Patent ID: 12196000

DETAILED DESCRIPTION

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

Unless defined otherwise, all terms of art, notations and other technical terms or terminology used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. All patents, applications, published applications and other publications referred to herein are incorporated by reference in their entirety. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the patents, applications, published applications, and other publications that are herein incorporated by reference, the definition set forth in this section prevails over the definition that is incorporated herein by reference.

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

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

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

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

The use of the term “about” applies to all numeric values specified herein, whether or not explicitly indicated. This term generally refers to a range of numbers that one of ordinary skill in the art would consider as a reasonable amount of deviation to the recited numeric values (i.e., having the equivalent function or result) in the context of the present disclosure. For example, and not intended to be limiting, this term can be construed as including a deviation of ±10 percent of the given numeric value provided such a deviation does not alter the end function or result of the value. Therefore, under some circumstances as would be appreciated by one of ordinary skill in the art a value of about 1% can be construed to be a range from 0.9% to 1.1%.

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

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

As used herein, the terms “optional” and “optionally” mean that the subsequently described, component, structure, element, event, circumstance, characteristic, property, etc. may or may not be included or occur and that the description includes instances where the component, structure, element, event, circumstance, characteristic, property, etc. is included or occurs and instances in which it is not or does not.

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

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

Key and Key Blank

FIGS.1-3show, respectively, a key110having a key blade116, a first side124of the key blade116, and a second side126of the key blade116, configured to operate a lock as disclosed herein. In an embodiment, key110includes a bow112and a shoulder114, or key stop, with the blade116extending from the key stop114. Key110includes a primary top edge118with primary bitting cuts120, a bottom edge122, and first124and second126opposed sides extending between the primary top edge118and the bottom edge122. Note that the designation of sides124and126as first and second is arbitrary. In some embodiments, the primary bitting cuts may120be skew type bittings that provide elevation and rotational positioning to the primary pins.

Each side of blade116may include warding grooves and ridges extending longitudinally along the blade, such as groove128and ridge130on the first side124and groove127and ridge133on the second side126. As further described below, groove127is located to align with and accept a multi-level ridge of a cylinder keyway as the key110is inserted into the lock.

First side124may include a rib132extending longitudinally along at least a portion of the length of the key blade116. Rib132defines a secondary top edge134on which may be formed secondary bittings136. Rib132may include warding grooves and ridges, such as groove129and ridge131, extending longitudinally along the rib. Groove127extends longitudinally along key blade116on a side of the blade116opposite the rib132.

Key110further includes a movable element, such as a shuttle pin138, disposed within a through-hole140extending transversely through the key blade116from the first side124to the second side126. Although the concepts disclosed herein are described in the context of shuttle pin138, these concepts also encompass other forms of “movable elements” configured to extend transversely through the key blade116from the first side124to the second side126.

The shuttle pin138may be positioned within the key blade116at different longitudinal locations.FIGS.4A,4B,4C,4Dare side views of varying embodiments of keys110a,110b,110c,110dincluding primary bittings120a,120b,120c,120dand secondary bittings136a,136b,136c,136d, respectively. The shuttle pin138and through-hole140are positioned at a first location, second location, third location, and fourth location along the key blade116a,116b,116c,116d. Note that primary bittings120a,120b,120c,120dmay each be the same or different and secondary bittings136a,136b,136c,136dmay each be the same or different.

In the embodiments shown inFIGS.1-4D, shuttle pin138extends through rib132and groove127. Alternatively, shuttle pin138may be located at a position along the length of the key blade116before the rib132, after the rib132, or on a key blade having no rib132.

FIG.5shows features of the shuttle pin138having a first end or enlarged head portion142and second end or enlarged head portion144at opposite longitudinal ends connected by a narrower, generally cylindrical center portion146.

Referring toFIGS.1-3, shuttle pin138is retained within the through-hole140and is configured to be moveable within the through-hole140across the width of the key110from a retracted or first position, in which the second end144of the shuttle pin138extends into the groove127, to an extended or second position, in which the second end144of the shuttle pin138is moved out of the groove127and the first end142of the shuttle pin138extends from the first side124of the key blade116to actuate a supplemental sidebar control element. See alsoFIGS.8A and8B. As will further be described below, shuttle pin138, or other movable element, is configured to engage a multi-level ridge within a keyway of a lock as key110is inserted into the keyway. The multi-level ridge moves the shuttle pin, or other moveable element, from the first position to the second position.

FIG.6depicts the bottom edge122of the key blade116. A shuttle pin retainer148is disposed in a retainer hole150extending vertically from the bottom edge122upwards towards the top edge118and intersecting through hole140.FIG.7is a cross sectional view ofFIG.6cut longitudinally through the blade116and shuttle pin138, looking down on key110inverted and the top edges118and134are facing downwards (i.e., a longitudinal cross-section of the key blade116along line VIa-VIa inFIG.2).FIG.7illustrates the position of the retainer148relative to the shuttle pin138. The shuttle pin retainer148extends into the through-hole140to contact the shuttle pin center portion146and blocks enlarged head portions142,144to retain the shuttle pin138within through-hole140while allowing limited axial movement of the shuttle pin138within the through-hole140.FIGS.8A and8Bare transverse cross-sections of the key blade along line VIb-VIb inFIG.2and show the shuttle pin138disposed within through hole140extending through the rib132within groove127extending longitudinally along key blade116on a side of the blade opposite the rib132. InFIG.8A, shuttle pin138is retracted within the through hole140with the first end142flush with or recessed from an outer edge of the rib132on the first side124of the key blade116and the second end144of the shuttle pin138extended into a longitudinal groove127on the second side126of the key blade116. InFIG.8B, shuttle pin138is extended within the through hole140with the first end142extending beyond the outer edge of the rib132on the first side124of the key blade116. The shuttle pin can be caused to move from the retracted position shown inFIG.8Ato the extended position shown inFIG.8Bwhen inserted into a keyway by a projecting rib or multi-level ridge in the keyway that extends into the groove127to contact the second end144of the shuttle pin138.

The present disclosure further contemplates a key blank from which key110may be formed. Such a key blank may include all features shown and described above with respect to key110, key blade116, and shuttle pin138, except the primary bittings120and the secondary bittings136, which are later formed (e.g., cut, machined) on the primary top edge118and secondary top edge134, respectively, with a key cutting machine to operate a specifically coded lock.

Lock Assembly—First Embodiment

FIG.9is an exploded, top perspective view of a first embodiment of a cylinder lock assembly100that may be operated by key110described above. Lock assembly100includes a housing152having an axial bore154in which a cylindrical plug or cylinder160is rotatably disposed. A sidebar222is positioned in a sidebar cavity166formed in the side of the plug160and a beveled projection, or nose,232extends into an axial sidebar groove156(not shown inFIG.9, seeFIGS.25,26,27) formed in the sidewall of the axial bore154in the housing152. The sidebar222is urged radially outwardly from the rotational axis of the plug160, for example, by springs234located in the sidebar222spring holes, and the beveled projection232is urged into the sidebar groove156to prevent rotation of the plug160within the axial bore154. The plug160cannot be rotated to the unlocked position until the sidebar222is moved radially upon application of a torque about the rotational axis of the plug160, and the beveled projection232forces the end of the sidebar222from the sidebar groove156.

Primary pin sets or primary sidebar control elements186(e.g., tumbler pins) may control rotation of the plug160within the bore154and control movement of the sidebar222out of engagement with the sidebar groove156, as will be described below. Each primary set186comprises a top, or primary, pin188, a top pin driver190, and a top pin spring (not shown). In the illustrated embodiment, the lock assembly100includes six pin sets186. Alternatively, the lock assembly may have a different number of pin sets186.

Lock assembly100may further include a secondary sidebar control element in the form of secondary pins, or side pins204, that are positioned by the secondary bitting cuts136of key110, and a supplemental sidebar control element comprising a supplemental pin, e.g., in the form of a lift pin238, that is positioned by the shuttle pin138of the key110. The side pins204and lift pin238control movement of the sidebar222out of engagement with the sidebar groove156, as will be described below. In the illustrated embodiment (FIG.9), the lock assembly100includes three side pins204and one lift pin238. Alternatively, as further described below, the lock assembly may have a different numbers of secondary pins204and lift pins238located at various positions within the plug160. In some embodiments, the lock assembly may have no side pins204. In various embodiments, the sidebar may be controlled by only one or more supplemental sidebar control elements (e.g., one or more lift pins), or by any combination of primary pins, secondary pins, and supplemental sidebar control elements.

