Patent Document

CROSS-REFERENCE TO RELATED APPLICATION(S) 
   The present application derives priority from U.S. Provisional Patent Application No. 60/848,592 filed Sep. 29, 2006. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to keyed-cylinder locks assemblies and, more particularly, to reset cradle for recovering a blown cylinder of a lock assembly of a type employing a quick rekey cylinder. 
   2. Description of the Background 
   There is a commercial need to provide interchangeable key-access security so that owners/operators of a premises do not need to replace the lock cylinders every time for example, that tenants change or a tenant key is lost or stolen. This situation is especially acute in multiple-unit buildings such as apartments and office buildings. 
   When rekeying a cylinder using a traditional cylinder design, the user is required to remove the cylinder plug from the cylinder body and replace the appropriate pins so that a new key can be used to unlock the cylinder. This typically requires the user to remove the cylinder mechanism from the lockset and then disassemble the cylinder to some degree to remove the plug and replace the pins. This requires a working knowledge of the lockset and cylinder mechanism and is usually only performed by locksmiths or trained professionals. Additionally, the process usually employs special tools and requires the user to have access to pinning kits to interchange pins and replace components that can get lost or damaged in the rekeying process. Finally, professionals using appropriate tools can easily pick traditional cylinders. 
   Electronic key systems now exist to allow an owner to selectively program various key codes, but these systems are cost prohibitive for many business and residential applications. 
   There have, however, been a few prior efforts to develop a mechanical controlled-access lock. For example, pin tumbler locks which may be rekeyed without removing the tumblers, and therefore rekeyed without a locksmith, are shown in U.S. Pat. No. 1,565,556 of Fremon, issued Dec. 15, 1925, and U.S. Pat. No. 2,603,081 to Pelle, issued Jul. 15, 1952. 
   U.S. Pat. No. 6,862,909 to Armstrong et al. shows rekeyable lock cylinder and rekeying tool.  FIG. 1  illustrates this rekeyable lock cylinder, which comprises a lock cylinder  10 , a lock cylinder body  12 , and a plug assembly  14 . The plug assembly  14  includes a plug body  40 , a carrier sub-assembly  42  and a plurality of spring-loaded pins  38 ,  113 . The plug body  40  includes a plug face  44 , a keyway opening  52 , a rekeying tool opening  54  and a pair of channels  56  extending radially outwardly for receiving anti-drilling ball bearings  60 . The carrier sub-assembly  42  includes a carrier  90 , a plurality of racks  92 , a spring catch  96 , a spring-loaded locking bar  94 , and a return spring  98 . The carrier  90  and the plug body  40  combine to form a cylinder that fits inside the lock cylinder body  12 . 
   To rekey the lock cylinder  10 , a valid key is inserted into the keyway and is rotated approximately 90 degrees counterclockwise from the home position. A paperclip or other pointed device is inserted into the rekeying tool opening  54  and is pushed against the carrier  90  to move the carrier  90  parallel to the longitudinal axis of the lock cylinder  10  into a learn mode. The valid key is removed and a second valid key is inserted and rotated clockwise. The carrier  90  is biased toward the plug face  44  by the return spring  98 , causing the racks  92  to re-engage the pins  113 . At this point, the lock cylinder  10  is keyed to the second valid key and the first valid key no longer operates the lock cylinder  10 . The lock cylinder  10  can be rekeyed further as desired. 
   One problem with the foregoing rekeyable cylinder is that if the second valid key is not fully inserted during the rekeying process, the pins will not be set to conform to the second valid key, resulting in a “blown cylinder.” To aid in recovering a lock cylinder from a blown condition, a manual reset procedure was developed to conform to a profile of a new key, without removing the plug assembly from the cylinder body. 
   First, with the lock cylinder exposed, a rekeying tool  310  is inserted into the cylinder body  12  to manually position the racks  92  and the pins  113  to release the locking bar  94 . 
