Mechanically keyed locks with isolated validation

Abstract

A lock assembly including a locking module assembly extending along an actuation axis. The locking module assembly includes a carrier assembly configured to rotate and translate along the actuation axis, a spacer assembly rotationally coupled to the carrier assembly, a validation bar movable with the carrier assembly, a key engaging assembly with key engaging elements, and a key validating assembly with corresponding key validating elements. A housing defines a cylindrical cavity to receive the locking module assembly and includes a clearance slot for the validation bar. A displacement mechanism induces relative movement between the carrier assembly and housing, causing separation of the key validating assembly from the key engaging assembly during operation. The lock assembly enables secure key validation and offers potential for rekeying functionality.

Description

Attorney Docket No.: 5193.004WO1 MECHANICALLY KEYED LOCKS WITH ISOLATED VALIDATIONCROSS REFERENCE TO RELATED APPLICATION

[0001] This patent application claims the benefit of U.S. Provisional Application No. 63 / 709,029, filed October 18, 2024, entitled “ MECHANICALLY KEYED LOCKS WITH ISOLATED VALIDATION,” the entire contents of which is incorporated by reference herein. The present application is related to International Patent Application No. PCT / US2024 / 025317, filed April 19, 2024, entitled “MECHANICALLY KEYED LOCKS WITH ISOLATED VALIDATION,” which claims the benefit of U.S. provisional Patent Application No. 63 / 461053, filed April 21, 2023, entitled “MECHANICALLY KEYED LOCKS WITH ISOLATED VALIDATION,” the entire contents of each of which are incorporated by reference herein. TECHNICAL FIELD

[0002] The present disclosure relates to mechanical lock assemblies, and more particularly to a mechanically keyed lock assembly with an axial displacement mechanism for enhanced security. BACKGROUND

[0003] Mechanical locks have been used for centuries to secure doors, containers, and other objects. Traditional lock designs typically rely on a series of pins or wafers that must be aligned correctly by inserting the proper key in order to allow the lock cylinder to rotate and open the lock. While these designs have proven effective, they can be vulnerable to various picking and manipulation techniques.

[0004] As lock technology has advanced, manufacturers have sought to develop more secure designs that are resistant to unauthorized entry attempts. Some approaches have involved increasing the complexity of pin and tumbler arrangements or incorporating additional security elements. However, added complexity often comes at the cost of increased manufacturing difficulty and potential reliability issues.

[0005] Another area of focus has been improving the interaction between the key and the internal locking components. Some designs have attempted to create more sophisticated key profiles and corresponding keyways to make unauthorized duplication more challenging. However, determined attackers may still find ways to manipulate or bypass these measures.Attorney Docket No.: 5193.004WO1

[0006] There is an ongoing need in the lock industry for mechanical lock designs that provide enhanced security while maintaining ease of manufacture and reliable operation. Ideally, such designs would incorporate novel mechanisms to prevent manipulation of internal components during the unlocking process. Additionally, lock assemblies that allow for convenient rekeying without requiring complete disassembly could provide added flexibility for users.

[0007] As mechanical locks continue to play a crucial role in physical security, further innovations are needed to stay ahead of evolving bypass and picking techniques. Designs that can provide robust protection against unauthorized entry while remaining cost-effective to produce at scale are particularly desirable in the marketplace. SUMMARY

[0008] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0009] According to an aspect of the present disclosure, a lock assembly is provided. The lock assembly includes a locking module assembly extending along an actuation axis. The locking module assembly comprises a carrier assembly configured to rotate about and translate along the actuation axis, a spacer assembly rotationally coupled to the carrier assembly, a validation bar movable with the carrier assembly along the actuation axis, a key engaging assembly configured to interact with a key, and a key validating assembly coupled to the carrier assembly. The key engaging assembly comprises a plurality of key engaging elements arranged along the actuation axis. The key validating assembly comprises a plurality of key validating elements corresponding to the key engaging elements. The lock assembly further includes a housing defining a cylindrical cavity configured to receive the locking module assembly. The housing defines a clearance slot extending parallel to the actuation axis, wherein the clearance slot is configured to accommodate movement of the validation bar and control rotation of the locking module assembly. The lock assembly also includes a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

[0010] According to other aspects of the present disclosure, the lock assembly may include one or more of the following features. The spacer assembly may comprise a plurality of spacers,Attorney Docket No.: 5193.004WO1 each spacer positioned adjacent to a corresponding key validating element. The displacement mechanism may comprise at least one angled surface on one of the carrier assembly or the housing, and at least one corresponding interaction surface on the other of the carrier assembly or the housing. The key validating elements may be configured to align with the key engaging elements when in a validated position. The validation bar may be configured to prevent rotation of the locking module assembly unless all key validating elements are in a validated position. In a rekeying position, the key validating elements may be axially displaced from the key engaging elements and rotatable to new positions corresponding to a new key configuration.

[0011] According to another aspect of the present disclosure, a method of operation of a lock assembly is provided. The method includes receiving a key in a locking module assembly, rotating a carrier assembly relative to a housing in response to key rotation, moving a key validating assembly relative to a key engaging assembly, separating the key validating assembly from the key engaging assembly, and configuring key validating elements based on the received key.

[0012] According to other aspects of the present disclosure, the method may include one or more of the following features. The method may further comprise enabling or preventing unlocking of the lock assembly based on the configuration of the key validating elements. Separating the key validating assembly from the key engaging assembly may comprise translating the carrier assembly along the actuation axis during rotation. Enabling or preventing unlocking may comprise allowing or blocking movement of a validation bar based on the configuration of the key validating elements. The method may further comprise re-engaging the key validating assembly with the key engaging assembly.

[0013] According to another aspect of the present disclosure, a method of making a lock assembly is provided. The method includes forming a carrier assembly by joining multiple carrier elements, arranging a plurality of key validating elements into validated positions in the carrier assembly to form a key validating assembly, aligning a plurality of key engaging elements with the plurality of key validating elements to form a key engaging assembly, positioning spacers adjacent to the validating elements, installing a validation bar that interfaces with the key validating assembly, forming a housing defining a cavity, positioning the carrier assembly with the key validating assembly, the key engaging assembly, and the validation bar in the cavity of the housing, and integrating a displacement mechanism configured to induce relative movement between the carrier assembly and the housing structure, wherein the relative movement causes separation of the validating elements from the engaging elements during operation of the lock assembly.Attorney Docket No.: 5193.004WO1

[0014] According to other aspects of the present disclosure, the method of making a lock assembly may include one or more of the following features. Forming the carrier assembly may comprise laser welding multiple carrier elements together. Arranging the key validating elements may comprise inserting the key validating elements into slots in the carrier assembly. Positioning the spacers may comprise inserting a spacer adjacent to each key validating element. Installing the validation bar may comprise inserting the bar through a clearance slot in the housing. Integrating the displacement mechanism may comprise machining at least one angled surface on either the carrier assembly or the housing. The carrier assembly, key validating elements, key engaging elements, and validation bar may be formed from hardened stainless steel. The housing may be formed from a metal alloy through an injection molding process. The spacers may be formed from a low-friction polymer material.

[0015] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive. BRIEF DESCRIPTION OF FIGURES

[0016] The disclosure can be understood in consideration of the following detailed description of various embodiments in connection with the accompanying drawings.

[0017] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[0018] Non-limiting and non-exhaustive examples are described with reference to the following figures.

[0019] FIG. 1 illustrates a perspective view of a lock, according to aspects of the present disclosure.

[0020] FIG. 2 depicts a perspective view of a mechanically keyed lock assembly, according to an embodiment.

[0021] FIG.3 shows a front view of a lock, according to aspects of the present disclosure.

[0022] FIG.4 illustrates a perspective view of a mechanically keyed lock assembly with a validation bar removed, according to an embodiment.

[0023] FIG. 5 depicts a sectional view of a mechanically keyed lock assembly, according to aspects of the present disclosure.Attorney Docket No.: 5193.004WO1

[0024] FIG. 6 shows a perspective view of a key for use with a mechanically keyed lock assembly, according to an embodiment.

[0025] FIG. 7 illustrates a sectional front view of the lock with a key inserted, according to aspects of the present disclosure.