FIG.10illustrates features of one embodiment of the sidebar222. The sidebar222has a first side223having the beveled projection232and a second side225having various blocking elements to block the sidebar222from moving radially when the lock assembly100is in the locked state and allow radial movement of the sidebar222when the lock assembly100is in the unlocked state. The various blocking elements include primary blocking lugs224projecting from the second side225, secondary pin cutouts226formed in the second side225between adjacent pairs of blocking lugs224, secondary blocking shelves228extending across each cutout226, and supplemental blocking elements (e.g., supplemental cutout256and supplemental blocking feature, such as supplemental blocking shelf258extending across cutout256). The second side225further includes spring holes235to house the springs234(not shown inFIG.10, seeFIG.9). The spring holes235may be positioned below primary blocking lugs224.FIG.10depicts two spring holes235positioned below the second outer-most primary blocking lugs224on each end of the sidebar222. Other embodiments may include various quantities and positions of the spring holes235.

Referring again toFIG.9, the plug160and the housing152have top, or primary, pin holes180,158, respectively, in which the top, or primary, pin sets186are positioned. Plug160further includes a keyway162extending longitudinally therein and aligned with the primary pin holes180. The top pins188have beveled tips194, and can be properly positioned to permit rotation of the plug160within the housing152by inserting a properly bitted key110into the keyway162to elevate the top pins188to align a shear line between the top pin188and the corresponding top pin driver190of each top pin set186with a shear line between the plug160and the housing152. Each top pin188may further include a sidebar recess196formed in a side of the pin (e.g., a longitudinal slot or hole) to permit movement of the sidebar222when the top pins188are properly oriented rotationally by beveled primary cuts120of the key110. Each top pin188may optionally include one or more false longitudinal sidebar recesses198to foil lock picking as further explained below.

FIGS.11A and11Billustrate alternate embodiments of the primary pin, specifically embodiments designated by reference numbers188a,188b,188c,188d. Each embodiment includes a different variation of a side bar recess196a,196b,196c,196d, respectively. The sidebar recesses196acan extend the full length of the pin188a, as with primary pin188. Alternatively, the sidebar recess196b,196c,196dcan extend a limited or partial length of the pin188b,188c,188d. In some embodiments, e.g., embodiment188d, the recess196dcan be shaped as a hole. To accommodate recess196d, the sidebar primary blocking lugs224can be shaped as a round post (not shown). When the lock assembly is in the locked state, the primary blocking lugs224contact the primary pins188to block the sidebar222from moving radially. When the lock assembly is in the unlocked state, as shown inFIGS.24and25, the primary pins188are rotationally oriented by the primary bittings and the sidebar recesses196are aligned with the primary blocking lugs224, so the primary pins188will not block axial movement of the sidebar222.

Referring toFIG.9, plug160has side pin holes, or secondary pin holes184, in which side pins204and associated springs208are positioned. Secondary pin holes184are laterally offset with respect to the keyway162, extend into the sidebar cavity166, and may be oriented so as to be generally parallel with the primary pin holes180.

Plug160further includes a lift pin hole262in which the lift pin238is disposed. Lift pin hole262is laterally offset with respect to the keyway162, extends into the sidebar cavity166, and may be oriented so as to be generally parallel with the primary pin holes180and aligned with the secondary pin holes184.

Referring toFIGS.12A,12B, and12C, each secondary pin may comprise a different configuration, as shown by pins204a,204b, and204c. Each pin204a,204b,204chas a pin body202, which may be generally cylindrical in shape, a transversely extending projection212extending from a lower end of the body202, and a top axial projection213that may be seated into the corresponding coil spring208. The transversely extending projection212extends laterally into the keyway162from the body202by a width sufficient to contact top edge134of a rib132and engage secondary cuts136of the rib132on the key110. On the opposite side of the transversely extending projection212, the secondary pins204a,204b, and204chave a second transversely extending projection211to limit rotation of the pins204a,204b,204cwithin the secondary pin holes184.

Each secondary pin204includes a transverse sidebar slot216formed transversely across the body202on an opposite side of the body202from the projection212. The sidebar slots216receive the secondary blocking shelves228on the sidebar222, to permit radial movement of the sidebar222when the secondary pins204are properly elevated by the secondary bittings136to align the sidebar slots216with the blocking shelves228, as will be described below. The sidebar slot216of each secondary pin204a,204b, and204cis located at a different axial position on the pin body202, thereby allowing for different key code variations depending on the pins used and where they are positioned within the lock. Each secondary pin204may optionally further include one or more false sidebar slots218to foil lock picking, as further explained below.

With the secondary pin204and spring208disposed within a secondary pin hole184, the projection212extends into the keyway162, and, upon inserting a properly bitted key, each secondary pin204can be properly elevated by secondary cuts136on the rib132of the key110engaging the projection212.

FIG.13is an exploded perspective view of the key110, the primary pins188, the secondary pins204, the lift pin238, and the sidebar222and shows the relative positions of key110inserted into plug160(not shown for clarity), primary pins188, secondary pins204and springs208, lift pin238and spring250, and sidebar222, with the secondary pins204and sidebar222exploded laterally from the key110.

As noted above, each primary pin188may optionally include one or more false sidebar recesses198extending longitudinally along the length of the primary pin188. In the event the lock assembly is being manipulated in an attempt to pick the lock, a blocking lug224of the sidebar222may engage the false sidebar recess198. The false sidebar recess198is not deep enough to allow sufficient radial movement of the sidebar222to disengage the nose232from the sidebar groove156of the bore154, but engagement of the false sidebar recess198by the blocking lug224will prevent further manipulation of the lock assembly, thereby foiling the pick attempt.

As shown inFIGS.14A and14B, the secondary pin cutouts226of the sidebar222are located between the blocking lugs224and correspond to the number and shape of the secondary pins204. A secondary blocking shelf228(e.g. rectangular or curved projection) extends across a portion of each secondary pin cutout226. When the lock assembly100is in the locked state, as depicted inFIG.14A, the blocking shelves228contact the secondary pins204to block the sidebar222from moving radially inwardly. When the lock assembly100is in the unlocked state, as depicted inFIG.14B, the secondary pins204are elevated by the secondary bittings136on a properly bitted key110and their transverse sidebar slots216are aligned with the blocking shelves228so that the blocking shelves228can enter the sidebar slots216, and the secondary pins204will not block axial movement of the sidebar222. See alsoFIGS.12A,12B,12C.

As noted above, each secondary pin204may also optionally include one or more false sidebar slots218extending transversely across the body202of the secondary pin204above and/or below the sidebar slot216. In the event the lock assembly is being manipulated in an attempt to pick the lock by lifting a secondary pin204, a secondary blocking shelf228of the sidebar222may engage the false sidebar slot218. The false sidebar slot218is not deep enough to allow sufficient radial movement of the sidebar222to disengage the nose232from the sidebar groove156of the bore154, but engagement of the false sidebar slot218by the secondary blocking shelf228will prevent further manipulation of the lock assembly, thereby foiling the pick attempt.

FIGS.15A,15B, and15Cdepict various views of one embodiment of the lift pin238. The lift pin238has a generally cylindrically-shaped body246with a top axial projection248that may be seated into a corresponding coil spring250. On a first side252, the lift pin238has shuttle pin cutout240at its lower end and a shuttle pin engaging portion or downwardly pointing beveled edge (or shuttle pin engaging portion)260. The beveled edge260of the lift pin238is laterally offset from the transversely extending projection212of the side pin(s)204so that the lift pin238is not actuated by the secondary cuts136of the rib132on the key110. On a second side254, the lift pin238has a sidebar engagement feature, such as a transverse sidebar slot242extending transversely across the body246of the lift pin238. The second side254further has a transversely extending projection264to limit rotation of the lift pin238within the lift pin hole262in the plug160.

