Patent Application
20250059797
The plug of a lock is the
Modern lock systems may have a plurality of security features. For instance, the keyways have relatively complex cross-sectional shapes, and exclude keys which do not have a matching cross-sectional shape. A locking mechanism, typically having a number of biased components referred to as tumblers, is typically also integrated to modern lock systems. The tumblers are biased into the keyway and interfere with the rotation of the plug unless all of them are pushed by just the right distance, which occurs when a key having a key blade with a matching edge profile (i.e. a matching key) is fully engaged into the keyway. In practice, many lock systems use tumbler configurations which can be operated by a very limited number of more than one matching edge profile, such as a master key adapted to open a number of different locks at premises and a unit key specific to the lock of a given unit of the premises. Modern lock systems may additionally have yet a third security feature in the form of a blocking mechanism. The blocking mechanism can also interfere with the rotation of the plug, but rather than allowing rotation contingent upon a matching edge profile, it can allow rotation contingent upon the key blade being of a given key blade type. The key blade types include a plurality of keys having different edge profiles but having a corresponding feature, such as a particular longitudinal abutment location.
An example of a blocking mechanism is presented in published U.S. application publication no. 2023/0082003, the contents of which are hereby incorporated. This example blocking mechanism includes a tumbler which pivots a rocker in a manner to unblock the rotation of the plug when pushed by just the right amount by a longitudinal abutment formed in a side of the key blade. Different key types can have abutments at different locations along the length of the blade, and keys of types other than the matching key type may not push the blocking mechanism tumbler enough, or push it too much, preventing the rocker from unblocking the rotation of the plug. Other blocking mechanism configurations may exist, and blocking mechanisms can be differentiated from locking mechanisms due to the fact that they discriminate between types of keys rather than between edge profiles. Another example is presented in U.S. application Ser. No. 18/224,969, the contents of which are hereby incorporated by reference.
While existing locks and plugs therefore have met commercial success and have shown suitable to a certain degree, there always remains room for improvement. In particular, there can be manufacturing challenges, such as may pertain to machining of components or assembly of components, which may affect the design of blocking mechanisms, and controlling production costs is a constant concern of lock manufacturers.
It was found that integrating components of the blocking mechanism in an insert component rather than in the primary component of the plug could provide enhanced satisfaction at least in some embodiments. The insert component can be assembled or can be disassembled from the primary component. In particular, it may be easier to machine features forming part of or cooperating with components of a blocking mechanism in an insert component than directly in a primary component. It may be easier or less costly to repair or replace blocking mechanism components if integrated in an insert component than if integrated in a primary component. It may be easier or less costly to assemble blocking mechanism components if integrated in an insert component than if integrated in a primary component. There may be other advantages to integrating components of a blocking mechanism in an insert component rather than in the primary component.
In accordance with one aspect, there is provided a lock plug configured to be rotatably mounted in a lock housing, the lock plug comprising: a plug body rotatably mountable within the lock housing for rotation relative the lock housing, around an axis, the plug body having a solid of revolution shape, the plug body having a insert component assembled to a primary component; a keyway defined in the plug body, the keyway having a length parallel to the rotation axis, the keyway adapted to receive a key blade matching a cross-sectional shape of the keyway; and a blocking mechanism protruding into the keyway, the blocking mechanism configured to prevent the plug from rotating unless actuated by the key blade and unless the key blade is of a matching type, the blocking mechanism integrated to the plug insert.
In accordance with another aspect, there is provided a modular lock plug configured to be rotatably mounted in a lock housing, the lock plug comprising: a plug body rotatably mountable within the lock housing for rotation relative to the lock housing around a rotation axis, the plug body having a solid of revolution shape, the plug body comprising an insert component assembled to a primary component; a keyway defined in the plug body, the keyway having a length parallel to the rotation axis, the keyway adapted to receive a key blade matching a cross-sectional shape of the keyway; and a blocking mechanism operable to protrude into the keyway, the blocking mechanism configured to prevent the plug from rotating unless actuated by the key blade, the blocking mechanism integrated into the plug body insert component; wherein the insert component is selected from a plurality of insert components each corresponding to at least one of a plurality of key blades, each insert component interchangeable with another insert component.
It may be provided that the plug body has a cylindrical shape concentric with the axis and a length extending parallel the axis, the length between a front end and a rear end, the keyway opening at the front end, the plug insert generally shaped as a segment of the cylindrical shape, the segment having a height extending radially relative the axis, the height lesser than a radius of the cylindrical shape, the segment having a portion of the length of the plug body.
It may be provided that the insert has a first transversal engagement surface extending transversally to the height and along the length, the plug body has a second transversal engagement surface, the first transversal engagement surface mating with the second transversal engagement surface and engaged with the second transversal engagement surface.
It may be provided that the first transversal engagement surface and the second transversal engagement surface are straight in the axial orientation and curved in the transversal orientation.
It may be provided that a retaining ring secures the insert component to the primary component, the retaining ring concentric to the axis.
