows a biasing member  966  to return the codebar posts  950  to engagement with the code blocks  908 , thereby securing the code blocks  908  in new radial positions with respect to the key axis. Consequently, the new positions correspond to the coded surface of the new key. Thereafter, insertion of the new key in the cylinder plug  930  aligns the wafer notches  935  with the code block protrusions  910  for disengagement of the sidebar  984  from the housing notch  916  and rotation of the cylinder plug  930  to either of the unlocked and recoding orientations. Also, to ensure that the key is fully inserted in the lock when recoding, an anti-rotation block  980  (Figures B and C) is provided in the cylinder plug  930  for interlocking engagement with the cylinder housing  914 , with the anti-rotation block  980  being configured to disengage from the housing  914  upon full insertion of the key. The anti-rotation block  980  includes a flex arm  981  that biases the block  980  back to interlocking engagement with the housing  914  upon withdrawal of the key. 
         [0006]    In the illustrated embodiment of the &#39;881 application, the liftbar  985  and pivot lever  991  are disposed in a holding block  917  (Figures D and E) extending from an outer cylindrical surface of the housing  914  (and may, but need not, be integral with the housing  914 ). A spring cover  921 , from which the biasing member  966  extends, is secured to the holding block  917  to retain the liftbar  985  and pivot lever  991 . To allow for engagement of the codebar appendage  945  with the liftbar catch  995 , a slot or channel  913  is provided in the housing  914  (Figure B), through which the codebar appendage  945  may travel as the cylinder plug  930  and sidebar  984  are rotated between locked, unlocked, and recoding orientations. A notch in the holding block  917  (Figure B) permits the appendage  945  to enter the holding block for engagement with the liftbar catch  995  in the recoding orientation. However, as the channel  913  is unable to extend around the entire circumference of the housing  914 , travel of the codebar appendage  945  and rotation of the cylinder plug  930  and sidebar  984  is limited to less than 180°. This limitation may restrict the applications in which the recodeable key cylinder lock set may be used, as some applications require upwards of 360° rotation of the key cylinder plug to operate the latch with which the key cylinder is being used. 
       SUMMARY  
       [0007]    According to an inventive aspect of the present application, a recodeable key cylinder locking arrangement may include a cylinder housing configured to permit increased rotation (e.g., greater than 180° rotation) of a cylinder plug having a codebar with an appendage that extends radially outward of the cylinder plug diameter, for example, to engage a liftbar for adjustment of code blocks assembled with the sidebar. In one embodiment, a cylinder housing may be provided with a circumferential wall having an circumferential track axially positioned to receive the appendage of the codebar for rotation of the cylinder plug and sidebar. 
         [0008]    Accordingly, in one embodiment, a recodeable lock includes a housing, a cylinder plug, a plurality of wafer tumblers, and a sidebar coupled with the cylinder plug. The sidebar is assembled with a plurality of code blocks and a codebar releasably securing the code blocks to the sidebar. A liftbar is disposed in the housing radially outward of the cylinder plug and is configured to selectively engage a radially outward extending appendage of the codebar when the cylinder plug and sidebar are rotated to a recoding orientation, to release the code blocks from the sidebar. The housing includes a circumferential track axially positioned to receive the appendage of the codebar to permit greater than 180 degree rotation of the cylinder plug and sidebar with respect to the housing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0009]    Features and advantages of the invention will become apparent from the following detailed description made with reference to the drawings, wherein: 
           [0010]    Figure A illustrates a perspective view of a recodeable key cylinder lock; 
           [0011]    Figure B illustrates an exploded view of the recodeable key cylinder lock of Figure A; 
           [0012]    Figure C illustrates another exploded view of the recodeable key cylinder lock of Figure A; 
           [0013]    Figure D illustrates a cross-sectional view of the recodeable key cylinder lock of Figure A; 
           [0014]    Figure E illustrates another cross-sectional view of the recodeable key cylinder lock of Figure A; 
           [0015]    Figure F illustrates a front perspective view of the recodeable key cylinder lock of Figure A; 
           [0016]    Figure G illustrates a bottom view of a portion of the recodeable key cylinder lock of Figure A; 
           [0017]    Figure H illustrates a side view of a portion of the recodeable key cylinder lock of Figure A; 
           [0018]    Figure I illustrates a perspective view of a portion of the recodeable key cylinder lock of Figure A; 
           [0019]      FIG. 1  illustrates a front right exploded perspective view of a lock assembly with a recodeable key cylinder lock; 