[0026] FIG. 8 depicts a perspective view of a lock module assembly with a correct key inserted, according to an embodiment.

[0027] FIG.9 shows a back view of the lock, according to aspects of the present disclosure.

[0028] FIG. 10 illustrates a side view of a mechanically keyed lock assembly, according to an embodiment.

[0029] FIG. 11 depicts a perspective view of a lock with a key inserted and rotated, according to aspects of the present disclosure.

[0030] FIG.12 shows a perspective view of the distal end of the housing, according to an embodiment.

[0031] FIG. 13 illustrates a front view of the lock module assembly, according to aspects of the present disclosure.

[0032] FIG. 14 depicts a back view of the lock module assembly, according to an embodiment.

[0033] FIG. 15 shows a side view of the lock module assembly, according to aspects of the present disclosure.

[0034] FIG. 16 illustrates a sectional view of the lock module assembly, according to an embodiment.

[0035] FIG. 17 depicts a perspective view of a lock during rotation and translation, according to aspects of the present disclosure.

[0036] FIG. 18 shows a front view of a lock at the point of validation, according to an embodiment.

[0037] FIG. 19 illustrates a perspective view of a lock module assembly at the point of validation, according to aspects of the present disclosure.

[0038] FIG. 20 depicts a side view of a lock module assembly at the point of validation, according to an embodiment.

[0039] FIG. 21 shows a perspective view of a lock module assembly with a receded validation bar, according to aspects of the present disclosure.

[0040] FIG. 22 illustrates a perspective view of a lock module assembly in a rekeying position, according to an embodiment.Attorney Docket No.: 5193.004WO1

[0041] FIG. 23 depicts a perspective view of a disassembled lock module assembly, according to aspects of the present disclosure.

[0042] FIG. 24 shows a perspective view of components of a disassembled lock module assembly, according to an embodiment.

[0043] FIG. 25 illustrates an orthogonal view of components of a lock module, according to aspects of the present disclosure.

[0044] FIG. 26 depicts a flowchart of a method for operating a lock assembly, according to an embodiment.

[0045] FIG.27 shows a flowchart of a method for assembling a lock assembly, according to aspects of the present disclosure. DETAILED DESCRIPTION

[0046] For purposes of promoting an understanding of the principles of the disclosure, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nonetheless be understood that no limitation of the scope of the disclosure is intended by the illustration and description of certain embodiments of the disclosure. In addition, any alterations and / or modifications of the illustrated and / or described embodiment(s) are contemplated as being within the scope of the present disclosure. Further, any other applications of the principles of the disclosure, as illustrated and / or described herein, as would normally occur to one skilled in the art to which the disclosure pertains, are contemplated as being within the scope of the present disclosure.

[0047] The present disclosure provides a lock assembly designed with enhanced security features and a modular design. The lock assembly includes a locking module assembly that extends along an actuation axis. The locking module assembly comprises a carrier assembly, a key engaging assembly, and a key validating assembly. The carrier assembly is configured to rotate about and translate along the actuation axis, providing a unique mechanism for the operation of the lock.

[0048] The key engaging assembly is designed to interact with a key and comprises a plurality of key engaging elements arranged along the actuation axis. The key validating assembly, which is coupled (e.g., axially coupled) to the carrier assembly, comprises a plurality of key validating elements corresponding to the key engaging elements. This configuration allows for a high degree of security by ensuring that the lock can only be operated with the correct key.Attorney Docket No.: 5193.004WO1

[0049] The lock assembly also includes a housing that defines a cavity configured to receive the locking module assembly. The housing defines a clearance slot extending parallel to the actuation axis, which is configured to accommodate movement of a validation bar and control rotation of the locking module assembly. The design feature further enhances the security of the lock by controlling the movement and interaction of the internal components.

[0050] Additionally, the lock assembly incorporates a displacement mechanism configured to induce relative movement between the carrier assembly and the housing. This relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly, providing an additional layer of security.

[0051] In some embodiments, the lock assembly may also include a spacer assembly rotationally coupled to the carrier assembly. The spacer assembly may comprise a plurality of spacers, each positioned adjacent to a corresponding key validating element.

[0052] The modular design allows for easy assembly and potential customization of the lock, further enhancing its versatility and adaptability to various locking applications.

[0053] The lock assembly described herein offers a unique combination of enhanced security features, modular design, and ease of operation, making it a valuable advancement in lock technology.

[0054] The described lock assemblies can be made from various materials such as hardened steel, stainless steel, other steel alloys, titanium, brass, or other material to improve its performance and durability. The housing, carrier, and locking module assembly can also incorporate additional features like tamper-evident rings or complex shapes to enhance security. Different configurations of the locking module assembly and spacer can be configured to provide added security benefits, such as more complex shapes that make it harder to manipulate the locking module assembly or asymmetric passages in the spacer that further complicate the insertion of the mechanical key.

[0055] Referring to FIG. 1, a perspective view of a lock 10 is shown. The lock 10 may include a lock body 40 that can house a mechanically keyed lock assembly 30. The lock assembly 30 may include a lock module assembly 34 positioned within the lock body 40. The lock module assembly 34 may be a cylindrical structure with a keyway 39 at one end for receiving a key. The keyway 39 may be positioned near or at the center of the actuation axis 38.

[0056] The lock module assembly 34 may include various components such as a carrier assembly, a spacer assembly, a validation bar, a key engaging assembly, and a key validatingAttorney Docket No.: 5193.004WO1 assembly. These components work together to enable the locking and unlocking functions of the lock assembly.

[0057] The carrier assembly is configured to rotate about and translate along the actuation axis. The rotation and translation of the carrier assembly are directly linked to the physical turning of the key by the user. The carrier assembly may include a cam protrusion 126 that extends from the proximal end of the lock module assembly 34. The cam protrusion 126 may be a displacement mechanism configured to induce relative movement between the carrier assembly and the housing.

[0058] The key engaging assembly is designed to interact with a key and comprises a plurality of key engaging elements arranged along the actuation axis. The key validating assembly, which is coupled to the carrier assembly, comprises a plurality of key validating elements corresponding to the key engaging elements. This configuration allows for a high degree of security by ensuring that the lock can only be operated with the correct key.

[0059] In some examples, the lock assembly may further include a displacement mechanism configured to induce relative movement between the carrier assembly and the housing. This relative movement may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly. The displacement mechanism may include one or more angled surfaces on either the carrier assembly or the housing, and corresponding interaction surfaces on the other of the carrier assembly or the housing. The interaction between these surfaces may facilitate the relative movement and the subsequent separation of the key validating assembly from the key engaging assembly.

[0060] In some embodiments, the lock assembly may also include a spacer assembly rotationally coupled to the carrier assembly. The spacer assembly may comprise a plurality of spacers, each spacer positioned adjacent to a corresponding key validating element. When the carrier is translated relative to the housing, the key validating assembly may slide out of engagement with the key engaging assembly and into engagement with the spacer assembly.

[0061] In FIG.1, when no key has been inserted into the keyway 39, the carrier assembly is not rotated or translated relative to the housing, and the proximal cap 52 is coplanar with the front surface of the first carrier element of the carrier assembly. The proximal cap 52 is coplanar with the non-protruding surface of the first carrier element (e.g., partial annular surface) of the carrier assembly 70, that is, the flat front surface excluding the cam protrusion 126.

[0062] Referring to FIG.2, a perspective view of a mechanically keyed lock assembly 30 is shown. The lock assembly 30 includes a locking module assembly 34 that extends along anAttorney Docket No.: 5193.004WO1 actuation axis. The lock module assembly 34 may include at least one locking module 36. The carrier assembly 70 may form the outer structure of the locking module 36. The locking module 36 may house the key engaging assembly 102, key validating assembly 104, and spacer 106. The carrier assembly 70 may support and guide the movement of the internal parts of the locking module 36. The lock assembly may include one or more locking modules 36. In some cases, the lock assembly may include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more locking modules 36.

[0063] The locking module assembly 34 comprises a carrier assembly 70, which is configured to rotate about and translate along the actuation axis. This configuration allows the carrier assembly 70 to move in response to the rotation of a key inserted into the lock assembly 30.