   Next, a bracing tool (a simple pin) is used to depress the locking bar  94  and allow the plug body to rotate in the cylinder body to the rekeying position. 
   Next, the plug  40  is rotated with respect to the cylinder body  12  by 90 degrees. This rotation moves the locking bar  94  into a recess inside the cylinder body  12 , which releases the locking bar  94 , allowing learn tool  200  to be inserted. 
   Finally, the learn tool  200  is inserted into the keyslot and this configures the lock cylinder to the learn mode. Once in the learn mode, the rekeying tool  310  and bracing tool are removed and a valid key is inserted in the keyway of the plug assembly. As the new key is inserted, the pins can ride up and down the ramps of the key. Once the key is fully inserted, the pin heights can correlate to the new key. Once the key is rotated to bring the plug  40  to the home position, the racks  92  are then re-engaged with the pins  113 , and at this point the lock cylinder  10  is keyed to the new key and any previously valid key no longer operates the lock cylinder  10 . 
   Thus, via the manual reset tool  310 , without requiring a valid key, the lock assembly can be placed into a learn mode, in which it can read and conform to a profile of a new key, without removing the plug assembly from the cylinder body. 
   One difficulty with such manual reset tool  310  is the need for some manual dexterity in handling the lock cylinder, the reset tool assembly, and all associated components of the reset tool that needs to be operated simultaneously (first the rekeying tool  310 , then the bracing tool, then cylinder plug  40  rotation, then insertion of the learn tool  200 ). Another difficulty with such reset tool is the relatively high number of operations that need to be performed in the right sequential order. Such reset tool doesn&#39;t have a robust means to prevent someone from performing operations in an incorrect order. Due to these difficulties, proper training needs to be conducted for the user to operate the product. 
   It would be greatly advantageous to provide a reset cradle with integral components that automatically positions the lock cylinder, inserts a rekeying tool, then a bracing tool, then rotates the cylinder plug  40  to allow insertion of the learn tool  200 , all in proper sequence. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to eliminate the need for manual dexterity when rekeying a rekeyable lock cylinder, making the process more user friendly, fool-proof, and easy to operate with very little or no training. 
   It is another object to provide a reset cradle for rekeyable lock cylinders as described above that consolidates the various components and operations involved in rekeying the lock, thereby reducing the need for the user to manually perform multiple operations. 
   It is still another object to provide a reset cradle as described above that prevents users from performing reset operations in an incorrect order. 
   It is still another object to provide a reset cradle in which most of the working components are hidden inside a housing. 
   In accordance with the foregoing objects, the present invention is a reset cradle for seating a rekeyable lock cylinder and for resetting the rekeyable lock cylinder with minimal effort. The reset cradle generally comprises a two-section housing including a base section having a centrally-protruding tubular post into which the lock cylinder may be inserted, and a separate hub section rotatably seated on the base. The hub has an aperture for exposing the lock cylinder seated in the post of the base section. Inside the housing, a cam is engaged against the post and is rotatable thereabout along with relative rotation of the two-section housing. A reset member is also operative inside the housing, and this comprises a plurality of protruding prongs. The reset member is slidably seated in the post and is engaged by rotation of the cam for radial displacement of the prongs into the lock cylinder. Similarly, a detent pin is slidably seated in the post and is engaged by the cam for radial displacement into the lock cylinder. Relative rotation of the two-part housing resets the lock cylinder with the reset member and detent pin, and allows the lock cylinder to be placed in a learn mode for rekeying without a valid key. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments and certain modifications thereof when taken together with the accompanying drawings in which: 
       FIG. 1  illustrates a rekeyable lock cylinder and rekeying tool from U.S. Pat. No. 6,862,909 to Armstrong et al. 
       FIG. 2  is a perspective exploded view of the reset cradle  2  according to one embodiment of the present invention. 
       FIG. 3  is an exploded perspective view of the reset cradle  2 . 