Optionally, the lift pin238may have one or more false sidebar slots244above and/or below the sidebar slot242. As with the false sidebar slot218on the secondary pins204, the false sidebar slot244on the lift pin238extends transversely across the body246of the lift pin238. If the lock assembly is being manipulated in an attempt to pick the lock by lifting the lift pin238, the supplemental blocking shelf258on the sidebar222may engage the false sidebar slot244. The false sidebar slot244is not deep enough to allow sufficient radial movement of the sidebar222to disengage the nose232from the sidebar groove156of the bore154, and engagement of the false sidebar slot244by the supplemental blocking shelf258will prevent further manipulation of the lock assembly, thereby foiling the pick attempt.

FIG.16show one embodiment of the keyway162that includes a multi-level ridge, or rib,164(forming part of the profile of the cylinder keyway162) having ridge164features of different heights and located at different locations along the length of the cylinder keyway162for actuating a movable element, such as shuttle pin138, movably mounted within key blade116. As further described below, these features interact with elements of key110to operate the cylinder lock100.

As shown inFIG.16, multi-level ridge164in the keyway162is located at a vertical height163within the keyway162, has different heights (e.g., first height266, second height268, and third height270) along the length of the ridge164, and may take on different transverse shapes, or profiles, to correspond to the shape of a corresponding groove127in the key110. The multi-level ridge164may not run the entire length of the keyway162.

FIGS.17A, and17Bshow one embodiment of keyway162within the plug160having multi-level ridge164extending into the keyway162, relief165, and a hole for a sidebar control element (e.g., lift pin hole262for lift pin238). The shuttle pin138is shown within the keyway162as it would be positioned if disposed within the key110inserted into the keyway162but, to illustrate the manipulation of the shuttle pin138, the key is omitted fromFIGS.17A, and17B. Although the embodiment shown inFIGS.17A and17Bdepict multi-level ridge164configured to engage one shuttle pin138, as further explained below, multi-level ridge164may be configured to engage more than one shuttle pin138within key blade.

As the key110(not shown) is inserted into the cylinder keyway162, the shuttle pin138(located in the groove127of the key110) engages the multi-level ridge164and moves across the width of the key110to engage the lift pin238on an opposite side (first side)161of the keyway162. For the key110to successfully unlock the lock100, a correct alignment between the shuttle pin138and the lift pin238must occur. The multi-level ridge164must be in a location along the length of the cylinder keyway162that corresponds to the location of the lift pin238in the cylinder160and the shuttle pin138in the key110. This alignment occurs when the key110is fully inserted into the cylinder160keyway162. In addition, the shuttle pin138must be moved the correct distance across the width of the key110to properly engage the lift pin238.

In traditional keyway designs, ridges begin at a front end of the cylinder and are continuous through the length of the cylinder. As disclosed herein, the multi-level ridge164is located a distance back from a front end280of the keyway162to provide clearance for the shuttle pin138during initial insertion of the key110. The location of the multi-level ridge164features (referred to herein as levels, planes, or surfaces of different heights and transitions between the levels) is different depending on the location of the lift pin238of the cylinder lock100.

Referring toFIGS.17A and17B, the multi-level ridge164may have three distinct levels, or planes or surfaces, (first level266, second level268, and third level270) at different heights from a multi-level ridge side (second side)167of the keyway162. The multi-level ridge164may further include two transition zones or ramps (first transition ramp272between first level266and second level268and second transition ramp274between second level268and third level270) utilized to engage and interact with the shuttle pin138in the key110. The first transition ramp272moves the shuttle pin138from the first level266to the second level268as the key110is inserted into the cylinder160keyway162. The second transition274blocks the shuttle pin138from progressing past the second level268, thus preventing the key110from further insertion as will be described below.

The extent of the multi-level ridge164having the first level266may be referred to as a first segment of the multi-level ridge164, the extent of the multi-level ridge164having the second level268may be referred to as a second segment of the multi-level ridge164, and the extent of the multi-level ridge164having the third level270may be referred to as a third segment of the multi-level ridge164.

Keyway162may further include a distal transition feature288and a third transition feature (e.g., ramp)276on side161of the keyway162opposite the multi-level ridge164. The distal transition feature288, in combination with the second transition274and third level270, blocks the shuttle pin from traveling further into the keyway and prevents further insertion of an improper key as further described below. Referring toFIG.17B, a dimension290from the front end280of cylinder keyway162to distal transition feature288is determined by the location of the lift pin238in cylinder160.

The third transition feature276moves the shuttle pin138back to the first position primarily contained within the groove127of the key110as the key110is being removed from the cylinder keyway162. This is required to allow clearance for the shuttle pin138in the keyway162as the key110is removed. Referring toFIG.17A, a dimension278from the front end280of cylinder keyway162to third transition feature276is determined by the location of the lift pin238in cylinder160. Note that as the key blade is retracted from the keyway162, the left side of head142(i.e., the side of head142closest to the front end280) moves down transition276while the right side of head144(i.e. the side of head144furthest from front end280) moves down transition272. The left side of head142reaches the end of transition276at the same time the right side of head144reaches the end of transition272.

As the key (not shown) is inserted into the keyway162, the shuttle pin138travels through the keyway162to a first position as shown inFIG.17A. In the first level266, the multi-level ridge164is sufficiently removed from the keyway162(i.e., the height of first level266from the side167of the keyway162is small (possibly zero)) to provide clearance for the shuttle pin138when the key110is being inserted into the keyway162and the shuttle pin138is primarily contained in the groove127of the key110so that the shuttle pin blocks the groove127. Without the shuttle pin clearance provided by the first level266, the key110could not be inserted into the cylinder160keyway162.FIG.19Ais a front view section showing the shuttle pin138positioned in the first position at first level266(first plane) of multi-level ridge164. Shuttle pin138is not engaged with the multi-level ridge164at this point and has clearance to pass through keyway162. In this position, as also shown inFIG.20A, the second end144of the shuttle pin138extends into a groove127on the second side126of the key blade116and the lift pin238is in a position (or locked state) where the sidebar slot242is not aligned with the supplemental blocking shelf258(seeFIG.10), preventing the sidebar222from moving radially.

Referring toFIG.17B, as the key110continues through the keyway162in the insertion direction A, the shuttle pin138engages the first transition ramp272(i.e., the shuttle pin138contacts the first transition ramp272) in the key110groove127, and the first transition ramp272pushes the shuttle pin138from the first level266to the second level268of the multi-level ridge164. Positioning the shuttle pin138to the second level268of the multi-level ridge164moves the shuttle pin138across the width of the key110, into the relief165formed in the keyway162. When the key110is fully inserted into the keyway162, the shuttle pin138aligns with the lift pin hole262. As further shown inFIGS.20B and21, the enlarged head portion142of the shuttle pin138contacts the beveled edge260of the lift pin238, which causes the beveled edge260to ride up onto the enlarged head portion142and elevate the lift pin238. The shuttle pin138remains in the extended position, resting in the cutout240of the lift pin238, and holding the lift pin238in the elevated position (or unlocked state). In the elevated position, the sidebar slot242is aligned with the supplemental blocking shelf258(seeFIG.10) so the supplemental blocking shelf258can enter the sidebar slot242, and the sidebar222is no longer blocked by the lift pin238.

FIG.19Bis a front view section showing shuttle pin138positioned at second level268(second plane) of multi-level ridge164. Shuttle pin138is properly engaging the lift pin238on the opposite side161of the keyway162.FIG.18Ais a section view of shuttle pin138in position two (i.e., the second of four possible supplemental locking element locations) with the key110fully inserted and the shuttle pin138seated on second level268(second plane) of the multi-level ridge164and moved across key110to engage the lift pin238on the opposite side161of keyway.FIG.18Bis a section view of shuttle pin138in position three (i.e., the third of four possible supplemental locking element locations) with the key110fully inserted and the shuttle pin138seated on second level268(second plane) of the multi-level ridge164and moved across key110to engage the lift pin238on the opposite side161of keyway.

Referring toFIGS.18A and18B, the first transition ramp272is precisely located to be aligned with the position of the lift pin238in the cylinder160. Since the shuttle pin138in the key110and the lift pin238in the cylinder160can be in different locations along the keyway162length, the first transition ramp272must be in the proper location to allow the shuttle pin138in a correct key110to align with and cause the shuttle pin138to engage the lift pin238. In other words, a dimension282from the front end280of cylinder keyway162to first transition ramp272is determined by the location lift pin238in cylinder160.