[0064] In some examples, the lock assembly 30 further includes an optional housing 32 that defines a cylindrical cavity. The housing 32 is configured to receive the locking module assembly 34. The housing 32 may be formed from a variety of materials, such as metal or plastic, and may be shaped to fit within a specific type of door or locking application. In some examples, the housing 32 may be designed to provide structural support and protection for the internal components of the lock assembly. Alternatively, a portion of lock assembly 30 may define housing 32, e.g., carrier assembly 70 may define housing 32.

[0065] A validation bar 76 is also included in the lock assembly 30. The validation bar 76 is movable with the carrier assembly 70 along the actuation axis. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. The grooves between the lock modules 36 may receive a spring mechanism, such as a c-clip for springing up the validation bar 76 when putting the lock in a locked configuration. The respective grooves may be defined by respective carrier elements of the carrier assembly 70.

[0066] The carrier assembly 70 of the lock assembly 30 includes a cam protrusion 126. The cam protrusion 126 extends from the proximal end of the lock module assembly 34. The cam protrusion 126 may be a displacement mechanism configured to induce relative movement between the carrier assembly 70 and the housing 32. This relative movement may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly. This separation is a physical action within the lock mechanism that occurs as part of the validation process.Attorney Docket No.: 5193.004WO1

[0067] In FIG.2, when no key has been inserted into the keyway 39, the carrier assembly 70 is not rotated or translated relative to the housing, and the proximal cap 52 is coplanar with the front surface (e.g., partial annular surface, flat front surface, non-protruding surface) of the first carrier element of the carrier assembly 70. This configuration represents the default or neutral position of the lock assembly 30 when not in use.

[0068] Referring to FIG. 3, a front view of the lock 10 is shown. The lock 10 includes a housing 32 that forms the outer structure of the lock module assembly 34. The housing 32 may be designed to provide structural support and protection for the internal components of the lock assembly. The housing 32 defines a clearance slot 168 extending parallel to the actuation axis 38. The clearance slot 168 is configured to accommodate movement of the validation bar 76 and control rotation of the locking module assembly 34. This design feature further enhances the security of the lock by controlling the movement and interaction of the internal components.

[0069] Inside the keyway 39 of the lock module assembly 34, a key engaging assembly 102 may include at least one alignment pin 108. In FIG.3, when no key has been inserted into the keyway 39, the at least one alignment pin 108 may be aligned along the same axis parallel to the actuation axis 38. Because the at least one alignment pin 108 are aligned, the alignment pin(s) behind the front alignment pin 108 may not be visible in FIG.3.

[0070] A validation bar 76 is also included in the lock assembly 30. The validation bar 76 is movable with the carrier assembly 70 along the actuation axis. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0071] When the carrier assembly 70 has not been rotate relative to the housing, the validation bar 76 may be positioned near or at the center of the clearance slot 168. The proximal portion of the clearance slot 168 may have at least one angled surface 172. The angled surface may be characterized as recessed surfaces or ramped surfaces.

[0072] Referring to FIG.4, a perspective view of a mechanically keyed lock assembly 30 is shown. The validation bar 76 has been removed to show the components internal to the carrier assembly 70. The lock assembly 30 includes a locking module assembly 34 that extends along an actuation axis. The locking module assembly 34 comprises a carrier assembly 70, which is configured to rotate about and translate along the actuation axis. This configuration allows the carrier assembly 70 to move in response to the rotation of a key inserted into the lock assembly 30.Attorney Docket No.: 5193.004WO1

[0073] The lock assembly 30 further includes a key validating assembly 104 coupled to the carrier assembly 70. The key validating assembly 104 comprises a plurality of key validating elements corresponding to the key engaging elements. This configuration allows for a high degree of security by ensuring that the lock can only be operated with the correct key.

[0074] In FIG. 4, no key has been inserted, and the key validating elements of the key validating assembly are in an unvalidated or non-validated position, where one or more of the key validating elements 104 protrude through validation aperture 78. In other words, the unvalidated position is where the key validating elements of the key validating assembly are not positioned so that the validation bar 76 is received within the validation aperture 78 such that it is flush with or below the surface of the carrier assembly 70. The key validating elements may be in a validated position when the validation bar receiving structure 114, such as a notch, aligns with the validation aperture, such that the validation bar can recede into the validation aperture 78.

[0075] In some cases, the key validating assembly 104 may also be in an unvalidated position when an incorrect key has been inserted into the keyway 39. This configuration represents a state of the lock assembly 30 where the key validating elements are not aligned with the key engaging elements, indicating that an incorrect key has been used.

[0076] When in an unvalidated position, the validation bar may be physically locked out from being able to rotate past the point of validation for unlocking the lock.

[0077] Referring to FIG.5, a sectional view of the lock module assembly 34 is shown. In this configuration, no key has been inserted into the keyway 39. The locking module assembly 34 includes a key engaging assembly 102 configured to interact with a key. The key engaging assembly 102 comprises a plurality of key engaging elements arranged along the actuation axis. These key engaging elements are designed to interact with the corresponding bitting of a key when inserted into the keyway 39. The bitting of a key may be considered a specific code a specific code that defines the unique cut depths on the key blade. The bitting code corresponds to the cuts that interact with the pins or wafers in a lock mechanism, allowing the key to unlock or engage the lock. Each cut in the key is associated with a particular depth, and the sequence of these depths forms the bitting code.

[0078] The lock assembly 30 further comprises a spacer assembly 106 rotationally coupled to the carrier assembly 70. The spacer assembly 106 comprises a plurality of spacers, each spacer positioned adjacent to a corresponding key validating element. The spacers in the spacer assembly 106 provide a physical separation between the key validating elements and the key engaging elements, allowing for independent movement and interaction of theseAttorney Docket No.: 5193.004WO1 components. The spacer assembly may be positionally (e.g., translationally) locked in place because the distal cap 54 limits the movement of the lock assembly 30. In some examples, a wave spring may be positioned between distal cap 54 and lock assembly 30 to urge lock assembly 30 away from distal cap 54.

[0079] In this configuration, the key validating elements of the key validating assembly 104 and the key engaging elements of the key engaging assembly 102 are aligned. In such cases, the key validating assembly 104 may physically contact the key engaging assembly 102. This alignment allows for the key validating elements and the key engaging elements to interact directly with each other when a key is inserted into the keyway 39. The alignment of these elements is crucial for the operation of the lock, as it allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0080] In some examples, the key validating elements and the key engaging elements may be designed to move radially about the actuation axis in response to the insertion and rotation of a key. This radial movement allows for the precise alignment and interaction of these elements, further enhancing the security and functionality of the lock assembly.

[0081] In some cases, the spacer assembly 106 may be designed to rotate in conjunction with the carrier assembly 70. This rotational coupling allows for the coordinated movement and interaction of the key validating elements, the key engaging elements, and the spacers, providing a robust and secure locking mechanism.

[0082] In some embodiments, the spacer assembly 106, the key validating assembly 104, and the key engaging assembly 102 may be formed from hardened stainless steel or other durable materials. This construction provides a high level of durability and wear resistance, ensuring the long-term reliability and performance of the lock assembly.

[0083] In some examples, the spacer assembly 106, the key validating assembly 104, and the key engaging assembly 102 may be designed for easy assembly and disassembly. This modular design allows for easy maintenance and repair of the lock assembly, as well as potential customization for specific locking applications.

[0084] In some cases, the key validating assembly 104, the key engaging assembly 102, and the spacer assembly 106 may be designed to fit within a specific type of door or locking application. This adaptability allows for the lock assembly to be used in a wide range of applications, providing a versatile and flexible locking solution.

[0085] Referring to FIG.6, a perspective view of a key 180 for use with the mechanically keyed lock assembly 30 is shown. The key 180 may include an elongated shaft extending from a handle portion to a tip. The handle portion may have a generally square or rectangular shapeAttorney Docket No.: 5193.004WO1 with rounded corners, providing a gripping surface for a user. The shaft of the key 180 may include a keyed section 182 near its tip. The keyed section 182 may include a key bitting, which may be specific cuts that correspond to the lock’s key engaging assembly. The key bitting may resemble that of a double-sided or four-sided key. The keyed section 182 may have bitting cuts on two opposite edges of the keyed section 182. In some cases, the keyed section 182 may have bitting on all four sides of the key shaft. The insertion of key 180 may cause the key engaging elements of the key engaging assembly to move into positions based on the bitting, such as radial movement around the actuation axis 38.