It may be provided that the insert component and the primary component have axially abutting surfaces.
It may be provided that one of the insert component and the primary component has at least one axially oriented male member protruding from the corresponding axially abutting surface, and the other one of the insert component and the primary component has at least one axially oriented female member recessed in the corresponding axially abutting surface, the at least one male member axially engaged with the at least one female member.
It may be provided that the blocking mechanism has a tumbler biased towards the key blade and configured to engage and be pushed back by a cam of the key blade, the mechanism unblocking the rotation when pushed back by an unblocking distance.
It may be provided that the blocking mechanism has a rack integrated to the tumbler, and a pinion rotatable by the rack around a pinion axis to selectively block or unblock the rotation of the lock plug.
The lock plug may be rotatably housed in the lock housing.
A sleeve may extend around the lock plug, between the lock plug and the lock housing.
It may be provided that the lock housing further comprises a locking mechanism having tumblers disposed along the length of the keyway, the tumblers biased into the keyway, the locking mechanism configured to prevent the plug from rotating unless activated by a key blade having a matching edge pattern.
The lock plug may be rotatably mounted within a case of a lock core, the lock core being of the small format interchangeable core (SFIC) format configured to be engaged within a corresponding opening formed in a lock housing.
In accordance with another aspect, there is provided a method of assembling a lock plug, the method comprising: assembling components of a blocking mechanism to an insert component partially defining a keyway; and assembling the insert component to a primary component of the lock plug to form a plug body, the primary component partially defining the keyway, the plug body having a solid of revolution shape defined around an axis, the plug insert generally shaped as a segment of the solid of revolution shape, the segment having a height lesser than a radius of the solid of revolution shape around the axis.
It may be provided that said assembling the insert component to the primary component includes abutting a first transversal engagement surface of the insert component against a second transversal engagement surface of the primary component and sliding the insert component along a length of the keyway until a first axial engagement surface of the insert component abuts a second axial engagement surface of the primary component, and then securing the insert component to the primary component.
It may be provided that the first transversal engagement surface has at least one axially oriented male member protruding from the surface and the second transversal engagement surface has at least one axially oriented female member recessed in the surface, the at least one male member axially engageable with the at least one female member.
It may be provided that the blocking mechanism is a first blocking mechanism and the insert component is a first insert component, further comprising assembling components of a second blocking mechanism to a second insert component, a geometry of the second blocking mechanism differing from a geometry of the first blocking mechanism, further comprising, prior to said assembling the first insert component to the primary component, selecting the first insert component based on the geometry of the first blocking mechanism.
It may be provided that the first blocking mechanism differs from the second blocking mechanism in that it is configured to match a key blade of a different type.
The method may further include rotatably mounting the lock plug within a mating recess of a lock housing, further comprising engaging a key blade of a matching type in the keyway, the key blade disengaging the blocking mechanism, thereby allowing the rotation of the lock plug, and rotating the lock plug in the housing by rotating the key blade.
It may be provided that the key blade disengaging the blocking mechanism includes a ram defined in a side of the key blade pushing a tumbler of the blocking mechanism towards a rear of the lock plug until a shoulder of the key blade abuts a front of the lock plug and the tumbler of the blocking mechanism reaches an unblocking position.
It may be provided that the key blade has an edge profile matching a locking mechanism configuration of the lock housing, the key blade further disengaging the locking mechanism, thereby allowing the rotation of the lock plug.
All technical implementation details and advantages described with respect to a particular aspect of the present invention are self-evidently mutatis mutandis applicable for all other aspects of the present invention.
Many further features and combinations thereof concerning the present improvements will appear to those skilled in the art following a reading of the instant disclosure.
In the figures,
The lock 10 in this example is configured to provide access when the lock plug 14 rotates in the housing 12. The lock 10 may have a plurality of safety features which may prevent undesired rotation of the lock plug 14. In this example, the lock plug 14 has a keyway 18 which has a particular cross-sectional shape, and which prevents keys with key blades 20 having non-matching cross-sectional shapes from even entering the keyway 18.
