Abstract:
A lock system, lock and key is provided. The lock includes additional cutouts on the face plate ( 123 ), requiring the insertion of a corresponding unblocking member on the keyblade ( 144 ). The unblocking portion engages an engagement portion ( 162 ) to allow release of a corresponding sidebar ( 126 ), thereby allowing rotation of the lock. The engagement portion ( 162 ) additionally must project to the correct length to allow the engagement portion ( 162 ) to travel the correct distance to release the sidebar ( 126 ).

Description:
TECHNICAL FIELD 
     The present invention relates to locks, keys and lock systems. 
     BACKGROUND OF THE INVENTION 
     Locksmiths typically use several relevant terms interchangeably when referring to particular features associated with locks. To avoid confusion the following terms will be assumed to be used in the following sense throughout the description and claims. 
     In a lock of the pin tumbler or similar type, the lock comprises a central core or plug and an outer housing or shell, in which the core rotates, the housing being mounted in a suitable latch structure. The terms core and housing will be used in this context. Similarly, it will be appreciated that the present invention may be applied to any type of latch structure for which pin tumbler and related locks are used, for example, cam locks, door locks, phone locks and security fittings. 
     Although such locks afford a high degree of security, it would be desirable if the resistance of the lock to unauthorised unlocking was increased even further. 
     In International PCT No. PCT/AU99/00722 by Australian Lock Company Pty Ltd, a locking system is described which was an improvement on their BILOCK™ locking system. The improved system added additional locking elements to the conventional BILOCK™ lock which was engaged by an additional moveable element on the modified BILOCK™ key. The disclosure of this application is hereby incorporated by reference into the present application. 
     In Australian Patent Application No. 2013204413 by Camware Holdings Pty Ltd, an improved locking system was proposed utilising sliding sidebar blocking members engaged by separate components on the key. 
     It is an object of the present invention to provide an alternative locking system. 
     SUMMARY OF THE INVENTION 
     According to the present invention there is provide a lock system including: 
     a lock, including:
         a lock housing having a cylindrical cavity for receiving a rotatable lock core, said housing having upon its internal surface a longitudinal slot;   a substantially cylindrical lock core arranged within said cavity; said lock core having a keyway formed therein and extending longitudinally from an end face of said lock core; said lock core further including a plurality of guide bores which extend outwardly from said keyway and communicate therewith; each guide bore receiving a respective locking pin; wherein coding on a key blade operatively inserted into said keyway causes each locking pin to move along the respective guide bore; said lock core further including a recess extending outwardly from said plurality of guide bores and communicating therewith; said recess receiving a sidebar; said lock core further including a channel, said channel including an opening which communicates with said recess, and a sidebar blocking member slideably received in said channel;   a face plate arranged to be positioned at the end face of said lock core, the face plate including a keyway cutout which aligns with said keyway, said face plate further including an additional cutout portion, wherein said additional cutout portion is located adjacent the keyway cutout and is selectably positioned at one of a plurality of heights relative to the height of the keyway cutout;   each locking pin further comprising a hole, the position of the hole along the locking pin defining a locking combination for the respective locking pin;   said sidebar further comprising protrusions which are directed inwardly towards said guide bores, said sidebar being biased outwardly away from said side bores and into said longitudinal slot; said sidebar further comprising a blockable portion which is arranged to protrude through said opening;   said sidebar blocking member further comprising a notch; wherein said sidebar blocking member is biased towards a position in which said notch is not aligned with said opening, in which position said sidebar blocking member presents a barrier to said blockable portion and prevents said sidebar from moving inwardly towards said guide bores; said sidebar blocking member further includes an engagement portion which extends from an end of said sidebar blocking member and is formed at one of a plurality of selectable heights with respect to the end of said sidebar blocking member, each of said plurality of selectable heights of said engagement portion corresponding to a respective one of said plurality of heights of said additional cutout portion on said face plate, wherein the engagement portion is exposed to contact via said additional cutout portion when the selected heights of said engagement portion and said additional cutout portion correspond;       

     said system further including:
         a key including a key handle and a key blade extending therefrom; said key blade having coded bitings, wherein upon insertion of said key blade into said keyway, correctly coded bitings move the locking pins along the guide bores until the holes are aligned with said recess; said key further including an unblocking member, which unblocking member operatively protrudes from said key handle substantially parallel to and adjacent a side of said key blade, wherein said unblocking member is selectively positioned at one of a plurality of heights relative to the height of said key blade, each of said plurality of heights corresponding respectively to one of said plurality of heights of said additional cutout portion on said face plate;   wherein operatively, during key blade insertion into said key way, said unblocking member, being positioned at a selected height corresponding with the selected height of the additional cutout portion, engages said exposed engagement portion and moves said sidebar blocking member to an unblocking position in which said notch is aligned with said opening, in which unblocking position said sidebar blocking member presents no barrier to said blockable portion; wherein turning the inserted key causes the lock core to attempt to rotate, causing the unblocked sidebar to move inwardly against its bias and the inwardly directed protrusions enter the aligned holes, whereby the unblocked sidebar is capable of moving out of the longitudinal slot, thereby allowing the lock core to rotate.       