[0086] In some examples, the key 180 may be designed to interact with the key engaging assembly 102 in a specific manner. The key 180 may be inserted into the keyway 39 of the lock module assembly 34, causing the key engaging elements of the key engaging assembly 102 to move into positions corresponding to the bitting of the key 180. This interaction between the key 180 and the key engaging assembly 102 may be crucial for the operation of the lock assembly, as it allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0087] In some cases, the key 180 may be designed with a specific bitting configuration to match the key engaging elements of the key engaging assembly 102. This bitting configuration may be unique to each individual lock assembly, providing a high level of security by ensuring that only the correct key can operate the lock. The bitting configuration of the key 180 may be determined based on the specific requirements of the locking application, such as the level of security required or the specific locking mechanism used in the lock assembly.

[0088] Referring to FIG. 7, a sectional front view of the lock 10 is shown. In this configuration, a key has been inserted into the keyway 39 of the lock module assembly 34. The key may be a correct key or an incorrect key. The insertion of the key into the keyway 39 causes the alignment pins 108 of the key engaging assembly 102 to move radially about the actuation axis 38. This radial movement of the alignment pins 108 is directly linked to the specific bitting of the key, allowing for the precise alignment and interaction of the key engaging elements with the key.

[0089] In some examples, the alignment pins 108 may be designed to interact with the bitting of the key in a specific manner. The alignment pins 108 may move into positions corresponding to the bitting of the key when the key is inserted into the keyway 39. This interaction between the alignment pins 108 and the key bitting allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.Attorney Docket No.: 5193.004WO1

[0090] In some cases, the alignment pins 108 may be designed to move into different positions based on the bitting of different keys. This allows for the lock assembly to be operated with different keys, each having a unique bitting configuration. This feature enhances the versatility of the lock assembly, allowing it to be used in various locking applications where different keys may be required.

[0091] In some embodiments, the alignment pins 108 may be designed to move into a specific position when an incorrect key is inserted into the keyway 39. This specific position of the alignment pins 108 may prevent the rotation of the locking module assembly 34, thereby preventing the unlocking of the lock assembly. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0092] In some examples, the alignment pins 108 may be designed to move into positions corresponding to the bitting of the received key. This configuration of the alignment pins 108 allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0093] Referring to FIG.8, a perspective view of a lock module assembly 34 is shown. In this configuration, the key validating assembly is in a validated position. The validated position is characterized by the alignment of the validation bar receiving structures, such as notches, with the validation aperture 78. This alignment allows the validation bar 76 to be received within the validation aperture 78. Surfaces of the validation bar receiving structure 114 may be flush with the surfaces of the validation aperture 78 to allow complete access of the validation aperture 78 by the validation bar 76.

[0094] In some examples, the validation bar 76 may be flush with or below the surface of the carrier assembly 70 when the key validating assembly is in the validated position. This configuration indicates that the correct key has been used to operate the lock assembly. The validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0095] In some cases, the validation bar receiving structures of the key validating elements may be notches. When the key validating elements are in a validated position, each of the notches may align with the validation aperture 78. The surfaces of each of the notches may become flush with the surfaces of the validation aperture 78. This alignment of the notches with the validation aperture 78 allows the validation bar 76 to recede into the validation aperture 78, indicating that the correct key has been used.Attorney Docket No.: 5193.004WO1

[0096] In other aspects, the key validating elements may be designed to move into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key. This interaction between the key validating elements, the carrier assembly 70, and the key allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0097] In some embodiments, the lock assembly may further include a displacement mechanism configured to induce relative movement between the carrier assembly and the housing. This relative movement may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly. The displacement mechanism may include one or more angled surfaces on either the carrier assembly or the housing, and corresponding interaction surfaces on the other of the carrier assembly or the housing. The interaction between these surfaces may facilitate the relative movement and the subsequent separation of the key validating assembly from the key engaging assembly.

[0098] Referring to FIG. 9, a back view of the lock assembly is shown. In this configuration, the validation bar 76 may be positioned within the clearance slot 168 of the housing 32. The clearance slot 168 extends parallel to the actuation axis 38 and is configured to accommodate movement of the validation bar 76 and control rotation of the locking module assembly 34. This design feature further enhances the security of the lock by controlling the movement and interaction of the internal components.

[0099] In this view, the visible components of the lock module assembly 34 include the distal cap 54, the carrier assembly 70, and the locking module 36. The distal cap 54 is attached to the lock module assembly 34 at the end opposite the keyway 39. The distal cap 54 may provide structural support to the lock module assembly 34 and may also serve as a stopper to prevent the internal components of the lock module assembly 34 from moving beyond a certain point. In some examples, a wave spring may be disposed between distal cap 54 and lock module assembly 34 to urge lock module assembly 34 away from distal cap 54. The spring force of the wave spring may provide feedback or resistance when actuating lock module assembly 34, particularly when moving from a validated configuration toward a re-keying configuration to reduce or prevent accidental transition to the rekeying configuration.

[0100] In some embodiments, the lock assembly may include a magnetic retention mechanism for maintaining the validation bar 76 in selected positions during operation. The magnetic retention mechanism may comprise one or more magnetic elements positioned within the carrier assembly 70 or housing 32 that interact with the validation bar 76 to provideAttorney Docket No.: 5193.004WO1 controlled retention forces. The magnetic elements may be permanent magnets, electromagnets, or magnetizable materials that create magnetic attraction or repulsion forces to hold the validation bar 76 in predetermined positions such as the locked position, unlocked position, or rekeying position. In some examples, the magnetic retention mechanism may provide tactile feedback to a user during key operation, indicating when the lock assembly has reached specific operational states. The magnetic forces may be calibrated to allow normal operation while preventing inadvertent movement of the validation bar 76 due to vibration or external forces.

[0101] The carrier assembly 70 forms the outer structure of the locking module 36 and is configured to rotate about and translate along the actuation axis 38. The carrier assembly 70 may include a cam protrusion 126 that extends from the proximal end of the lock module assembly 34. The cam protrusion 126 may be a displacement mechanism configured to induce relative movement between the carrier assembly 70 and the housing 32. This relative movement may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

[0102] The locking module 36 is housed within the carrier assembly 70 and may include various components such as a key engaging assembly and a key validating assembly. These components work together to enable the locking and unlocking functions of the lock assembly.

[0103] Referring to FIG. 10, a side view of a mechanically keyed lock assembly 30 is shown. In this configuration, the carrier assembly 70 is positioned within the housing 32. The carrier assembly 70 is configured to rotate about and translate along the actuation axis 38. This configuration allows the carrier assembly 70 to move in response to the rotation of a key inserted into the lock assembly 30.

[0104] The carrier assembly 70 includes a cam protrusion 126 that extends from the proximal end of the lock module assembly 34. The cam protrusion 126 may be a displacement mechanism configured to induce relative movement (e.g., translational movement, axial movement) between the carrier assembly 70 and the housing 32. This relative movement may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

[0105] In some examples, the cam protrusion 126 may be designed to interact with a corresponding feature on the housing 32, such as a pocket or groove. This interaction may facilitate the relative movement of the carrier assembly 70 and the housing 32, allowing for the separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.Attorney Docket No.: 5193.004WO1

[0106] The lock assembly 30 also includes a proximal cap 52 and a distal cap 54. The proximal cap 52 is positioned at the proximal end of the lock module assembly 34, while the distal cap 54 is positioned at the distal end of the lock module assembly 34. The proximal cap 52 and the distal cap 54 may provide structural support to the lock module assembly 34 and may also serve as stoppers to prevent the internal components of the lock module assembly 34 from moving beyond certain points.

[0107] In FIG.10, when no key has been inserted into the keyway 39, the carrier assembly 70 is not rotated or translated relative to the housing, and the proximal cap 52 is coplanar with the front surface of the first carrier element of the carrier assembly 70. In such cases, the proximal cap 52 does not protrude or extend from the first carrier element of the carrier assembly 70. This configuration represents the default or neutral position of the lock assembly 30 when not in use.