       FIG. 4  is an isolated view of the driver  160  with flange  168  there beneath. 
       FIG. 5  is an enlarged illustration of the bottom of the reset cradle  2 . 
       FIG. 6  is a cross-section of the reset cradle  2  of  FIGS. 2-3 . 
       FIGS. 7-9  are composite views of the reset cradle  2  in the home (0 degree) position. 
       FIGS. 10-12  are composite views of the reset cradle  2  in the first (54 degree) position. 
       FIGS. 13-15  are composite views of the reset cradle  2  in a second (146 degree) position. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   As described above, using a manual override or reset tool an operator can reset a lock cylinder by putting it into a learn mode without requiring a valid key. This reset operation could sometimes prove challenging because of the number of actions to perform while holding a compact lock cylinder. The present invention is a reset cradle for manually resetting a quick rekey cylinder without need of a valid key, thereby allowing easier manual reset thereof, and especially for recovery of a blown cylinder of a rekeyable lock assembly. 
     FIG. 2  is a perspective exploded view of the reset cradle  2  according to one embodiment of the present invention. The reset cradle  2  includes a housing  22  with central recess  24  extending there through configured to receive and seat the lock cylinder  10 . 
   As seen in  FIG. 3  the housing  22  further comprises an annular hub  124  rotatably attached to a base  126 . Annular hub  124  is a hollow cover that flares outward from a central aperture  125 . The annular hub  124  rotatably seats against a peripheral groove  128  formed in the base  126 , thereby enclosing an upwardly protruding tubular post  130  formed integrally on the base  126 . The post  130  forms a hollow cylinder that defines the central recess  24  for receiving the lock cylinder  10 . Post  130  protrudes axially from base  126  so that when hub  124  is seated in groove  128  the cylindrical walls of post  130  conform to the aperture  125  in hub  124 . The base  126  is formed with a recess  127  (obscured in  FIG. 3 , see  FIG. 6 ) in its underside immediately beneath the post  130 . A spring-loaded annular driver  160  is rotatably journalled in the recess  127  in base  126 . The driver  160  is a hollow annular member having an inwardly-directed radial pin  161  for engaging the lock cylinder when inserted into the reset cradle  2 . The driver  160  has a flange  168  at the bottom for anchoring an extension spring  166 . The other end of extension spring  166  is connected internally to the base  126  for biasing rotation of the driver  160  with respect to the base  126 , providing a spring-return to a home position. The driver  160  also has an outwardly protruding arm  163  that engages a cam as described below. A washer  162  and screw  164  are secured to the bottom of the base  126  to trap driver  160  within the bottom recess. The driver  160  is held captive in the base  126  by a washer  162  screwed into the bottom of the base  126 . 
     FIG. 4  is an isolated view of the driver  160  with flange  168  there beneath. A compression pin  169  is inserted into a bore hole in the flange  168  for anchoring the extension spring  166  for spring-return to a home position.  FIG. 4  also provides perspective of the outwardly protruding arm  163  that engages the cam described below. The inwardly-directed axial pin  161  is inserted into a bore-hole in the wall of driver  160  for engaging the lock cylinder once inserted into the reset cradle  2 . The axial pin  161  fits into a notch formed in the lowermost edge of the lock cylinder for turning the cylinder. The bore-hole may be formed as a slot to give the axial pin  161  a limited degree of freedom in order to accommodate lock cylinders of different lengths. 