           [0020]      FIG. 2  illustrates a front left exploded perspective view of the lock assembly of  FIG. 1 ; 
           [0021]      FIG. 3  illustrates a front right perspective view of the recodeable key cylinder lock of the lock assembly of  FIG. 1 ; 
           [0022]      FIG. 4  illustrates a rear right perspective view of the recodeable key cylinder lock of  FIG. 3 ; 
           [0023]      FIG. 5  illustrates a side perspective view of the cylinder housing of the recodeable key cylinder lock of  FIG. 3 ; 
           [0024]      FIG. 6  illustrates a side cross-sectional view of the recodeable key cylinder lock of  FIG. 3 ; 
           [0025]      FIG. 7  illustrates a top cross-sectional view of the recodeable key cylinder lock of  FIG. 3 ; 
           [0026]      FIG. 8  illustrates an exploded front left perspective view of a recodeable key cylinder lock and mortise housing lock assembly; 
           [0027]      FIG. 9  illustrates an exploded front right perspective view of the lock assembly of  FIG. 8 ; 
           [0028]      FIG. 10  illustrates a side cross-sectional view of the lock assembly of  FIG. 8 ; 
           [0029]      FIG. 11  illustrates another side cross sectional view of the lock assembly of  FIG. 8 ; and 
           [0030]      FIG. 12  illustrates a top cross-sectional view of the lock assembly of  FIG. 8 . 
       
    
    
     DETAILED DESCRIPTION  
       [0031]    This Detailed Description merely describes embodiments of the present application and is not intended to limit the scope of the claims in any way. Indeed, the invention as described in the specification and claims is broader than and unlimited by the preferred embodiments, and the terms used in the claims have their full ordinary meaning. 
         [0032]    The present application contemplates a recodeable key cylinder lock having a lock housing adapted to permit increased rotation of the cylinder plug and recodeable locking mechanism, for use with locking arrangements requiring extended rotation of the cylinder plug (e.g., greater than 180° rotation, 360° rotation, or greater than 360° rotation). In one embodiment, a recodeable lock includes a housing having a recodeable locking mechanism with a radially outward extending portion or appendage that is engaged by a liftbar within the housing to permit “re-coding” of the lock, to allow the lock to be unlocked by a new and different authorized key. According to an inventive aspect of the present application, the housing may be provided with a circumferential track that is axially aligned with the appendage to receive the appendage during rotation of the unlocked cylinder plug, thereby allowing greater rotation of the cylinder plug. In one such embodiment, a circumferential track may extend around the entire circumference of the housing to permit 360° rotation of the cylinder plug. While the circumferential track may take one or more of several suitable forms, in one embodiment, the circumferential track includes a first portion formed by a slot extending through a peripheral wall of the housing, and a second portion formed by a recess or pocket disposed on an inner periphery of the housing. 
         [0033]      FIGS. 1-7  illustrate various views of an exemplary lock assembly  100  having a recodeable key cylinder lock  129  configured to allow for 360° rotation of the cylinder plug  130  within the housing  114  upon insertion and rotation of an authorized key. The housing  114  includes a circumferential wall  111  having an inner circumferential recess or pocket  112  ( FIG. 5 ) sized and positioned to receive an appendage  145  of a locking mechanism  120  extending radially outward of the cylinder plug diameter (defined by the cylinder plug  130  and the locking mechanism  120 ). The radially extending appendage  145  may engage a liftbar  185  radially outward of the cylinder plug diameter, while allowing for rotation of the cylinder plug  130  and locking mechanism  120 . The pocket  112  is axially aligned with a circumferential slot or channel  113 , which together fowl a circumferential track extending around the entire circumference of the housing  114  to allow for 360° rotation of the cylinder plug  130  and locking mechanism  120 , as they provide clearance for free, full rotation of the appendage  145 . While another embodiment may include a gap or channel around the entire periphery of the housing to similarly allow for 360° rotation of the cylinder plug and sidebar (not shown), the lack of reinforcing material between portions of the cylinder housing may affect durability of the lock, and may leave the locking arrangement susceptible to tampering. As shown, the housing may be provided with an outer circumferential band of material or rib  107  ( FIGS. 3-4 ) axially and circumferentially aligned with the pocket  112  to provided added strength and durability. This rib  107  may also facilitate pinning or staking the housing  114  into the lock assembly, for example, by aligning pins or fasteners with the end shoulders of the rib  107 , to impede unauthorized removal of the cylinder lock (for example, by drilling). A nub  106  extending from the rib  107  and a complementary shaped cutout  104  on the spring cover  121  assist with proper alignment and orientation of the spring cover  121  on the holding block  117 . 