[0108] Referring to FIG.11, a perspective view of a lock 10 is shown when a key has been inserted and rotated. The lock 10 includes a lock body 40 that houses a mechanically keyed lock assembly 30. The lock assembly 30 includes a lock module assembly 34 positioned within the lock body 40. The lock module assembly 34 may be a cylindrical structure with a keyway 39 at one end for receiving a key.

[0109] In this configuration, the carrier assembly 70 has been rotated and translated relative to the housing 32 in response to the rotation of the key. This rotation and translation of the carrier assembly 70 cause a physical separation between the key validating assembly 104 and the key engaging assembly 102. This separation is a key feature of the lock assembly's operation, as it allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0110] The validation bar 76, which is movable with the carrier assembly 70 along the actuation axis, has also shifted in position (e.g., radially inward) due to the rotation and translation of the carrier assembly 70. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0111] The proximal cap 52, which is positioned at the proximal end of the lock module assembly 34, has also shifted in position (e.g., radially) due to the rotation and translation of the carrier assembly 70. In this configuration, the proximal cap 52 is not coplanar with the front surface of the first carrier element of the carrier assembly 70 as compared to FIGS. 1, 2, 4, 5,Attorney Docket No.: 5193.004WO1 and 8. This shift in position of the proximal cap 52 is a direct result of the movement of the carrier assembly 70 and indicates that the lock assembly is in the process of being unlocked.

[0112] Referring to FIG.12, the housing 32 of the lock assembly is depicted in more detail. The housing 32 includes a body portion 140 having a proximal end 142 and a distal end 144. In some embodiments, the proximal end 142 includes a flange portion 146 that defines an access port 148 for passage of the mechanical key. The flange portion 146 may be designed to provide a secure and stable interface for the key, ensuring accurate and reliable operation of the lock assembly.

[0113] The body portion 140 of the housing 32 defines a clearance slot 168, also referred to as a validation bar slot. The clearance slot 168 includes a recessed surface 172 that defines a radius R relative to the actuation axis 38 about a transition angle ^. The clearance slot 168 may include ramped lateral edges 174 that transition from the recessed surface 172. The clearance slot 168 is configured to accommodate movement of the validation bar 76 and control rotation of the locking module assembly 34. This design feature further enhances the security of the lock by controlling the movement and interaction of the internal components.

[0114] Rotation of the carrier assembly 70 may cause the angled cam surface 130 of the cam protrusion 126 to slide against the pocket 164 of the stationary flange portion 146 of the housing 32, thereby causing the carrier 70 to be translated axially along the carrier axis 72 as the locking module assembly 34 is rotated through the transition angle ^. The axial translation of the carrier assembly 70 may cause the key validating elements of the key validating assembly 104, which are coupled to the carrier elements of the carrier assembly 70, to slide out of engagement with the key validating elements 104 and into engagement with the spacer 106.

[0115] As rotation of the locking module assembly 34 and carrier 70 continues through and beyond the transition angle ^, the ramped lateral edge 174 of the clearance slot 168 forces the validation bar 76 radially inward, toward the actuation axis 38, so that the validation bar 76 is seated within the validation receiving structure 114, such as notches, of the key validating element 104. Rotation may continue until the mechanically keyed lock assembly 30 is in a fully unlocked configuration.

[0116] In some cases, the housing 32 may be formed from a metal alloy through an injection molding process. This manufacturing process may provide a high level of precision and consistency in the production of the housing 32, ensuring accurate and reliable operation of the lock assembly. The housing 32 may also be designed to provide structural support and protection for the internal components of the lock assembly, further enhancing the durability and longevity of the lock assembly.Attorney Docket No.: 5193.004WO1

[0117] Referring to FIG.13, a front view of the lock 10 is shown when the carrier assembly 70 has been rotated and translated relative to the housing 32. In this configuration, the key validating assembly 104 is moved relative to the key engaging assembly 102, causing a physical separation between these two assemblies. This separation is a key feature of the lock assembly's operation, as it allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0118] The validation bar 76, which is movable with the carrier assembly 70 along the actuation axis, has also shifted in position due to the rotation and translation of the carrier assembly 70. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0119] The carrier assembly 70 may be rotated relative to the housing 32 to the point of rotation at which the carrier assembly 70 is translated relative to the housing 32 that causes isolation or separation between the key validating assembly 104 and the key engaging assembly 102. The translation may occur at any point when the validation bar 76 is shifted radially inward. In some cases, the translation may occur prior to the point when the validation bar 76 contacts the angled surfaces (e.g., recessed surface 172 or ramped lateral edges 174) of housing 32.

[0120] In some examples, the lock assembly may be designed to provide a high level of security by ensuring that the lock can only be operated with the correct key. The key validating elements of the key validating assembly may be designed to move into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key. This interaction between the key validating elements, the carrier assembly 70, and the key allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0121] Referring to FIG.14, a back view of the lock module assembly 34 is shown. In this configuration, the validation bar 76 may be shifted radially inward just before contacting the angled surfaces (e.g., recessed surface 172 or ramped lateral edges 174) of housing 32 when translation of the carrier assembly 70 relative to the housing 32 occurs. The back view shows the validation bar 76 positioned on an axis parallel to the actuation axis 38 along a circumference just outside the outer circumference of the distal cap 54. This radial inward shiftAttorney Docket No.: 5193.004WO1 of the validation bar 76 is a direct result of the rotation and translation of the carrier assembly 70 in response to the rotation of a key inserted into the keyway 39.

[0122] In some examples, the validation bar 76 may be designed to move radially inward in response to the rotation and translation of the carrier assembly 70. This movement of the validation bar 76 may be crucial for the validation of the correct key insertion and the subsequent unlocking of the lock assembly. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some cases, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0123] Referring to FIG. 15, a side view of a mechanically keyed lock assembly 30 is shown. In this configuration, the carrier assembly 70 has been translated relative to the housing 32. The translation of the carrier assembly 70 is facilitated by the interaction of the cam protrusion 126 with the pocket 164 of the stationary flange portion 146 of the housing 32. As the carrier assembly 70 translates, the proximal cap 52 protrudes or extends from the carrier assembly 70. The cam protrusion 126 may become coplanar with the front surface of the proximal cap 52. This protrusion of the proximal cap 52 is a direct result of the movement of the carrier assembly 70 and indicates that the lock assembly is in the process of being unlocked.

[0124] In some examples, the distal cap 54 may include slotted tracks that allow the last lock module assembly, adjacent to the distal cap 54, to slide along the tracks. Less of the slotted tracks are visible in FIG.15 since the carrier assembly 70 is translated toward the distal cap 52 when compared to FIG.10. This sliding movement may facilitate the translation of the carrier assembly 70 and the subsequent separation of the key validating assembly from the key engaging assembly. The slotted tracks on the distal cap 54 may be designed to provide a smooth and controlled movement of the last lock module assembly, ensuring accurate and reliable operation of the lock assembly.

[0125] In some cases, the translation of the carrier assembly 70 may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly. This separation is a physical action within the lock mechanism that occurs as part of the validation process. The separation of the key validating assembly from the key engaging assembly may enhance the security of the lock by ensuring that the lock can only be operated with the correct key.

[0126] Referring to FIG. 16, a sectional view of the lock module assembly is shown. In this configuration, the carrier assembly 70 has been moved relative to the housing 32. This movement is facilitated by the interaction of the cam protrusion 126 with the pocket 164 of theAttorney Docket No.: 5193.004WO1 stationary flange portion 146 of the housing 32. As the carrier assembly 70 translates, the proximal cap 52 protrudes or extends from the carrier assembly 70. This protrusion of the proximal cap 52 is a direct result of the movement of the carrier assembly 70 and indicates that the lock assembly is in the process of being unlocked.

[0127] In some examples, the distal cap 54 may include slotted tracks that allow the last lock module assembly, adjacent to the distal cap 54, to slide along the tracks. This sliding movement may facilitate the translation of the carrier assembly 70 and the subsequent separation of the key validating assembly from the key engaging assembly. The slotted tracks on the distal cap 54 may be designed to provide a smooth and controlled movement of the last lock module assembly, ensuring accurate and reliable operation of the lock assembly.