     In exemplary embodiments, the position of the notch on the sidebar blocking member can be selected from a number of possible positions, the selected position dictating the required length which the corresponding unblocking member is required to operatively protrude from the key handle in order to align the selected notch position with the opening. This advantageously extends the coding possibilities of the lock system and provides powerful masterkeying options for the system. 
     According to further aspects of the present invention there are provided a lock, a key and a key handle, each having features which are adapted to be employed in the lock system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Embodiments of the present invention will now be described with reference to the accompanying drawings, in which: 
         FIG. 1  is an exploded view of a lock system according to a preferred embodiment; 
         FIG. 2  is a view of the lock core of the system of  FIG. 1 ; 
         FIG. 3  shows different notch positions on a sidebar blocking member and different configurations for an engagement portion; 
         FIG. 4  is a cross-sectional view of the lock system of  FIG. 1  having the sidebars blocked; 
         FIG. 5  is a cross-sectional view of the lock system of  FIG. 4  having the sidebars unblocked. 
         FIG. 6  is an exploded view of one embodiment of a key; 
         FIG. 7  shows different configurations of possible cutout positions on a face plate. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will be discussed in the context of the BILOCK™ devices manufactured and sold by Australian Lock Company, a description of which can be found in U.S. Pat. No. 4,478,061, the disclosure of which is herein incorporated by way of reference. It is emphasised, however, that in addition the present invention is readily applicable to single bladed key systems or any lock arrangement using a central core containing the complete set of lock coding elements, with suitable modifications to the recesses and sidebar arrangement as will be discussed below. 
     The present implementation, which will be described below, has been conceived as a direct improvement of the lock system disclosed in Australian Patent Application No. 2013248267, the disclosure of which is herein incorporated by reference. However, it will be apparent that the present invention may be applied to locks with different mechanisms, and the present invention is not limited to BILOCK type devices. The disclosures of the priority applications, Australian Application No 2014203184 and 2013248267, are hereby incorporated by reference. 
     Referring to  FIGS. 1 and 2 , a lock  110  has a core  112  received in a longitudinal cavity  116  of a housing  118 . As is well known, the core  112  has a keyway  119  and a plurality of guide bores  120  aligned with the keyway  119  and receptive locking pins  122 . A face plate  123  is located at the end face of the core  112 . The locking pins  122  are inwardly biased in the guide bores  120  by springs  125  and a cover plate  127  as per the original BILOCK™ design. On either side, the core  112  features a longitudinally disposed sidebar recess  124  for the accommodation of sidebars  126 . The sidebar recess  124  is in communication with the guide bores  120 . The sidebars  126  feature a series of inwardly extending protrusions  128  in the shape of pins and are biased away from the guide bores  120  by sidebar springs  129  or other biasing means as known in the art. At the end of the core  112  opposite the key entry of the keyway  119  the body of the core  112  is flattened on either side to provide a suitable means for interacting with a latch mechanism (not shown). 
     As per the original BILOCK™ design, on the inner surface of the housing are two longitudinal slots  130 . The longitudinal slots  130  are shaped to receive the sidebars  126 , which are biased theretowards. 
     Each locking pin  122  is provided with a hole  136 . The holes  136  correspond to locking combinations for the lock dictated by the relative position of the hole  136  along the height of the locking pin  122 . 
     The combination of a key  140  is provided by bittings  142  cut on the key blade  144 . When the key blade  144  is inserted into the keyway  119 , the bittings  142  move the locking pins  122  a corresponding height along the respective guide bores  120 . In accordance with the normal operation of BILOCK™, a correctly coded key moves the locking pins  122  so that the respective holes  136  are aligned with the sidebar recess  124  and are capable of receiving the inwardly extending protrusions  128  of the sidebars  126  when the sidebars  126  are caused to move against their bias inwardly. 