         [0034]    While the recodeable key cylinder arrangement may be provided in a variety of configurations, as shown in the illustrated embodiment, the arrangement may include some components that are consistent with the recodeable lock  929  of the &#39;881 application. For example, as shown in  FIGS. 1-7 , the locking mechanism  120  may include a sidebar  184  and a codebar  146  with an appendage  145  extending radially outward of the plug diameter to engage a catch  195  of a liftbar  185 , such that the liftbar  185  may be operated (through a pivot lever  191 ) by an inserted tool to disengage codebar posts  150  ( FIG. 7 ) from corresponding code blocks  108  to allow the positions of the code blocks  108  to be adjusted by the coded surface of a new key. A spring sleeve  122  may be provided around the cylinder plug  130  and sidebar  184  to bias the sidebar  184  and codebar  146  radially inward and out of engagement with the housing  114  when the code blocks  108  align with corresponding wafer tumblers  123  ( FIG. 2 ). 
         [0035]    The recodeable cylinder lock  129  of  FIGS. 1-7  is shown assembled with a mortise housing  140 , a cam  160  and screw  170 , and a face plate  180 , for installation, for example, in a residential or commercial entry door. The cam  160  may be operably connected to a latching arrangement, such as, for example, a door latch or deadbolt, such that rotation of the key cylinder moves the latching arrangement between locked and unlocked conditions. According to another inventive aspect of the present application, a recodeable key cylinder lock may be configured for direct assembly with a mortise housing, such that the cylinder may be provided without a separate cylinder housing (such as, for example, the cylinder housing  114  of the embodiment of  FIGS. 1-7 ). In one such embodiment, a mortise housing may be configured to allow for increased rotation (e.g., greater than 180° rotation, or 360° rotation) of the cylinder plug within the mortise housing upon insertion and rotation of an authorized key. 
         [0036]      FIGS. 8-12  illustrate various views of an exemplary recodeable key cylinder and mortise housing locking arrangement  200  configured to allow for 360° rotation of the cylinder plug  230  within the mortise housing  240  upon insertion and rotation of an authorized key. The mortise housing  240  includes an axially extending notch  216  ( FIG. 9 ) configured to receive a portion of a sidebar  284  ( FIG. 12 ) assembled with the cylinder plug  230  to prevent rotation of the cylinder plug  230  in the locked condition. When an authorized key is inserted in the cylinder plug  230 , the coded surface of the key (not shown) positions wafer tumblers  223  within the cylinder plug  230  to align with code blocks  208 . In this aligned condition, the sidebar  284  is permitted to move radially inward to disengage the sidebar  284  from the mortise housing  240 , thereby allowing the cylinder plug  230  and sidebar to rotate by turning the key. 
         [0037]    The exemplary mortise housing  240  includes a circumferential wall  211  having an inner circumferential pocket or recess  212  sized and positioned to receive an appendage  245  of the codebar  246  extending radially outward of the cylinder plug diameter (defined by the cylinder plug  230  and the sidebar  284 ). This arrangement allows the appendage  245  to engage a liftbar  285  radially outward of the cylinder plug diameter, while allowing for rotation of the cylinder plug  230  and sidebar  284 . The pocket  212  and the housing slot or channel  213  ( FIGS. 10 and 11 ) together form a circumferential track around the entire circumference of the housing  214  to allow for 360° rotation of the cylinder plug  230  and sidebar  284 , as they provide clearance for free, full rotation of the appendage  245 . 