[0128] In some cases, the key validating assembly 104 is slid out of engagement with the key engaging assembly 102 and into engagement with spacer 106. In contrast to FIG. 5, the key validating assembly 104 and the key engaging assembly 102 are slid out of engagement with each other, such that their circumferences are aligned in parallel planes, maintaining a distance between them, or their circumferences are spaced apart along a common axis, maintain parallel planes. In FIG. 5, the circumferences of the key engaging assembly 102 and key validating assembly may be in the same plane.

[0129] In some cases, the translation of the carrier assembly 70 may cause separation of the key validating assembly from the key engaging assembly during operation of the lock assembly. This separation is a physical action within the lock mechanism that occurs as part of the validation process. The separation of the key validating assembly from the key engaging assembly may enhance the security of the lock by ensuring that the lock can only be operated with the correct key.

[0130] Referring to FIG.17, a perspective view of a lock 10 is shown when a key has been inserted and rotated. The lock 10 includes a lock body 40 that houses a mechanically keyed lock assembly 30. The lock assembly 30 includes a lock module assembly 34 positioned within the lock body 40. The lock module assembly 34 may be a cylindrical structure with a keyway 39 at one end for receiving a key.

[0131] In this configuration, the carrier assembly 70 has been rotated and translated relative to the housing 32 in response to the rotation of the key. This rotation and translation of the carrier assembly 70 cause a physical separation between the key validating assembly 104 and the key engaging assembly 102. This separation is a key feature of the lock assembly's operation, as it allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.Attorney Docket No.: 5193.004WO1

[0132] The validation bar 76, which is movable with the carrier assembly 70 along the actuation axis, has also shifted in position due to the rotation and translation of the carrier assembly 70. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0133] As the carrier assembly 70 rotates and translates, the validation bar 76 may shift radially inward toward the angled surfaces of the clearance slot 168. The validation bar 76 may be fully seated within the validation aperture 78 when it reaches or passes the point of validation, where the angled surface guides it into the aperture after the key validating assembly 104 is in a validated position, indicating the correct key has been used (i.e., the obstruction by the key validating elements in the aperture 78 is cleared).

[0134] The proximal cap 52, which is positioned at the proximal end of the lock module assembly 34, has also shifted in position due to the rotation and translation of the carrier assembly 70. In this configuration, the proximal cap 52 is not coplanar with the front surface of the first carrier element of the carrier assembly 70. This shift in position of the proximal cap 52 is a direct result of the movement of the carrier assembly 70 and indicates that the lock assembly is in the process of being unlocked.

[0135] Referring to FIG.18, a front view of the lock 10 at the point of validation is shown. In this configuration, the validation bar 76 may be shifted radially inward just before contacting the angled surfaces (e.g., recessed surface 172 or ramped lateral edges 174) of housing 32 when translation of the carrier assembly 70 relative to the housing 32 occurs. This radial inward shift of the validation bar 76 is a direct result of the rotation and translation of the carrier assembly 70 in response to the rotation of a key inserted into the keyway 39.

[0136] In some examples, the validation bar 76 may be designed to move radially inward in response to the rotation and translation of the carrier assembly 70. This movement of the validation bar 76 may be crucial for the validation of the correct key insertion and the subsequent unlocking of the lock assembly. The validation bar 76 may interact with the internal components of the lock module assembly 34 to validate the correct key insertion. In some cases, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position.

[0137] At the point of validation, the validation bar 76 may contact the angled surfaces of the clearance slot 168 to start the process of the validation bar 76 receding into the validation aperture 78.Attorney Docket No.: 5193.004WO1

[0138] Referring to FIG. 19, a perspective view of the lock module assembly 34 at the point of validation is shown. In this configuration, the key validating elements of the key validating assembly 104 are in a validated position. The validated position is characterized by the alignment of the validation bar receiving structures, such as notches, with the validation aperture 78. This alignment allows the validation bar 76 to be received within the validation aperture 78. The validation bar 76 is removed to show that the notches of the key validating assembly 114 align with the validation aperture 78, such that the key validating elements of the key validating assembly 114 are not obstructions to preventing the validation bar 76 from fully seating within the validation aperture 78.

[0139] In some examples, the validation bar 76 may be flush with or below the surface of the carrier assembly 70 when the key validating assembly is in the validated position. This configuration indicates that the correct key has been used to operate the lock assembly. The validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0140] In some cases, the validation bar receiving structures of the key validating elements may be notches. When the key validating elements are in a validated position, each of the notches may align with the validation aperture 78. The surfaces of each of the notches may become flush with the surfaces of the validation aperture 78. This alignment of the notches with the validation aperture 78 allows the validation bar 76 to recede into the validation aperture 78, indicating that the correct key has been used.

[0141] In other aspects, the key validating elements may be designed to move into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key. This interaction between the key validating elements, the carrier assembly 70, and the key allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0142] At the point of validation, the protruding surface of the cam protrusion 126 may be coplanar with the circumferential surface of the proximal cap 52.

[0143] Referring to FIG. 20, a side view of a lock module assembly 34 at the point of validation is shown. In this configuration, the carrier assembly 70 has been rotated and translated relative to the housing 32 to the point of validation. The point of validation is characterized by the alignment of the validation bar receiving structures, such as notches, with the validation aperture 78. This alignment allows the validation bar 76 to be received withinAttorney Docket No.: 5193.004WO1 the validation aperture 78, indicating that the correct key has been used to operate the lock assembly.

[0144] At the point of validation, the validation bar is shifted radially toward the angled surface of the clearance slot 168. The protruding portion of the cam protrusion 126 appears to align with the front surface of the proximal cap 52.

[0145] In some examples, the validation bar 76 may be flush with or below the surface of the carrier assembly 70 when the key validating assembly is in the validated position. This configuration indicates that the correct key has been used to operate the lock assembly. The validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0146] In some cases, the validation bar receiving structures of the key validating elements may be notches. When the key validating elements are in a validated position, each of the notches may align with the validation aperture 78. The surfaces of each of the notches may become flush with the surfaces of the validation aperture 78. This alignment of the notches with the validation aperture 78 allows the validation bar 76 to recede into the validation aperture 78, indicating that the correct key has been used.

[0147] In other aspects, the key validating elements may be designed to move into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key. This interaction between the key validating elements, the carrier assembly 70, and the key allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0148] Referring to FIG. 21, a perspective view of a lock module assembly 34 is shown after validation. When the correct key has been inserted into the keyway, the key validating elements are in a validated position, and the carrier assembly 70 has been translated and rotated at or past the point of validation, the validation bar 76 may recede into the validation aperture 78, such that the validation bar 76 may be flush with the surface of the carrier assembly 70, protrude from the validation aperture 78 slightly, or the exposed surface of the validation bar 76 is at a lower height than the surface of the carrier assembly 70. In previous figures, such as FIG. 2, the validation bar 76 protrude from the validation aperture 78 more prominently. In contrast to FIG. 2, the carrier assembly 70 is rotated past the point of validation with the validation bar 76 noticeably shifted inwardly.Attorney Docket No.: 5193.004WO1

[0149] In this configuration, the validation bar 76 has receded into the validation aperture 78. The receded position of the validation bar 76 indicates that the correct key has been used to operate the lock assembly. The validation bar 76 may be flush with or below the surface of the carrier assembly 70 when the key validating assembly is in the validated position. This configuration indicates that the correct key has been used to operate the lock assembly.

[0150] In some examples, the validation bar 76 may be designed to prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0151] In some cases, the validation bar receiving structures of the key validating elements may be notches. When the key validating elements are in a validated position, each of the notches may align with the validation aperture 78. The surfaces of each of the notches may become flush with the surfaces of the validation aperture 78. This alignment of the notches with the validation aperture 78 allows the validation bar 76 to recede into the validation aperture 78, indicating that the correct key has been used.

[0152] In other aspects, the key validating elements may be designed to move into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key. This interaction between the key validating elements, the carrier assembly 70, and the key allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0153] Referring to FIG. 22, a perspective view of a lock module assembly 34 in a rekeying position is shown. When the key validating assembly 104 is in a validated position and the validating bar 76 is receded within the validation aperture 78, which may prevent further rotation of the key validating assembly 104, the carrier assembly may be translated further toward the distal cap 54. A new key may be inserted into the keyway 39 to move the key engaging elements of the key engaging assembly 102 into positions corresponding to the new key, and the key validating assembly may be translated back to engage with the key engaging component.