   Referring back to  FIG. 3 , a two-section cam  132  formed of halves  132 A and  132 B is rotatably seated on the post  130  inside base  126 . The cam  132  can move rotationally along with hub  124  with respect to the base  126 . The inner surface of cam  132  comprises a camming surface that radially displaces two operative components mounted in the post  130  of base  126 . As the cam  132  rotates around the post  130  of base  126  to a first position, it radially displaces, within a particular order and timing, the two working components both being housed inside the base  126  as will be described. These working components engage the lock cylinder, and are generally spring biased outward so they will return to their starting position once their particular functions are completed. The cam  132  is also formed with a downwardy-protruding finger  133  for engagement with the arm  163  of driver  160 . Note also that the finger  133  protrudes laterally from the cam  132  to key the cam  132  to the hub  124  for rotation therewith. As the cam  132  rotates past the first position to a second position the finger  133  of cam  132  engages arm  163  of driver  160  and rotates the driver, which in turn rotates, the plug  40  (see  FIG. 1 ) with respect to the cylinder body  12 . Rotation of the plug  40  by 90 degrees with respect to the cylinder body  12  moves the locking bar  94  into the recess inside the cylinder body  12 , which releases the locking bar  94 , allowing a learn tool  200  to be inserted. 
     FIG. 5  is an enlarged illustration of the bottom of the reset cradle  2  showing the downwardly-protruding finger  133  of cam  132  which, at a predetermined angle of rotation, engages the outwardly protruding arm  163  of driver  160 . The driver  160  wields the inwardly-directed axial pin  161  that engages the edge of the lock cylinder (here inserted into the reset cradle  2 ). Consequently, turning the hub  124  of housing  22  past the first position causes the cam  132  to begin to drive the driver  160 , which in turn engages the pin  161  to rotate the lock cylinder seated therein. 
   The cam  132  is formed with an interior camming surface. As mentioned above, as the cam  132  rotates around the post  130  of base  126 , this camming surface radially displaces, within a particular order and timing, two working components both being housed inside the base  126 . Referring back to  FIG. 3 , one of these components is a reset member  150  comprising a shoulder with a plurality of protruding prongs. The reset member  150  generally fulfills the function of the rekeying tool  310  described in the background section with regard to  FIG. 1 , and the protruding prongs insert into the cylinder body to manually position the cylinder racks and pins to release the locking bar of the lock cylinder. However, in the context of the reset cradle  2  the operation of the reset member  150  becomes automatic. The shoulder of the reset member  150  is rounded and seats within an alcove  137  formed along the inner wall of the cam  132 . The forefront of the reset member  150  is slidably seated in a notch formed through the post  130  in base  126 , and is spring-biased outward by a pair of springs  152  that engage the post  130 . This way, as the hub  124 , and hence cam  132  and alcove  137  are rotated the sidewalls of the alcove  137  will engage the reset member  150  and displace it radial into the post  130 . Upon radial displacement the prongs of reset member  150  are inserted through the apertures of the cylinder body, such that the prongs of the reset member  150  engage the racks  92  (see  FIG. 1 ) of the rekeyable lock cylinder  10 . The reset member  150  thereby relocates the plurality of racks  92 , such that the racks are aligned at a common level. 
   At about the same time that the reset member  150  engages, a detent pin  140  also begins to engage to depress the locking bar  94  and allow the plug body to rotate in the cylinder body to the rekeying position. The detent pin  140  is likewise slidably seated in a through bore formed through the post  130  in base  126 , and is spring-biased outward by a spring  142  seated inside the post  130 . 
   Referring back to  FIG. 3 , the outward end of the detent pin  140  is formed with a rounded cap that engages an arcuate bearing surface  139  protruding inward along the inner wall of the cam  132 . This way, as the cam  132  and bearing surface  139  are rotated the bearing surface  139  will engage the detent pin  140  and displace it radially into the post  130  and into the detent ball  36  ( FIG. 1 ) of the lock cylinder  10 . Upon radial displacement the pin  140  displaces the locking bar  94 , thereby fulfilling the function of the bracing tool (described in the background section) and allowing the plug body  40  to rotate. With the lock cylinder racks  92  aligned by the reset member  150  as above, the detent pin  140  (of  FIG. 3 ) moves the locking bar  94  into engagement with cut-outs in the racks  92 , thereby preventing relative movement among the racks, and consequently, relative movement between the pins  113  engaged with the racks  92 . This effectively frees the plug body  40  for rotation within the cylinder body  20  and readies the rekeyable lock cylinder  10  for insertion of the learn tool  200 . 