In the embodiment illustrated, the lock 10 further has a blocking mechanism 34 which prevents keys of a wrong key type from opening the lock 10, even if it has a cross-sectional shape matching the cross-sectional shape of the keyway 18 and a matching edge profile. In the embodiment illustrated, the key type is defined by longitudinal position of an abutment 40 relative to a length of the key. Depending on the approach associated to a particular key manufacturer, the longitudinal position may need to be set with a relatively high degree of precision, and can be defined as a longitudinal distance between the abutment 40 and another stop feature of the key. For instance, in one embodiment, a stop 41 may be defined near the tip 48 of the key 22 and configured to come into abutment, when in the fully engaged position, with a corresponding stop 43 defined at the rear end of the plug 14, in which case longitudinal position of the abutment 40 can be defined as the longitudinal distance d1 between the abutment 40 and the stop 43. In another embodiment, a shoulder 38 may be defined near the bow 24 of the key 20 and configured to come into abutment, when in the fully engaged position, with a front face of the lock plug 14, in which case the longitudinal position of the abutment 40 can be defined as the longitudinal distance d2 between the abutment 40 and the shoulder 38. In the specific example illustrated, the abutment 40 is embodied as the longitudinal tip of a longitudinally extending bulge 36 formed in a face of the key blade 22, and the longitudinal position of the abutment 40 can be set by cutting out a longitudinal groove 46 from the tip to the longitudinal location, removing the bulge 36 along a portion of the length of the key blade 20, allowing the bulge 36 to act as a ram, but many different approaches to forming the abutment may be used in alternate embodiments. It will be noted that this is but one example, and depending on the details of the blocking mechanism 34, key types may further be defined by the cross-sectional shape or cross-sectional size of the ram or abutment 40, for instance. In some embodiments, a very limited number of more than one key type, such as two key types for instance, may correctly trigger the blocking mechanism, while all other key types will not.
In the specific example illustrated, as shown in
It will be understood based on the description presented above, that independently of the detail of their construction, blocking mechanisms may include relatively small components having relatively complex geometries. This is particularly the case for blocking mechanisms incorporated into small format interchangeable cores, but may also be the case for blocking mechanisms incorporated into large format interchangeable cores, or in blocking mechanisms incorporated into lock plugs directly and permanently incorporated into lock housings. Accordingly, blocking mechanisms integrated to lock plugs may pose manufacturing challenges, such as machining challenges and/or assembly challenges, which may affect the cost and/or functionality of a given lock.
It was found that at least in some embodiments, it could be more suitable to provide the lock plug 14 in the form of an assembly of a primary component 52 and of an insert component 54, where components of the blocking mechanism 34 are integrated to the insert component 54. An example of such an embodiment is presented in
In the example presented in
In this example, the fitting of the insert component 54 with the primary component 52 is guided by four main features: mating transversal engagement surfaces 60, 62, mating axial engagement surfaces 64, 66, a male member 68 and female member 70 engagement and a ring 72 and groove 74 engagement. Indeed, in this example, the insert component 54 has a first transversal engagement surface 62 which is generally horizontally oriented, and the primary component 52 has a second transversal engagement surface 60 which has a matching shape and is also generally horizontally oriented. The engagement between these two engagement surfaces stops the transversal relative displacement of the insert component 54 towards the primary component 52. Moreover, in this example, the insert component 54 has a first axial engagement surface 66 which is generally vertically oriented, and the primary component 52 has a second axial engagement surface 64 which has a matching shape and is also generally vertically oriented. The engagement between these two engagement surfaces stops the axial relative displacement of the insert component 54 towards the primary component 52.
In addition to these two sets of matching surfaces which may, in some embodiments, be sufficient to correctly locate the insert component 54 relative the primary component 52, two additional features are used in this embodiment. Firstly, a male member 68 and female member 70 engagement, including at least one male member 68 axially protruding from one of the first axial engagement surface 66 and the second axial engagement surface 64, and at least one mating female member 70 axially recessed into the other one of the first axial engagement surface 64 and the second axial engagement surface 66. Secondly, in this embodiment, the insert component 54 is held into position against the primary component 52 by a retaining ring 72 engaged in a groove 74 which partially extends around the primary component 52 and partially extends around the insert component 54, at the rear end 58. In addition to holding the insert component 54 into position in the matching recess formed in the primary component 52, the ring 72 and groove 74 engagement further assists in maintaining the correct relative position between the insert component 54 and the primary component 52. The male member 68 and female member 70 engagement can also cooperate with the ring 72 and groove 74 engagement in holding the insert into position during manipulations of the lock plug 14. In this specific example, two male and female member engagements are provided, one on each side, and the male members 68 are integrated to the insert component 54, but many various alternate embodiments are possible, such as male members integrated into the primary component 52. Moreover, in this example, the transversal engagement surfaces 62, 60 are straight in the axial orientation, but wavy in the transversal orientation, providing additional positioning reference features. An additional function of the male and female engagement is that if the insert component 54 is not correctly transversally aligned relative the primary component 52, the male member(s) will not engage the female member(s), leaving an axial gap between axial engagement surfaces 66, 64 and an offset in the rear faces of the insert component 54 and of the primary component 52, providing the assembler a visual cue that the alignment is incorrect and preventing the engagement of the ring 72 with the groove 74 until the misalignment has been corrected and the insert component 54 fully pushed in.
Turning to
When assembling the insert component 54 to the primary component 52, one may first abut the first transversal engagement surface 62 of the insert component 54 against a second transversal engagement surface 60 of the primary component 52, and then slide the insert component 54 along a length of the keyway until a first axial engagement surface 66 of the insert component 54 abuts a second axial engagement surface 64 of the primary component 52. Then, the insert component 54 can be secured to the primary component 52.
As can be understood, the examples described above and illustrated are intended to be exemplary only. Indeed, while