[0154] In this configuration, the carrier assembly 70 can be translated further toward the distal cap 54. This additional translation of the carrier assembly 70 is facilitated by the interaction of the cam protrusion 126 with the pocket 164 of the stationary flange portion 146 of the housing 32. As the carrier assembly 70 translates, the proximal cap 52 protrudes or extends from the carrier assembly 70. This protrusion of the proximal cap 52 is a direct resultAttorney Docket No.: 5193.004WO1 of the movement of the carrier assembly 70 and indicates that the lock assembly is in the process of being rekeyed.

[0155] In some examples, a new key may be inserted into the keyway 39 to move the key engaging elements of the key engaging assembly 102 into positions corresponding to the new key. This interaction between the new key and the key engaging assembly 102 allows for the reconfiguration of the lock assembly to match the new key.

[0156] In some cases, the key validating elements of the key validating assembly 104 may be moved into new positions corresponding to the new key. This movement of the key validating elements into the new positions may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the new key. This interaction between the key validating elements, the carrier assembly 70, and the new key allows for the reconfiguration of the lock assembly to match the new key.

[0157] In some examples, the rekeying functionality of the lock assembly may incorporate mechanisms similar to those employed in conventional lock systems, such as those manufactured by Schlage, Kwikset, or other established lock manufacturers. The rekeying process may utilize removable key plugs, master keying capabilities, or progressive key systems that allow authorized personnel to reconfigure the lock without complete disassembly. The lock assembly may include rekeying tools or fixtures that interface with the key validating elements and key engaging elements to facilitate repositioning or replacement of internal components. In some cases, the rekeying mechanism may employ spring-loaded pins, wafers, or other conventional locking elements that can be accessed and adjusted through specialized procedures or tools. The modular design of the carrier assembly 70 and associated components may accommodate various rekeying protocols established in the lock industry, providing compatibility with existing key management systems and security procedures.

[0158] Referring to FIG.23, a perspective view of a disassembled lock module assembly 34 is shown. In this view, the carrier elements of the carrier assembly 70 have been removed to reveal the internal components of the lock module assembly 34. The key validating assembly 104, key engaging assembly 102, and spacer assembly 106 are visible in this disassembled view, providing a clear illustration of their relative positions and interactions within the lock module assembly 34.

[0159] The key validating assembly 104 is coupled to the carrier assembly 70 and comprises a plurality of key validating elements. These key validating elements are designed to interact with the key engaging elements of the key engaging assembly 102 to validate the correct key insertion. In some examples, the key validating elements may be designed to moveAttorney Docket No.: 5193.004WO1 into a validated position when a correct key is inserted into the keyway 39. The movement of the key validating elements into the validated position may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the key.

[0160] The key engaging assembly 102 is configured to interact with a key and comprises a plurality of key engaging elements arranged along the actuation axis. These key engaging elements are designed to interact with the corresponding bitting of a key when inserted into the keyway 39. In some cases, the key engaging elements may be designed to move into positions corresponding to the bitting of the key when the key is inserted into the keyway 39. This interaction between the key engaging elements and the key bitting allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0161] The spacer assembly 106 is rotationally coupled to the carrier assembly 70 and comprises a plurality of spacers. Each spacer is positioned adjacent to a corresponding key validating element. The spacers in the spacer assembly 106 provide a physical separation between the key validating elements and the key engaging elements, allowing for independent movement and interaction of these components. In some examples, the spacer assembly 106 may be designed to rotate in conjunction with the carrier assembly 70. This rotational coupling allows for the coordinated movement and interaction of the key validating elements, the key engaging elements, and the spacers, providing a robust and secure locking mechanism.

[0162] At the proximal end of the lock module assembly is the proximal cap 52. The key validating assembly 104 may engage with either the key engaging assembly 102 or the spacer assembly 106. For example, when a key has not been inserted into the keyway 39, the key validating assembly 104 may engage with the key engaging assembly 102. When a correct key has been inserted into the keyway 39 and the carrier assembly 70 rotated and translated relative to the housing 32, the key validating assembly 104 may engage with the spacer assembly 106.

[0163] Referring to FIG. 24, a perspective view of the disassembled components of the lock module assembly is shown. The lock module assembly includes a carrier assembly 70, a key validating assembly 104, a key engaging assembly 102, and a spacer assembly 106. Each of these components plays a crucial role in the operation of the lock assembly.

[0164] The carrier assembly 70 is designed to rotate about and translate along the actuation axis. The carrier assembly 70 may be formed by joining multiple carrier elements together. In some cases, the carrier elements may be laser welded together to form a robust and durable structure. The carrier assembly 70 may include a plurality of carrier elements, each carrier element positioned adjacent to a corresponding key validating element.Attorney Docket No.: 5193.004WO1

[0165] The key validating assembly 104 is coupled to the carrier assembly 70 and comprises a plurality of key validating elements. The key validating elements are designed to interact with the key engaging elements of the key engaging assembly 102 to validate the correct key insertion. The key validating elements may be arranged into validated positions within the carrier assembly 70. The key validating elements may be coupled to the carrier assembly 70 by positioning the key validating elements into recesses, grooves, or cavities of the carrier elements of the carrier assembly 70 or ensuring contact between the surfaces of the key validating element and the surfaces of the carrier element.

[0166] The key engaging assembly 102 is configured to interact with a key and comprises a plurality of key engaging elements arranged along the actuation axis. The alignment pins 108 of the key engaging elements are designed to interact with the corresponding bitting of a key when inserted into the keyway. The alignment pins of the key engaging elements may be designed to move into positions corresponding to the bitting of the key when the key is inserted into the keyway.

[0167] The spacer assembly 106 is rotationally coupled to the carrier assembly 70 and comprises a plurality of spacers. Each spacer is positioned adjacent to a corresponding key validating element. The spacers in the spacer assembly 106 provide a physical separation between the key validating elements and the key engaging elements, allowing for independent movement and interaction of these components.

[0168] In some examples, the spacer assembly 106, the key validating assembly 104, and the key engaging assembly 102 may be formed from hardened stainless steel or other durable materials. This construction provides a high level of durability and wear resistance, ensuring the long-term reliability and performance of the lock assembly.

[0169] Each of the carrier elements, key validating elements, key engaging elements, and spacer elements may have mating structures, such as arcuate teeth. The teeth of the key validating element may engage with the teeth of either the spacer element or the key engaging element.

[0170] The outer circumference of the spacer element and the key engaging element correspond to the opening of the key validating element to facilitate translation from the key engaging element to the spacer element, and vice versa. The spacer element and the key engaging element may be received within the key validating element.

[0171] The spacer element includes an outer circumference and a central protruding portion extending from the spacer element’s surface. The protruding portion has a smaller outer circumference, forming a stepped profile, which is sized to receive and securely seat a keyAttorney Docket No.: 5193.004WO1 engaging element around the protruding portion. When the notches of the key validating elements align with the notches carrier elements, the validation bar may contact the notch base or notch floor of the notches of the carrier elements and / or key validating elements.

[0172] Referring to FIG. 25, a view of the individual components of the lock module assembly is shown. The lock module assembly includes a carrier assembly 70, a key validating assembly 104, a key engaging assembly 102, and a spacer assembly 106. Each of these components plays a crucial role in the operation of the lock assembly.

[0173] The top left element is a carrier element of the carrier assembly 70. The carrier element may be a circular structure with gear-like teeth around its outer edge. The carrier element may include a notch, which appears as a small indentation on its upper edge; the notches of the carrier elements may form the validation aperture 78.

[0174] Below the carrier 70 is a key validating element of the key validating assembly 104. The key validating element may be a circular structure with gear-like teeth around its outer edge. The key validating element may be a notch 114; the notches of the key validating elements may form the validation aperture when they are aligned with the notches of the carrier elements.

[0175] On the right side of the figure, the top element is a spacer element of the spacer assembly 106. The spacer element may have a circular shape with gear-like teeth around its outer edge and a semi-circular cutout in its center.

[0176] The bottom right element is a key engaging element of the key engaging assembly 102. Like the other components, the key engaging element may have a circular structure with gear-like teeth around its outer edge. The key engaging assembly 102 may include an alignment pin 108, which appears as a small protrusion extending from its inner surface towards the center.