   In the presently-preferred embodiment, the alcove  137  and arcuate bearing surface  139  are formed along the inner wall of the cam  132  in order to move both the reset member  150  and detent pin  140  into the lock cylinder  10  at approximately 33 degrees, and then allow spring-biased retraction of the reset member at approximately 54 degrees while detent pin  140  remains displaced. 
     FIG. 6  is a cross-section of the of the reset cradle  2  of  FIGS. 2-3  with rekeyable lock cylinder  10  removed from the central recess  24  of housing  22 . The hub  124  is rotatably seated on the groove  128  of base  126 , thereby enclosing post  130  of base  126 . The extent of the post  130  is visible as well as its central recess  24  for receiving the lock cylinder  10 . Here only cam half  132 A is visible. as well as the detent pin  140  which is slidably seated in the through bore formed through the post  130  in base  126 . The spring  142  encircles the detent pin  140  and abuts a constriction inside the through-bore in post  130 . 
   In use, the user should first ensure that the arrow on the front annular hub  124  is in the starting (0 degree) position, as shown in  FIG. 7 . If not, then the front hub  124  should be returned clockwise until it bottoms out (indicating the starting position shown in  FIG. 7 ). The user then rotates the hub  124  of reset cradle  2  from the home position to a first position (54 degrees) which displaces detent pin  140  and reset member  130  into the lock cylinder as described above, and then retracts the reset member  150 , followed by 90 degree rotation to a second 146 degree position which rotates the plug  40  within the cylinder body  20  and readies the rekeyable lock cylinder  10  for insertion of the learn tool  200 . The learn tool  200  may then be inserted and the lock cylinder rekeyed. 
     FIGS. 7-15  are sequential illustrations of the operation of the reset cradle  2 . Specifically,  FIGS. 7-9  are a front view of the reset cradle  2  in the home (0 degree) position, a lower cross-section showing the position of driver  160 , and an upper cross-section showing the positions of the reset member  150  and detent pin  140  relative to post  130  and cam  132 , respectively. An arrow  12  embossed in the front face of the hub  22  of the reset cradle  2  tells the user that the assembly is in the home (0 degree) position, as shown in  FIG. 7 . A second arrow  14  tells the user the direction to turn. While in the starting position the rekeyable lock cylinder  10  may be inserted frontally into the reset cradle  2  (already done so as shown). 
   Thus, as seen in  FIG. 8 , the arm  163  of driver  160  is not engaged since the hub  124  must be rotated approximately past the first (54 degree) position before the finger  133  protruding downward from cam  132  engages the arm  163  of the driver  160 . Likewise, as seen in  FIG. 9 , the reset member  150  remains seated in the alcove  137  of cam  132  and is spring-biased fully outward so as not to engage the lock cylinder, and the detent pin  140  has not yet engaged the cam surface  139  of cam  132  and is spring-biased fully outward so as not to engage the lock cylinder. 
   Further rotation to the first (54 degree) position extends both the reset member  150  and the detent pin  140  into the lock cylinder, then retracts the reset member  150 . 
     FIGS. 10-12  are a front view of the reset cradle  2  in the first (54 degree) position, a lower cross-section showing the position of driver  160 , and an upper cross-section showing the positions of the reset member  150  and detent pin  140  relative to post  130  and cam  132 , respectively. The arrow  12  on the reset cradle  2  tells the user that the assembly has been rotated 54 degrees to the first position, as shown in  FIG. 10 , where the arrow  12  is 54 degrees offset from the keyslot of the lock. 
   As seen in  FIG. 11 , this rotation turns the cam  132  and at approximately 54 degrees of rotation engages the arm  163  of driver  160  with the finger  133  of the cam  132 . The lock cylinder does not rotate. 