The location of the second level268is determined by the location of the first transition ramp272and is specific to the location of the lift pin238in the cylinder160. The width of the second level268relative to how far it extends into the keyway162determines the amount of travel the shuttle pin138is moved within the groove127of key110to engage the lift pin238on the opposite side161of the keyway162(seeFIG.19B). If the second level268is too shallow, the shuttle pin138will not fully engage the lift pin238and will not unlock the lock100. If the second level268is too wide, the shuttle pin138located in the key110groove127will jam and the key110will not operate the lock100.

The second transition ramp274is located beyond the lift pin238in the cylinder160where the second level268will transition to the third level270. Second transition ramp274is located at a distance284from the first transition ramp272determined by the position of the lift pin238in the cylinder160.

The third level270is where the multi-level ridge164extends to its maximum height into the keyway162and completely engages in the corresponding groove127of the key110. The third level270prevents the shuttle pin138disposed within the groove127from passing and also provides alignment and tracking of the key110in the cylinder keyway162.FIG.19Cis a rear view of keyway162with a fully inserted key110. The multi-level ridge164at third level270(third plane) is fully engaged with groove127of the key blade116. As shown inFIGS.18A and18B, shuttle pin138in key110does not have clearance to engage third level270(i.e. traverse the second transition274). In some embodiments, the third level270of the multi-level ridge164extends across a centerline286bisecting the width of the keyway162in the cylinder160(paracentric) (see alsoFIG.16). The groove127in the key110may also be paracentric to the centerline of the key110.

The shuttle pin138located in the key110prevents the key110from being inserted beyond the point where the shuttle pin138contacts the distal transition feature288and second transition ramp274. This causes the shuttle pin138of a non-matching key to jam into the multi-level ridge164. This becomes important when keys110with different shuttle pin138positions are inserted into cylinders100without matching multi-level ridge164locations.

FIGS.22A-22Dshow a cylinder160with the second level268of the multi-level ridge164in the second position (i.e., the second from the front end280of four possible supplemental locking element locations) and keys110a,110b,110c, and110dhaving different locations of shuttle pin138.

FIG.22Ashows key110awith shuttle pin138located in the first location fully inserted into a cylinder160with second level268of multi-level ridge164in the second position. Shuttle pin138does not extend far enough into the keyway162to reach the second level268, and thus shuttle pin138will not be extended to engage the lift pin238, in which case the cylinder160will not rotate.

FIG.22Bshows key110bwith shuttle pin138located in the second location fully inserted into a cylinder160with second level268of multi-level ridge164in the second position. Shuttle pin138extends far enough into the keyway162to reach the second level268, and thus shuttle pin138is extended to engage lift pin238, in which case the cylinder160will rotate.

FIG.22Cshows key110cwith shuttle pin138located in the third location fully inserted into a cylinder160with second level268of multi-level ridge164in the second position. The right side of head142(i.e., the side of head142furthest from the front end280) contacts and begins traveling down distal transition feature288while the right side of head144(i.e. the side of head144furthest from front end280) contacts and begins traveling up transition274until the clearance between distal transition feature288and transition274(and between side161and third level270) is too small for the shuttle pin138to continue through the keyway. The engagement of shuttle pin138by the distal transition feature288and the second transition ramp274, thereby prevents the key110cfrom being inserted completely, in which case the cylinder160will not rotate.

FIG.22Dshows key110dwith shuttle pin138located in the fourth location fully inserted into a cylinder160with second level268of multi-level ridge164in the second position. Shuttle pin138contacts the distal transition feature288and the second transition ramp274, thereby preventing the key110dfrom being inserted completely, in which case the cylinder160will not rotate.

FIGS.23A-23Dshow a cylinder160with the second level268of the multi-level ridge164in the third position (i.e., the third from the front end280of four possible supplemental locking element locations) and keys110a,110b,110c, and110dhaving different locations of shuttle pin138.

FIG.23Ashows key110awith shuttle pin138located in the first location fully inserted into a cylinder160with second level268of multi-level ridge164in the third position. Shuttle pin138does not extend far enough into the keyway162to reach the second level268, and thus shuttle pin138will not be extended to engage lift pin238, in which case the cylinder160will not rotate.

FIG.23Bshows key110bwith shuttle pin138located in the second location fully inserted into a cylinder160with second level268of multi-level ridge164in the third position. Shuttle pin138does not extend far enough into the keyway162to reach the second level268, and thus shuttle pin138will not be extended to engage lift pin238, in which case the cylinder160will not rotate.

FIG.23Cshows key110cwith shuttle pin138located in the third location fully inserted into a cylinder160with second level268of multi-level ridge164in the third position. Shuttle pin138extends far enough into the keyway162to reach the second level268, and thus shuttle pin138is extended to engage lift pin238, in which case the cylinder160will rotate.

FIG.23Dshows key110dwith shuttle pin138located in the fourth location fully inserted into a cylinder160with second level268of multi-level ridge164in the third position. Shuttle pin138contacts the distal transition feature288and the second transition ramp274, thereby preventing the key110dfrom being inserted completely, in which case the cylinder160will not rotate.

FIG.24shows a top cross sectional view of lock assembly100having shuttle pin (not shown) located in the fourth location fully inserted into cylinder160with second level of multi-level ridge (not shown) and lift pin238in the corresponding fourth position. As the key110is inserted into the keyway (not shown), the primary bittings120elevate and rotate the primary pins188to positions shown inFIGS.24and25, the secondary bittings136elevate the secondary pins204to positions shown inFIGS.24and26, and the shuttle pin138elevates the lift pin238to a position shown inFIGS.24and27. InFIG.25, the top pin188and the corresponding top pin driver190of each top pin set186are aligned with a shear line168between the plug160and the housing152. Further, the sidebar recesses196are aligned with the blocking lugs224of the sidebar222. InFIG.26, the secondary pins204, aligned with the cutouts226of the sidebar222are elevated so that the transverse sidebar slots216are aligned with the blocking shelves228of the sidebar222. InFIG.27, the first end142of the shuttle pin138is extended into the cutout240of the lift pin238and elevates lift pin238so that the sidebar slot242is aligned with the supplemental blocking shelf258of the sidebar222.

Referring toFIG.24, with the components of the lock assembly100aligned, as torque is applied to the key110, the blocking lugs224on the sidebar222can move into the respective longitudinal sidebar recesses196of primary pins188, the blocking shelves228of sidebar222can move into the respective transverse sidebar slots216of secondary pins204, and the supplemental blocking shelf258of sidebar222can move into the sidebar slot242of the lift pin238so as to allow the sidebar222to move radially inwardly from a locked position to an unlocked position. The longitudinal sidebar recesses196, transverse sidebar slots216, and lift pin sidebar slot242are deep enough to allow sufficient radial movement of the sidebar222to disengage the nose232from the sidebar groove156of the bore154. With the sidebar nose232disengaged from the sidebar groove156the plug160may rotate within the housing152.

Referring toFIGS.28A-28C, the third transition feature276opposite the multi-level ridge164engages the shuttle pin138in the key110as the key110is removed from the cylinder160and the extended end142of the shuttle pin138leaves the relief165and moves the shuttle pin138from a position previously determined by the second level268back to a position primarily contained within the key110groove127at the first level266. Movement of the shuttle pin138back to the retracted position allows clearance for the shuttle pin138in the keyway162as the key110is removed.

FIG.28Ashows the position of the shuttle pin138with the correct key fully inserted (key is omitted from the figure for clarity). Shuttle pin138is seated on the second level268of the multi-level ridge164and moved across keyway162to engage lift pin238.

FIG.28Bshows the position of shuttle pin138with the correct key being withdrawn from the fully-inserted position (key is omitted from the figure for clarity). As the key is withdrawn from cylinder160, shuttle pin138contacts third transition276and is moved back toward the key groove127.

FIG.28Cshows the position of shuttle pin138with correct key being further withdrawn from the fully-inserted position (key is omitted from the figure for clarity). As the key is further withdrawn from the cylinder160, the shuttle pin138has been moved by third transition276to first level266of the multi-level ridge164such that the shuttle pin138has clearance in the keyway162to permit the key to be fully withdrawn.