         [0038]    While the recodeable key cylinder arrangement may be provided in a variety of configurations, as shown in the illustrated embodiment, the arrangement may include some components that are consistent with the recodeable lock  929  of the &#39;881 application. For example, the illustrated locking mechanism  220  includes a sidebar  284  and a codebar  246  with an appendage  245  extending outward of the plug diameter, the codebar  246  also including posts  250  ( FIG. 12 ) that are disengageable from corresponding code blocks  208  to allow the positions of the code blocks  208  to be adjusted by the coded surface of a new key. As another example, holes  244  may be provided in the mortise housing  240  to interlock with an anti-rotation block  280  provided with the cylinder plug  230  ( FIG. 12 ), consistent with the anti-rotation block  980  of the &#39;881 application, to ensure full insertion of the key during recoding. However, according to an inventive aspect of the present application, some components of a recodeable key cylinder locking arrangement may be modified for use with a cylinder plug assembled directly with a mortise housing (as opposed to a cylinder plug and cylinder housing assembled with a mortise housing). As an example of the limitations resulting from use with a cylinder housing, such as the cylinder housing  914  of the lock  929  of the &#39;881 application, reduced size and wall thickness may limit the types of components provided outside the cylinder plug but within the housing, such as, for example, the spring member (sleeve  920 ) for biasing the sidebar  984  out of engagement with the cylinder housing  914 , and the liftbar  985  and associated components for pulling the codebar  946  out of engagement with the code blocks  908 . 
         [0039]    Due to the additional wall thickness and space available in the larger mortise housing, some of these components may be modified, for example, to be more durable, more cost effective, and/or more simple (using fewer components). As one example, the mortise housing may be configured to retain a liftbar for engaging a portion of a codebar of a recodeable cylinder. In the illustrated embodiment of  FIGS. 8-12 , the mortise housing  240  includes a cavity  241  sized to retain a liftbar  285  and positioned to align a catch  295  of the liftbar with the codebar appendage  245  when the cylinder plug  230  and sidebar  284  are in a recoding orientation. To raise the liftbar  285  (and with it, the codebar  246 ) for recoding the lock (as described in greater detail above), the liftbar  285  may include a tapered tool engaging surface  279  ( FIGS. 10 and 11 ) that aligns with a lock cylinder access hole  236  ( FIG. 8 ) when the cylinder plug  230  and sidebar  284  are in a recoding orientation. When a tool is inserted in the access hole  236  and is axially pressed against the tool engaging surface  279 , the resulting radial force raises the liftbar  285  and codebar  246  against spring member  266  to disengage the codebar posts  250  from the corresponding code blocks  208  for recoding the lock. As shown, a cover plate  221  may be staked into the cavity  241  to retain the liftbar  285  and spring member  266  within the mortise housing  240 . The liftbar  285  may include a post  273  for aligning with the spring member  266  and a tab  272  to prevent installation of the liftbar  285  in the reverse orientation. 
         [0040]    As shown, the use of a liftbar  285  configured to engage a tool directly may eliminate the need for a pivoting mechanism or an intermediate pivoting component, as are shown in the embodiment of  FIGS. 1-7  and in the lock  929  of the &#39;881 application. Further, the additional wall thickness and space available in the mortise housing  240  allow for use of a conventional compression spring  266 , which may be more readily available and may provide for more consistent spring biasing performance. 
         [0041]    As another example of a modified component for use with the recodable key cylinder and mortise housing locking arrangement, the mortise housing may retain one or more spring loaded biasing members configured to bias the sidebar, when in the locked orientation, towards engagement with a series of wafer tumblers in the cylinder, such that proper positioning of the wafer tumblers (in response to insertion of an authorized key) allows the sidebar to be moved out of engagement with a locking portion of the mortise housing for rotation of the cylinder plug. In the illustrated embodiment, compression springs  222  and bearing members  276  disposed in holes or openings  242  in the mortise housing  240  bias the sidebar  284  and codebar  246  inward, thereby allowing the cylinder plug  230  and sidebar to rotate by turning the key. While plugs, fasteners or other such components may be installed in the openings  242  to retain the springs  222  and bearing members  276  in the mortise housing  240 , in another embodiment, the openings  242  may be crimped or coined to retain the spring members and bearing members. While other suitably shaped bearing members may be used, the spherical shape of the illustrated bearing members  276  allows the sidebar  284  and codebar  246  to smoothly rotate into or out of engagement with the bearing members  276 . 
         [0042]    While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure; however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.