     As will be appreciated, an incorrectly coded key blade would not align the holes  136 , which would prevent the sidebar  126  moving inwardly and retain the sidebar  126  in the longitudinal slot  130 , hence preventing rotation of the lock core  112 . 
     In contrast to the original BILOCK™ design, the core  112  includes a channel  150  which extends longitudinally alongside the keyway  119  and adjacent the recess  124 . The channel  150  has an opening  152  between the channel  150  and the adjacent recess  124 . Within the channel  150  is slideably arranged a sidebar blocking member  154  which is biased towards the end face of the core  112  by springs  156  or other biasing means as known in the art. 
     As shown in  FIG. 3 , the sidebar blocking member  154  has a notch  158  which can be arranged on one of a number of positions along the member  154 . 
     The sidebar  126  includes additional protrusions  160  on its upper and lower surface which are arranged and shaped to protrude through the opening  152  with the adjacent channel  150 . These additional protrusions  160  therefore extend into the adjacent channel  150  and are able to interact with the sidebar blocking member  154  as blockable portions of the sidebar  126 . 
     When the sidebar blocking member  154  is positioned so that its notch  158  is not aligned with the opening  152 , the sidebar blocking member  154  acts as a barrier which prevents the sidebar  126  from moving inwardly due to the fact that the blockable portions  160  of the sidebar  126  would find their inward passage blocked by the sidebar blocking member  154 , see  FIG. 4 . 
     However, when the sidebar blocking member  154  is positioned so that its notch  158  is aligned with the opening  152 , the notch  158  is shaped and sized so as to present an inward passage for the blockable portions  160  of the sidebar  126  and therefore allow inward movement of the sidebar  126 , see  FIG. 5 . 
     As will be appreciated, the sidebar blocking member  154  and the modification to the sidebar act as an additional locking element to the lock. While a correctly coded BILOCK™ key would, when the blade is inserted into the keyway  119 , properly align the holes  136  of the locking pins  122 , the sidebar  126  would be prevented from being able to engage the holes  136  of the locking pins  122  due to the notch  158  of the sidebar blocking member  154  being unaligned with the opening  152 . 
     The sidebar blocking member is formed with an engageable portion  162  at one end. The engagement portion  162  is selectably formed in one of a number of positions. In the embodiment shown in  FIG. 3 , there are two possible positions, an upper position and a lower position, on each side of the keyway  119 . 
     The face plate  123  includes a keyway cut out  164  which, when the face plate is in position at the end face of the core, aligns with the keyway  119 . In addition to the keyway cutout  164  are additional cutout portions  166 . As shown, each additional cutout  166  can be selectively positioned at different heights with respect to the keyway cutout  164 . The different heights correspond with the different positions of the engageable portion  162  on the sidebar blocking member  154 . As will be appreciated, properly selecting the engagement portion position to correspond to the height of the additional cutout exposes the engagement portion  162  via the additional cutout  166 . 
     In order to facilitate correct operation of the lock, not only do the holes  136  of the locking pins  122  need to be aligned by correct coding on a corresponding key  140 , but the sidebar blocking member  154  needs to be moved so that the notch  158  is aligned with the opening  152 . Movement of the sidebar blocking member  154  is achieved by modification to the original BILOCK™ key. 
     As shown in  FIG. 6 , the key  140  is formed of a key handle  146  and an attachable key blade  144 . The key  140  includes unblocking members  170  which operatively protrude from the key handle  146  alongside the attached key blade  144 . 
     The unblocking member  170  includes protrusions  186  which engage holes  188  formed on the key blade  144  and are retained within the key handle  146  when the key handle  146  is attached. Aside from attaching the unblocking member  170  to the key blade  144 , this arrangement also properly aligns the unblocking member  170  with the key blade  144 . The unblocking member  170  is formed with an elongated portion  190  which extends alongside the key blade  144 . As shown, the elongated portion  190  can be selectively formed at an upper or lower position. These different positions correlate to different heights, relative to the height of the key blade  144 , in which the elongated portion  190  can be arranged. 
     In operation, it is the elongated portion  190  which enters the additional cutout  166 , during key blade insertion into the key way  119 , and engages the engageable portion  162  of the sidebar blocking member  154 . As will be appreciated, for correct operation, the selected height position of the elongated portion  190  of the unblocking member  170  needs to correlate with the selected height of the cutout portion  166  and the corresponding position of the engagement portion  162  of the sidebar blocking member  154  in order for engagement to occur. If the positions of the elongated portion  190  and the additional cutout  166  do not correlate, then engagement will not occur during key blade insertion and, hence, the sidebar  126  will remain blocked. As a consequence, the selectable positions of both the elongated portion  190  and the additional cutout  166  offer extra coding for the lock system. 