Lock Assembly—Second Embodiment

FIG.29illustrates a second embodiment of lock assembly300, which is a variation of lock assembly100configured for a slider304instead of a lift pin238as the supplemental sidebar control element. As with lock assembly100, described above, lock assembly300may include housing152having a bore154and sidebar groove156(not shown), primary pin sets186, and secondary pins204. A plug354is disposed in the bore154of the housing152with a keyway356extending longitudinally through the plug354. Like plug160described above, plug354may include sidebar cavity366, primary pin holes180, and secondary pin holes184. Additionally, plug354includes a slider hole326in which the slider304resides. A sidebar328is positioned in the sidebar cavity366formed in the side of the plug354and a beveled projection, or nose,342on a first side of the sidebar328extends into the sidebar groove156(seeFIG.36) formed in the sidewall of the axial bore154in the housing152.

FIGS.30A and30Bdepict one embodiment of the slider304. The slider304has a body306with a sidebar blocking lug320projecting above a top surface322and a shuttle pin engaging portion or projection324which extends into the keyway356on a medial side308(or inner side facing the keyway356) of the body306when the slider is disposed in the slider hole326. The projection324is laterally offset from a transversely extending projection212of the side pin(s)204, and thus the projection324is not engaged or contacted by secondary cuts136of the rib132on the key110. On a first end312of body306, the slider304has a cylindrical hole316to receive a spring318, which spring-biases the slider304within the slider hole326in a blocking position (seeFIG.35A) whereby a portion of the sidebar328contacts blocking lug320, which prevents the sidebar328from moving radially into an unlocked position.

FIG.31shows one embodiment of a sidebar328corresponding to the slider304. Similar to the sidebar222in lock assembly100, the sidebar328has a first side332having a beveled projection or nose342and a second side334having various blocking elements to block the sidebar328from moving radially when the lock assembly300is in the locked state (seeFIG.35A) and allow radial movement of the sidebar when the lock assembly is in the unlocked state (seeFIGS.35B and35C). The sidebar328includes primary pin blocking lugs336, secondary cutouts338formed in the second side334between adjacent pairs of blocking lugs336, secondary blocking shelves340extending across each cutout338, and a slider cutout330corresponding to the slider304. The slider cutout330comprises a first cutout portion346, a second cutout portion348, and a third cutout portion350. In one embodiment, the slider cutout330is generally in the shape of a trefoil cutout. The first cutout portion346and the second cutout portion348are shallow and receive the blocking lug320of the slider304in a locked, blocking position (seeFIG.35A). That is the blocking lug320when residing in cutout portion346or cutout portion348will contact a back wall of the respective cutout portion to block the sidebar328from inward radial movement. The third cutout portion350is deeper than the first346and second348cutout portions and receives the blocking lug320of the slider304in an unlocked, non-blocking position (seeFIGS.35B and35C).

Referring toFIGS.32and33, the key110may be the same key110, described above, used in lock assembly100with key blade116, primary bittings120on a top edge118, secondary bittings136on a secondary top edge134of rib132, and a shuttle pin138contained within a through-hole140extending transversely through the key blade116.

The slider304resides in the slider hole326in the plug354(seeFIG.29), and is spring-biased by a spring318in a locked position. The illustrated embodiment ofFIG.29depicts two secondary pins204with one slider304disposed to one side of the two secondary pins204, and this is also shown inFIGS.32and33. In other embodiments, the secondary pin(s) may be located on an opposite side of the slider, or one or more secondary pins may be located on either side of the slider. As shown inFIGS.4A-4D, the shuttle pin138can be positioned at varying longitudinal positions along the length of the blade116a-116dto accommodate various numbers and arrangements of the secondary pins and supplemental lift pins or slider. In some embodiments, the lock assembly may have no secondary pins. In various embodiments, the sidebar may be controlled by only one or more supplemental sidebar control elements (e.g., one or more sliders), or by any combination of primary pins, secondary pins, and supplemental sidebar control elements.

FIGS.34A and34Bshow the keyway356within the plug354having a multi-level ridge164and a slider304disposed within slider hole326. The slider304is shown within the keyway356as it would be positioned by the shuttle pin138of a key110inserted into the keyway356. To illustrate the manipulation of the shuttle pin138more clearly, the key110is omitted fromFIGS.34A and34B.

Referring toFIG.34A, as the key110is inserted into the keyway356, the shuttle pin138travels through the keyway356to a first position. In the first position, a second end144of the shuttle pin138extends into a groove127on the second side of the key blade116. The slider304is in a resting position where the blocking lug320is in a locked position, not aligned with the third cutout portion350of sidebar328, as shown inFIG.35A, and the sidebar328is prevented from moving radially inwardly to retract from the groove156.

Referring toFIG.34B, as the key110continues through the keyway356in the insertion direction A, the shuttle pin138engages a first transition ramp272of the multi-level ridge164extending into the groove127in the key blade116and moves from a first level266to a second level268of the multi-level ridge164. Positioning the shuttle pin138at the second level268of the multi-level ridge164pushes the shuttle pin138into the slider hole326opposite the multi-level ridge164. In this position, as shown inFIG.36, the enlarged first end142of the shuttle pin138extends out of the first side124of the key blade116. As the key110moves forward into a fully inserted position, the first end142of the shuttle pin138slides forward to contact the projection324on the slider304and pushes the slider304forward until the top blocking lug320on the slider304is aligned with the third cutout portion350, as shown inFIG.35B.

The shuttle pin138remains in the extended position holding the slider304in the unlocked, forward position with the top blocking lug320aligned with the third cutout portion350. As a torque is applied to the key110, the sidebar328may move radially into the plug354, with the third cutout portion350receiving the blocking lug320, as shown inFIG.35c. The third cutout portion350is sufficiently deep to enable the sidebar328to move radially inward. As the sidebar328moves radially inward, the beveled projection342withdraws from the axial groove156and permits the plug354to rotate within the housing152.

As the key blade116is removed from the plug354, the extended end142of the shuttle pin138engages third transition feature275opposite the multi-level ridge164. The third transition feature275moves the shuttle pin138from a position previously determined by the second level268back to a position primarily contained within the key blade116groove127at the first level266. Movement of the shuttle pin138back to the retracted positions allows clearance for shuttle pin138in the keyway356as the key blade116is removed.

In an alternate embodiment, the sidebar includes a protruding blocking lug and the slider includes a lug-receiving recess (not shown) Movement of the slider from a locked state or position to an unlocked state or position comprises engaging the slider with the shuttle pin as described above to move the slider from a first position, in which the lug-receiving recess is not aligned with the blocking lug of the sidebar so that the blocking lug contacts the slider to prevent lateral (e.g., radial) movement of the sidebar within the sidebar cavity, to a second position, in which the lug-receiving recess is aligned with the blocking lug of the sidebar so that the blocking lug can enter the lug-receiving recess to permit lateral (e.g., radial) movement of the sidebar within the sidebar cavity.

Lock Assembly—Third Embodiment

FIG.37illustrates a third embodiment of a lock assembly500. As with lock assembly100, described above, lock assembly500includes housing152having axial bore154in which a cylindrical plug562, having a longitudinally-extending keyway564, is rotatably disposed. Primary pin sets186, as described above, control rotation of the plug562within the bore154and secondary pins204, as described above, are positioned by the secondary bitting cuts136of key110. Lock assembly500, includes a side bar536disposed within a sidebar cavity566formed in plug562and is operable to engage a sidebar groove156formed in the wall of bore154as described above. Sidebar536includes a beveled nose550that engages the sidebar groove156. The lock assembly500includes a supplemental sidebar control element comprising a supplemental pin, e.g., in the form of a flipper pin502rotationally oriented by shuttle pin138of key110to control movement of the sidebar536out of engagement with the sidebar groove156, as will be described below.

As shown inFIGS.4A-4D, the shuttle pin138can be positioned at varying longitudinal positions along the length of the blade116a-116dto accommodate various numbers and arrangements of the supplemental sidebar control element. In some embodiments, the lock assembly may have no secondary pins. In various embodiments, the sidebar may be controlled by only one or more supplemental sidebar control elements (e.g., one or more flipper pins), or by any combination of primary pins, secondary pins, and supplemental sidebar control elements.