   Meanwhile, as seen in  FIG. 12 , at approximately 22 degrees the reset member  150  engages the walls of the alcove  137  of cam  132  and is urged inward to engage the lock cylinder. At approximately 33 degrees the detent pin  140  begins to engage the cam surface  139  of cam  132  and is radially extended through the post  130  to engage the lock cylinder. This in turn moves the locking bar  94  ( FIG. 1 ) into engagement with cut-outs in the racks  92 , thereby preventing relative movement among the racks, and consequently, relative movement between the pins  113  engaged with the racks  92 . By full rotation the first 54 degree position the cam  132  frees the reset member  150 . which retracts, but the detent pin  140  remains engaged. While in this configuration it is now necessary to rotate the plug  40  ( FIG. 1 ) approximately 90 degrees within the cylinder body  12  in order to move the locking bar  94  into the recess inside the cylinder body  12 , which in turn releases the locking bar  94 , allowing learn tool  200  to be inserted. This rotation is implemented by operation of the driver  60 . 
     FIGS. 13-15  are a front view of the reset cradle  2  in a second (146 degree) position, a lower cross-section showing the position of driver  160 , and an upper cross-section showing the positions of the reset member  150  and detent pin  140  relative to post  130  and cam  132 , respectively. The arrow  12  on the reset cradle  2  tells the user that the assembly has been rotated 146 degrees to the third position, which puts the lock cylinder in the learn mode, as shown in  FIG. 13 , where the arrow  12  is 146 degrees offset from the starting position. As stated above, at 54 degrees of rotation the arm  163  of driver  160  is engaged with the finger  133  of the cam  132 . Consequently, this segment of rotation between 54-146 degrees turns the cam  132  as well as the plug along with the hub  124 . This can be seen in  FIG. 14  where the plug  40  itself is rotated approximately 90 degrees within the lock cylinder body  12 . 
   Meanwhile, as seen in  FIG. 15 , as the cam rotates to the third position the cam  132  opens up again for the detent pin  140 , the detent pin  140  falling back into the recess of the cam surface  139  and retracting from the post  130 . This backs the locking bar  94  ( FIG. 1 ) out of engagement with cut-outs in the racks  92 , thereby allowing relative movement among the racks, and consequently, relative movement between the pins  113  engaged with the racks  92 . This effectively readies the rekeyable lock cylinder for insertion of the learn tool  200 . 
   Referring back to  FIG. 13 , the learn tool  200  may next be inserted into the keyslot in the face of the lock cylinder to configure the lock cylinder to the learn mode. 
   Once in the learn mode, the lock cylinder can be removed from the reset cradle  2  and a valid key inserted in the keyway of the lock cylinder. The new key is inserted and rotated clockwise 90° to key the lock cylinder  10  to the new key (the cylinder pins correlating to the new key). Thus, rotating the key back 90 degrees to the home position effectively keys the lock cylinder  10  to the new key. Any previously valid key no longer operates the lock cylinder  10 . Thus, via the reset cradle  2 , without requiring a valid key, the lock assembly can be rekeyed without removing the plug assembly from the cylinder body. 
   Once the lock cylinder is removed from the reset cradle, then the reset cradle is returned to its home position, and indeed the return-bias spring  166  promotes this return. 
   By using the reset cradle  2  the process of rekeying the lock cylinder  10  becomes easier to handle. First the reset cradle  2  holds the lock cylinder  10  in place thereby freeing up one hand of the operator. Also, the reset cradle  2  automatically operates the reset member  150  and the bracing bar, thereby eliminating the need for manual manipulation of these components. This facilitates both the operation of engaging the prongs of the reset member  150  against the racks  92  ( FIG. 1 ) and the action of using the bracing bar to move the locking bar  94  ( FIG. 1 ) into engagement with the racks  92 . 
   Having now fully set forth the preferred embodiment and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It is to be understood, therefore, that the invention may be practiced otherwise than as specifically set forth in the appended claims.

Technology Category: 4