     In addition, the length of the elongated portion  190  is important for correct operation. The length of the elongated portion  190  dictates the amount that the sidebar blocking member  154  is moved in its channel  150 , assuming that the selected positions of the elongated portion  190  and the additional cutout  166  correlate. For correct operation, the selected length of the elongated portion  190  needs to correlate with the selected notch position on the sidebar blocking member  154  so that the sidebar blocking member  154  is moved to the position in which the notch  158  is aligned with the opening  152 . As a consequence, the selectable length of the elongated portion  190  and the selectable notch position on the sidebar blocking member  154  adds further coding options for the lock system. 
     In effect, a correct key is required to have a number of correct factors in order to function. Firstly, it must have correctly coded bitings  142  corresponding to the lock combination provided by the locking pins  122 . Secondly, the elongated portion  190  position must correlate with the selected height of the additional cutout  166  as well as the corresponding position of the engageable portion  162  of the sidebar blocking member  154  in order for the elongated portion  190  to engage and, therefore, move the sidebar blocking member  154 . Lastly, the length of the elongated portion  190  must correlate with the notch position on the sidebar blocking member  154  in order for the notch  158  to be moved to the unblocking position, in which it is aligned with the opening  152 . In other words, the depth of penetration by the elongated portion dictates how far the sidebar blocking member  154  is moved. 
     In the embodiment illustrated, for each side of the key, there are effectively eight interchangeable variations on the unblocking member  170  in order to provide for the two different heights of the elongated portion  190 , as well as the four different lengths of the elongated portion  190  (to correspond to the four different notch positions shown in  FIG. 3 ). In an alternative embodiment, instead of having different variations on the unblocking member  170 , the requirements for providing different heights and depth of penetration of the elongated portion  190  could be facilitated by varying the position of the holes  188  on the key blade  144  to achieve the same result. In this way a uniform version of the unblocking member  170  could be utilised. The different height of its elongated portion could be dictated by forming the holes  188  at different heights on the key blade. Similarly, the different penetration depths, in order to move the notch  158  the required distance, could be dictated by forming the holes at different positions along the length of the key. 
     In the embodiment illustrated, there is shown a BILOCK™ type of lock with two sidebars  126 . Each sidebar  126  having only one respective sidebar blocking member  154  in a respective channel  150 . In this embodiment, the key only requires a corresponding number of unblocking members  170 , that being two. However, as shown in  FIG. 7 , this offers four variations on the positions of the additional cutouts  166 . 
     It will be appreciated that while the embodiment shown in  FIG. 3  show only two optional positions for the engageable portion  162 , it may be possible to provide more than two options using precision engineering. In such a case, there would need to be a corresponding number of selectable heights for the associated elongated portion  190  of the unblocking member as well as a corresponding number of heights for the additional cutout  166 . As a consequence, more than just the four variations shown in  FIG. 7  could be derived. 
     It will be appreciated that in a single bladed key embodiment only a single set of locking pins  122  would be required and, hence, use of only a single sidebar  126 . Consequently, a single sidebar arrangement may only require one respective sidebar blocking member  154  and associated channel  150 ; whereby the key would only require a single corresponding unblocking member  170 . 
     Conceivably, a variation on the embodiment illustrated could be the use of more than one sidebar blocking member for each sidebar. In which case, an additional channel would be required for the additional sidebar blocking member. Furthermore, an additional access would be required to allow engagement of the additional sidebar blocking member as well as an additional unblocking member appropriately positioned on the key for engaging the additional sidebar blocking member. 
     In the assembled key of the illustrated embodiment, the elongated portion  190  of the unblocking member  170  is a fixed protrusion extending from the key handle. Conceivably, it would be possible to modify the design in order to allow the protrusions to be retractable within the key handle, such modifications have been proposed in Australian Patent Application No. 2013204413, the disclosure of which is hereby incorporated by reference. 
     Reference should be made to the various references incorporated herein in order to clarify any details of operation or construction, as the basic operation of the lock and key according to the implementation described as described in those references in more detail. 
     It will be appreciated that variations and additions are possible within the general scope of the present invention. The embodiments described should be taken as illustrative of the implementation of the present invention, and not limitative thereof.