FIGS.40and41illustrate features of one embodiment of the sidebar536. Similar to sidebar222in lock assembly100, sidebar536has various blocking elements to block the sidebar536from moving radially when the lock assembly500is in the locked state and allow radial movement of the sidebar536when the lock assembly500is in the unlocked state. The sidebar536includes primary pin blocking lugs544projecting from a second side542of the sidebar536, secondary pin cutouts546formed in the second side542between adjacent pairs of blocking lugs544, secondary pin blocking shelves548(e.g., curved) extending across each cutout546, and a supplemental blocking feature, such as a flipper pin cutout538. The flipper pin cutout538is a cutout that received a portion of the flipper pin502in the unlocked state after the shuttle pin138rotates the flipper502. As shown inFIG.47A, the flipper pin cutout538includes first and second initial cutouts535,537extending from the second side542of the sidebar536, and a center cutout539between the initial cutouts535,537and extending deeper into the sidebar536than the initial cutouts535,537.

FIGS.38A and38Bdepict one embodiment of the flipper pin502. The flipper pin502has a body504, which is generally cylindrical in shape. On a first side506of the flipper pin502near a bottom end512, a transversely extending shuttle pin engaging portion (lobe, or flipper)522extends into the keyway564to be engaged by shuttle pin138on key blade116. The flipper522is laterally offset from a transversely extending projection212of the side pin(s)204, and thus the flipper522is not engaged or contacted by secondary cuts136of the rib132on the key110.

On a second side508of the flipper pin502, near a top end510, the flipper pin502has a lateral projection524with a cutout526. In the illustrated embodiment, the top end510has two cutouts518,520on opposite sides of the body504to form a sidebar engagement feature, such as sidebar engaging lug528, on the top end510of the flipper pin502. As shown inFIG.39, cutout518is defined by a first portion515and a second portion517, and cutout520is defined by a first portion519and a second portion521. Sections515and519may be parallel to one another, thereby defining the sidebar engaging lug528. Portions517and521diverge away from each other extending from the first portions515,519, respectively, toward the outer periphery of the body504. Other embodiments may contemplate various shapes on the top end510, which are configured to operate with the sidebar536. The flipper pin502is spring-biased by a spring516(seeFIG.37) to maintain a position with the flipper502positioned into the keyway564. The spring516is positioned off-center from a longitudinal center line through the body504and engages projection524, thereby creating a rotational bias on the flipper pin502.

As shown inFIG.42, the key110may be the same key110, described above, used in lock assembly100with key blade116, primary bittings120on a top edge118, secondary bittings136on a secondary top edge134of rib132, and a shuttle pin138contained within a through-hole140extending transversely through the key blade116.FIG.42further shows the positional relationship between the key110, primary pins188, secondary pins204, flipper pin502, flipper spring516, and sidebar536. The beveled tips194of the primary pins188engage the primary bittings120on the top edge118of the key110to elevate and rotate the primary pins188. The transversely extending projections212of the secondary pins204engage the secondary bittings136on the secondary top edge134of the rib132to elevate the secondary pins204. The shuttle pin138is protruding from the first side124of the key110in an unlocked position, and the flipper pin502is rotated into an unlocked orientation by the shuttle pin138. The sidebar536is engaging the primary pins186, secondary pins204, and flipper pin502.

FIGS.43A and43Bshow the keyway564within the plug562having a multi-level ridge164, a flipper pin hole530with the flipper pin502in a spring-biased resting position, and a flipper pin recess532extending from the flipper pin hole530. The flipper pin502is shown within the keyway564as it would be positioned by the shuttle pin138of a key110inserted into the keyway564. To illustrate the manipulation of the shuttle pin138more clearly, the key110is omitted fromFIGS.43A and43B.

Referring toFIG.43A, as the key (not shown) is inserted into the keyway564, the shuttle pin138travels through the keyway564to a first position. In the first position, as shown inFIG.44, the second end144of the shuttle pin138extends into a groove127on the second side126of the key blade116. The flipper pin502is in a spring-biased resting position where sidebar engagement lug528on the top end510does not align with the flipper pin cutout538on the sidebar536, and the sidebar536is prevented from moving radially inwardly to retract from the groove156.

Referring toFIG.43B, as the key110continues through the keyway564in the insertion direction A, the shuttle pin138engages a first transition ramp272of the multi-level ridge164extending into the groove127in the key blade116and moves from a first level266to a second level268of the multi-level ridge164. Positioning the shuttle pin138at the second level268of the multi-level ridge164pushes the shuttle pin138into a shuttle pin relief568formed in the keyway564opposite the multi-level ridge164. In this position, the enlarged first end142of the shuttle pin138extends out of the first side124of the key blade116(seeFIG.45), and contacts the flipper522that is rotated into the relief568. As the key110moves forward into a fully inserted position, the second end144of the shuttle pin138continues up the multi-level ridge164and moves the shuttle pin138forward to rotate the flipper522into the flipper recess532in the flipper hole530, thereby rotating the flipper pin502. In the rotated position, the sidebar engagement lug528of the flipper pin502is now aligned with center cutout539of the flipper cutout538on the sidebar536. This is illustrated inFIGS.47B and47C. InFIG.47B, with the flipper pin502rotationally biased into a locked orientation, the sidebar engagement lug528, is oriented transversely to the center cutout539of the flipper cutout538. Thus, the initial cutouts535,537of the flipper cutout538contact the flipper pin502, thereby blocking radial movement of the sidebar536. InFIG.47C, the flipper pin502is rotated by the shuttle pin138of the inserted key110into an unlocked orientation, the side bar engagement lug528is aligned with the center cutout539of the flipper cutout538, and the sidebar536is able to move radially into an unlocked position.

The shuttle pin138remains in the extended position holding the flipper pin502in the unlocked rotational orientation with flipper522in the flipper recess532and sidebar engagement lug528of the flipper pin502aligned with the center cutout539of the flipper cutout538on the sidebar536. Once a torque is applied to the plug562, the sidebar536may move radially into the plug562. As the sidebar536moves radially inward, the beveled projection550withdraws from the axial groove156and permits the plug562to rotate within the housing152(seeFIG.46).

As the key blade116is removed from the plug354, the extended end142of the shuttle pin138engages third transition feature275opposite the multi-level ridge164. The third transition feature275moves the shuttle pin138from a position previously determined by the second level268back to a position primarily contained within the key blade116groove127at the first level266. Movement of the shuttle pin138back to the retracted positions allows clearance for shuttle pin138in the keyway as the key blade116is removed. Key, Key Blank, and Lock Assembly—Fourth Embodiment

As noted above, in other embodiments, lock assemblies100,300, and500may be configured to have two or more supplemental sidebar control elements (i.e., various combination of two or more lift pins, sliders, and/or flipper pins located at various positions along the length of the keyway).

To operate lock assemblies having two or more supplemental sidebar control elements, key blades/blanks and the corresponding bitted key may have two or more shuttle pins in a single key blade.FIGS.48and49depict first side124and second side126, respectively, of a key blade blank117having a first shuttle pin138adisposed within a through-hole140aand a second shuttle pin138bdisposed within a through-hole140b. Key blade blank117and shuttle pins138a,138bmay have all features shown and described above with respect to key blade116and shuttle pin138, respectively, except key blade blank117has two shuttle pins138a,138binstead of single shuttle pin138in key blade116.

Blade117extends from key stop114and includes a primary top edge118configured to receive primary bitting cuts, a bottom edge122, and first124and second126opposed sides extending between the primary top edge118and the bottom edge122. Each side may include warding grooves and ridges extending longitudinally along the blade, such as groove128and ridge130on the first side124and groove127and ridge133on the second side126. The first side124may further include a rib132extending longitudinally along at least a portion of the length of the key blade117. Rib132defines a secondary top edge134configured to receive secondary bitting cuts. Rib132may include warding grooves and ridges, such as groove129and ridge131, extending longitudinally along the rib.

Shuttle pin138ais positioned at a first longitudinal location proximally located near key stop114and extending transversely through blade117from the first side124to groove127on second side126of blade117. Shuttle pin138ais moveable within the through-hole140aacross the width of the blade117by a corresponding multi-level ridge within a keyway of a lock. In some embodiments, as shown inFIG.48, the shuttle pin138amay extend through rib132.

As further described below, multi-level ridge engages shuttle pin138aand moves shuttle pin138afrom a first position, in which a second end144aof the shuttle pin138aextends into the groove127, to a second position, in which the second end144aof the shuttle pin138ais moved out of the groove127and a first end142aof the shuttle pin138aextends from the first side124of the key blade117to actuate movement of a supplemental sidebar control element from a first locked state to an unlocked state. A retainer pin disposed in a retainer hole (not shown) blocks enlarged head portions of first end142aand second end144ato retain the shuttle pin138awithin through-hole140awhile allowing axial movement of the shuttle pin138awithin the through-hole140a.

Shuttle pin138bis positioned at a second longitudinal location at a distance further along the length of the blade117from key stop114and in line with shuttle pin138aalong the length of the key blade117. Shuttle pin138bextends transversely through blade117the first side124to groove127on second side126of blade117and is moveable within the through-hole140bacross the width of the blade117by the corresponding multi-level ridge within the keyway. In some embodiments, as shown inFIG.48, the shuttle pin138bmay extend through rib132.

As further described below, multi-level ridge engages shuttle pin138band moves shuttle pin138bfrom a first position, in which a second end144bof the shuttle pin138bextends into the groove127, to a second position, in which the second end144bof the shuttle pin138bis moved out of the groove127and a first end142bof the shuttle pin138bextends from the first side124of the key blade117to actuate movement of the lift pin238b. A retainer pin disposed in a retainer hole (not shown) blocks enlarged head portions of first end142band second end144bto retain the shuttle pin138bwithin through-hole140bwhile allowing axial movement of the shuttle pin138bwithin the through-hole140b.

Although the embodiment inFIGS.48and49show two shuttle pins138a,138b, disposed within key blade blank117, other embodiments may include more than two shuttle pins and the shuttle pins may be located in various positions along the length of the key blade. Moreover, the key blade blanks may be machined into bitted keys having primary bittings machined or cut into the top edge and/or secondary bittings machined or cut into the second edge.

FIG.50illustrates one embodiment of a lock assembly700having a first lift pin238aand a second lift pin238bconfigured to be operated by a properly bitted key from key blade blank117. Lock assembly700may have all features shown and described above with respect to lock assembly100except lock assembly700is configured for two lift pins238a,238binstead of single lift pin238.

Referring toFIG.50, as with lock assembly100(seeFIG.9), lock assembly700includes housing152having bore154and sidebar groove156(not shown), primary pin sets186, and secondary pins204. Plug712is disposed in the bore154of the housing152with a keyway702extending longitudinally through the plug712. Like plug160described above, plug712may include sidebar cavity166, primary pin holes180, and secondary pin holes184. Additionally, plug712includes a first lift pin hole262ato house lift pin238aand a second lift pin hole262bto house lift pin238b. A sidebar710is positioned in the sidebar cavity166formed in the side of the plug712and a beveled projection, or nose,232on a first side of the sidebar223extends into the sidebar groove156(not shown) formed in the sidewall of the axial bore154in the housing152. In various embodiments, the sidebar may be controlled by only two or more supplemental sidebar control elements, or by any combination of primary pins, secondary pins, and supplemental sidebar control elements.

FIG.51shows one embodiment of a sidebar710corresponding to lock assembly700having first lift pin238aand second lift pin238b. Similar to sidebar222in lock assembly100, the sidebar710has first side223having beveled projection or nose232and a second side225having various blocking elements to block the sidebar710from moving radially when the lock assembly700is in the locked state and allow radial movement of the sidebar710when the lock assembly700is in the unlocked state. The sidebar710includes primary pin blocking lugs224, secondary cutouts226formed in the second side225between adjacent pairs of blocking lugs224, and secondary blocking shelves228extending across each cutout226. Sidebar710further includes a first supplemental cutout256aand first supplemental blocking shelf258aextending across cutout256ato correspond with first lift pin238a, and second supplemental cutout256band second supplemental blocking shelf258bextending across cutout256bto correspond with second lift pin238b.

FIG.52shows the keyway702within the plug712having a multi-level ridge704, first lift pin238adisposed in first lift pin hole262a, and a second lift pin238bdisposed in second lift pin hole262b. Lift pin238ais shown within the keyway702as it would be positioned by shuttle pin138aof key blade117, and lift pin238bis shown within the keyway702as it would be positioned by the shuttle pin138bof key blade117. To illustrate the manipulation of the shuttle pin138aand shuttle pin138bmore clearly, the key blade117is omitted fromFIG.52.

As shown inFIG.52, first lift pin238ahas a shuttle pin cutout240aand a downwardly pointing beveled edge260aon a first side and a transverse sidebar slot (not shown) on a second side. Second lift pin238bhas a shuttle pin cutout240band a downwardly pointing beveled edge260bon a first side and a transverse sidebar slot (not shown) on a second side. See alsoFIGS.15A,15B,15C.

Multi-level ridge704is designed with transition ramps and levels to support two shuttle pins in a single key interacting with two lift pins in a single keyway. Multi-level ridge704may be referred to as having two sections—a first section704acorresponding to lift pin238aand shuttle pin138aand a second section704bcorresponding to lift pin238band shuttle pin138bwhen key blade117is fully inserted. Lift pin238ais in position one (i.e., a first location of four possible supplemental locking element locations in plug712) and closest to a front end280of keyway702. The first section704aof multi-level ridge704is on a side (second side)716of the keyway702opposite lift pin238a. Lift pin238bis in position three (i.e., a third location of four possible supplemental locking element locations in plug712) and is the furthest supplemental sidebar locking element from the front end280of keyway702. The second section704bof multi-level ridge704is on the side716of the keyway702opposite lift pin238b. In various embodiments, the second section704bmay be in any location along the length of keyway702on side716opposite the furthest supplemental sidebar locking element from the front end280. The first section704amay be in multiple locations and in any location along the length of the keyway on side716opposite a supplemental sidebar control element located before the second section704b(i.e., located before the furthest supplemental sidebar locking element from the front end).

As the key blade117is inserted into keyway702, multi-level ridge704first section704aengages and moves shuttle pin138bacross the width of the key blade117to engage lift pin238aon an opposite side (first side)714of the keyway702. As the key blade117continues through the keyway704, shuttle pin138bdisengages from lift pin238aand moves away from multi-level ridge704first section704ato multi-level ridge704second section704b. The multi-level ridge704first section704athen engages and moves shuttle pin138aacross the width of the key blade117to engage lift pin238aon opposite side714of the keyway702. Concurrently, multi-level ridge704second section704bengages and moves shuttle pin138bacross the width of the key blade117to engage lift pin238bon side714of the keyway702. For the key blade117to successfully unlock the lock700, a correct alignment of both shuttle pin138awith lift pin238aand shuttle pin138bwith lift pin238bmust occur. When key blade117is fully inserted into the keyway702, the first section704aof multi-level ridge location along the length of the cylinder keyway702corresponds to the location of lift pin238ain the keyway702and shuttle pin138ain the key blade117, and the second section704bof multi-level ridge location corresponds to the location of lift pin238bin the keyway702and shuttle pin138bin the key blade117.

Referring toFIG.52, the first section704aof multi-level ridge is similar to the multi-level ridge164described above in connection with lock100except the first section704aof multi-level ridge704has a regression ramp706as opposed to the second transition ramp274and third level270of lock100. Multi-level ridge704first section704ahas two distinct levels (first level266aand second level268a) at different heights from the second side716of the keyway702and two transition zones or ramps (first transition ramp272abetween first level266aand second level268aand regression ramp706between second level268aand a first level266bof the second section704b). Second transition ramp274and third level270are omitted from first section704aof multi-level ridge704to allow shuttle pin138bto travel over multi-level ridge first section704ato second section704bwithout being blocked by third level.

In the first level266aof the first section704a, the multi-level ridge704is sufficiently removed from the keyway702to provide clearance for both the first shuttle pin138aand second shuttle pin138bwhen the key blade117is inserted into the keyway702and the shuttle pins138a,138bare primarily contained in groove127of the key blade117. Without the shuttle pin clearance provided by the first level266a, the key blade117could not be inserted into the cylinder keyway702.

The first transition ramp272amoves the second shuttle pin138band thereafter the first shuttle pin138afrom the first level266a, across the width of the key blade117, into a relief165aformed on side714of the keyway702, and onto the second level268a. When the key blade117is fully inserted, first shuttle pin138ais seated on the second level268aand first shuttle pin138aproperly engages the first lift pin238ain the plug712as shown inFIG.52.

Regression ramp706allows the shuttle pin138bto move from the second level268aof first section704ato the first level266bof second section704bas the key blade117is inserted into the keyway702. Referring toFIG.52, keyway702includes a fourth transition feature (e.g., ramp)708on side714of the keyway702opposite multi-level ridge704first section704ato move the second shuttle pin138bdown the regression ramp706and back to the retracted first position primarily contained within the groove127of the key blade117. A dimension718from the front end280of cylinder712keyway702to fourth transition feature708is determined by the location of the first lift pin238ain cylinder712. Regression ramp706and fourth transition feature708are necessary to allow clearance for the shuttle pin138bto continue traveling through the keyway702after engaging the first section704aof the multi-level ridge704and to allow shuttle pin138bto properly engage a beveled edge260bof lift pin238b.

The second section704bof multi-level ridge may include all features shown and described above with respect to multi-level ridge164in lock100. Multi-level ridge704second section704bhas three distinct levels, (first level266b, second level268b, and third level270) at different heights from side716of the keyway702and two transition zones or ramps (first transition ramp272bbetween first level266band second level268band second transition ramp274between second level268band third level270) utilized to engage and interact with the shuttle pin138bin the key blade117.

In the first level266b, the multi-level ridge704second section704bis sufficiently removed from the keyway702to provide clearance for shuttle pin138bto travel through the keyway702from the first section704ato the second section704bas the key blade117is being inserted into the keyway702. Without the shuttle pin clearance provided by the first level266b, shuttle pin138bmay engage side716of the keyway702or other supplemental locking elements (e.g., side pin204) and prevent key blade117from fully inserting into the cylinder keyway702.

The first transition ramp272bmoves the second shuttle pin138bfrom the first level266bto the second level268bas the key blade117travels through the keyway702. Positioning shuttle pin138bat the second level268bof the multi-level ridge704moves shuttle pin138bacross the width of the key blade117, into a relief165bformed in the keyway702, and onto the second level268bto properly engage the lift pin238bin the cylinder712when the key blade117is fully inserted. As shown inFIG.52, shuttle pin138b, positioned at second level268bof multi-level ridge704, is properly engaging lift pin238bon the opposite side714of the keyway702.

The second transition274blocks the shuttle pin138bfrom progressing past the second level268b. The third level270is where the multi-level ridge704extends to its maximum height into the keyway702and completely engages in the corresponding groove127of the key blade117. The third level270prevents the shuttle pin138bdisposed within the groove127from passing and also provides alignment and tracking of the key blade117in the cylinder keyway702.

Referring toFIG.52, as the key blade117is inserted into the keyway702, second shuttle pin138btravels through the keyway702to the first level266aof multi-level ridge704first section704a. At this point, a second end144bof shuttle pin138bextends into groove127on the second side126of the key blade117. The first lift pin238aand second lift pin238bare in a resting position where sidebar slots242on first lift pin238aand second lift pin238bare not aligned with supplemental blocking shelf258aand supplemental blocking shelf258b, respectively, and the sidebar710is prevented from moving radially inwardly to retract from the groove156.

As the key blade117is inserted further into the keyway702, the first transition ramp272aengages the second end144bof shuttle pin138b(i.e., the second shuttle pin138bcontacts the first transition ramp272a) in the key blade117groove127and moves shuttle pin138bfrom the first level266ato the second level268aof the multi-level ridge704first section704a. Positioning the shuttle pin138bto the second level268aof the first section704amoves the shuttle pin138bacross the width of key blade117, into relief165aformed in the keyway162, to properly engage the first lift pin238ain the cylinder712. In this position, the sidebar slot242on the first lift pin238ais aligned with supplemental blocking shelf258a, but second lift pin238bremains in a resting position where sidebar slots242on second lift pin238bare not aligned with supplemental blocking shelf258b. The sidebar710is prevented from moving radially inwardly to retract from the groove156.

As the key blade117moves forward, shuttle pin138bdisengages lift pin238aand continues traveling in the insertion direction A at a position or height within the keyway702determined by the second level268a. The extended end142bof shuttle pin138bcontacts the fourth transition feature708opposite the multi-level ridge704. The fourth transition feature708moves the shuttle pin138bfrom the position previously determined by the second level268ato the regression ramp706and to a position primarily contained within the key blade117groove127at the first level266bof second section704b. Movement of the second shuttle pin138bback to the retracted position allows clearance for shuttle pin138bin the keyway702as the key blade117continues traveling in the insertion direction.

In continuing through the keyway702in the insertion direction A, the second shuttle pin138btravels to the first level266bof multi-level ridge704second section704b. Concurrently, as second shuttle pin138bleaves the first section704aof multi-level ridge704and travels to the second section704bof multi-level ridge704, first shuttle pin138aenters the keyway702and travels through the keyway702to the first level266aof multi-level ridge704first section704a. In this position, a second end144aof the shuttle pin138aextends into groove127on the second126side of the key blade117. The lift pins238a,238bare in a resting position and not aligned with supplemental blocking shelves258a,258b.

In continuing through the keyway702in the insertion direction A, shuttle pin138bengages first transition ramp272bextending into the groove127in the key blade117. First transition ramp272bpushes shuttle pin138bfrom the first level266bto the second level268bof the multi-level ridge second section704b. Positioning the shuttle pin138bto the second level268bof the multi-level ridge704moves the shuttle pin138bacross the width of the key blade117, into relief165bformed in the keyway702. As shown inFIG.52, the enlarged first end142bof the shuttle pin138bextends out of the first side124of the key blade117and contacts the beveled edge260bof the lift pin238b, which causes the beveled edge260bto ride up onto the enlarged head portion142band elevate the lift pin238b. The shuttle pin138bremains in the extended position and holding the lift pin238bin the elevated position. In the elevated position, the sidebar slot242bis aligned with the supplemental blocking shelf258b.

As shuttle pin138bis engaging the first transition ramp272band moving to the second level268bof second section704b, shuttle pin138ais simultaneously engaging first transition ramp272aof first section704aand moving to the second level268a. First transition ramp272aextending into the groove127in the key blade117pushes shuttle pin138aacross the width of the key110, into relief165aand onto second level268aof the multi-level ridge704first section704a. The enlarged first end142aof the shuttle pin138aextends out of the first side124of the key blade117and contacts the beveled edge260aof the lift pin238a, which causes the beveled edge260ato ride up onto the enlarged head portion142and elevate the lift pin238a. In the elevated position, the sidebar slot242ais aligned with the supplemental blocking shelf258a.

With both lift pin238aand lift pin238bin the elevated position having the sidebar slots242aligned with the supplemental blocking shelf258aand supplemental blocking shelf258b, respectively, the supplemental blocking shelves258a,258bcan enter the sidebar slots242, and the sidebar710is no longer blocked by lift pin238aand lift pin238b. As the sidebar710moves radially inward, the beveled projection232withdraws from the axial groove156and permits the plug712to rotate within the housing152.

As the key blade117is removed from the cylinder712, the extended end142aof the shuttle pin138aleaves the relief165aand engages third transition feature276aopposite the multi-level ridge704first side704a, and the extended end142bof the shuttle pin138bleaves the relief165band engages third transition feature276bopposite the multi-level ridge704second section704b. The third transition feature276amoves the shuttle pin138afrom a position previously determined by the second level268aback to a position primarily contained within the key blade117groove127at the first level266a. Third transition feature276bmoves the shuttle pin138bfrom a position previously determined by the second level268bback to a position primarily contained within the key blade117groove127at the first level266b. Movement of the shuttle pin138aand shuttle pin138bback to the retracted positions allows clearance for shuttle pin138aand shuttle pin138bin the keyway702as the key blade117is removed.

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