[0177] The arrangement of these components may be a modular design where each element interacts with the others to form a complete locking mechanism. The gear-like teeth on each component may allow for precise rotational alignment and interaction between the parts. The validation aperture 78, validation bar receiving structure 114, and alignment pin 108 contribute to the proper functioning and security of the locking mechanism.

[0178] The arrangement of these components suggests a modular design where each element interacts with the others to form a complete locking mechanism. The gear-like teeth on each component likely allow for precise rotational alignment and interaction between the parts. The validation notch 78, validation slot 114, and alignment pin 108 appear to be features that contribute to the proper functioning and security of the locking mechanism.Attorney Docket No.: 5193.004WO1

[0179] Referring to FIG. 26, a flowchart depicting a method 300 for operating a lock assembly is shown. The method 300 outlines the sequence of steps involved in the key validation and lock operation process.

[0180] In step 302, a key is received in a locking module assembly. This step initiates the lock operation process by introducing the key into the system. The key may be inserted into a keyway of the lock module assembly, which may be positioned near or at the center of an actuation axis.

[0181] In step 304, a carrier assembly is rotated relative to a housing in response to key rotation. This rotation of the carrier assembly is directly linked to the physical turning of the key by the user. The carrier assembly may include a cam protrusion that extends from the proximal end of the lock module assembly. The cam protrusion may be a displacement mechanism configured to induce relative movement between the carrier assembly and the housing.

[0182] In step 306, a key validating assembly is moved relative to a key engaging assembly. This movement is a result of the carrier assembly rotation and is part of the mechanism to verify the key's authenticity. The key validating assembly, which is coupled to the carrier assembly, comprises a plurality of key validating elements corresponding to the key engaging elements.

[0183] Step 308 involves separating the key validating assembly from the key engaging assembly. This separation is a physical action within the lock mechanism that occurs as part of the validation process. The separation of the key validating assembly from the key engaging assembly may be facilitated by the relative movement between the carrier assembly and the housing, which is induced by the displacement mechanism.

[0184] In step 310, validation bar receiving structures are configured based on the received key. This configuration step determines whether the key is correct and authorized to operate the lock. The validation bar receiving structures may be configured to align with the validating bar when in a validated position. This alignment allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0185] In some examples, the method 300 further comprises enabling or preventing unlocking of the lock assembly based on the configuration of the key validating elements. This step is crucial for the security of the lock assembly, as it ensures that only the correct key can operate the lock.

[0186] In some cases, enabling or preventing unlocking may involve allowing or blocking movement of a validation bar based on the configuration of the key validating elements. TheAttorney Docket No.: 5193.004WO1 validation bar may be designed to prevent rotation of the locking module assembly unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0187] In other aspects, the method may include re-engaging the key validating assembly with the key engaging assembly. This step may occur after the key has been removed from the keyway, allowing the lock assembly to return to its default or neutral position. The re- engagement of the key validating assembly with the key engaging assembly ensures that the lock assembly is ready for the next operation.

[0188] In some embodiments, the method may also include a step of rotating the carrier assembly to a rekeying position, and aligning the key validating elements with a different set of key engaging elements. This step allows for the reconfiguration of the lock assembly to match a new key, providing a convenient method for rekeying the lock without the need for disassembly or replacement of components.

[0189] In some cases, configuring the key validating elements may involve rotating the key validating elements to positions corresponding to the bitting of the received key. This configuration step determines whether the key is correct and authorized to operate the lock. The key validating elements may be configured to align with the key engaging elements when in a validated position. This alignment allows for the validation of the correct key insertion and the subsequent unlocking of the lock assembly.

[0190] Referring to FIG. 27, a flowchart depicting a method 400 for assembling a lock assembly is shown. The method 400 outlines the sequence of steps involved in the construction and integration of the key components of the lock assembly.

[0191] In step 402, a carrier assembly is formed by joining multiple carrier elements. This step establishes the foundation of the lock assembly structure. The carrier elements may be joined together using various methods, such as laser welding, to form a robust and durable carrier assembly. Other welding methods include friction welding, ultrasonic welding, etc. Other joining methods may include precision assembly or tooling process, such as metalworking, which may involve jig and fixture-based assembly, die-casting, metal stamping, or precision assembly fixtures for aligning and assembling components. These methods may also be used to produce other components of the lock. The carrier assembly may be designed to rotate about and translate along an actuation axis, providing a unique mechanism for the operation of the lock.

[0192] In step 404, key validating elements are arranged into validated positions within the carrier assembly to form a key validating assembly. This arrangement is crucial for theAttorney Docket No.: 5193.004WO1 lock's validation mechanism. The key validating elements may be inserted into slots in the carrier assembly, ensuring their correct positioning and alignment.

[0193] In step 406, key engaging elements are aligned with the key validating elements to form a key engaging assembly. This alignment ensures proper interaction between these two sets of components. The key engaging elements are designed to interact with the corresponding bitting of a key when inserted into the keyway of the lock assembly.

[0194] Step 408 involves positioning spacers adjacent to the validating elements. The spacers play a role in the lock's internal structure and functionality. The spacers may be inserted adjacent to each key validating element, providing a physical separation between the key validating elements and the key engaging elements. The positioning of the spacers is a crucial step in the assembly process as it provides a physical separation between the key validating elements and the key engaging elements. This separation allows for independent movement and interaction of these components, enhancing the functionality and security of the lock assembly. In some examples, the positioning of the spacers may involve inserting a spacer adjacent to each key validating element. This configuration ensures the correct alignment and positioning of the spacers within the lock assembly.

[0195] In step 410, a validation bar is installed that interfaces with the key validating assembly. This bar is a component of the lock's security mechanism. The validation bar may be inserted through a clearance slot in the housing, ensuring its correct positioning within the lock assembly. The validation bar is a key component of the lock's security mechanism, designed to prevent rotation of the locking module assembly unless all key validating elements are in a validated position. The installation of the validation bar may involve inserting the bar through a clearance slot in the housing. This configuration ensures the correct positioning of the validation bar within the lock assembly and allows for its interaction with the key validating elements. In some cases, the validation bar may be designed to be flush with or below the surface of the carrier assembly when the key validating assembly is in the validated position. This feature enhances the security of the lock assembly by ensuring that only the correct key can operate the lock.

[0196] In step 412, a housing is formed that defines a cavity. This housing will contain and protect the internal components of the lock assembly. The housing may be formed from a variety of materials, such as metal or plastic, and may be shaped to fit within a specific type of door or locking application.

[0197] In step 414, the carrier assembly, along with its associated components, is positioned within the cavity of the housing. This step involves the integration of the carrierAttorney Docket No.: 5193.004WO1 assembly, the key validating assembly, the key engaging assembly, and the validation bar into the housing. The positioning of these components within the housing ensures their correct alignment and interaction within the lock assembly.

[0198] In step 416, a displacement mechanism is integrated between the carrier assembly and the housing. This mechanism is designed to induce relative movement between the carrier assembly and the housing. The displacement mechanism may include one or more angled surfaces on either the carrier assembly or the housing, and corresponding interaction surfaces on the other of the carrier assembly or the housing. The interaction between these surfaces facilitates the relative movement and the subsequent separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

[0199] In some examples, the method may also involve additional steps or variations, such as the use of different materials for the carrier assembly, key validating elements, key engaging elements, and validation bar, or the use of different methods for joining the carrier elements. These variations may be implemented based on the specific requirements of the locking application, such as the level of security required or the specific locking mechanism used in the lock assembly.

[0200] In some examples, the lock assembly 10 may include additional features and operational aspects that enhance its functionality and security. For instance, the lock assembly 10 may be configured between a locked state, an unlocked state, and a rekeyable state. In the locked state, the validation bar 76 may prevent rotation of the locking module assembly 34 unless all key validating elements are in a validated position. This feature enhances the security of the lock assembly 10 by ensuring that only the correct key can operate the lock. In the unlocked state, the validation bar 76 may be received within the validation aperture 78, indicating that the correct key has been used to operate the lock assembly 10. In the rekeyable state, the key validating elements may be axially displaced from the key engaging elements and rotatable to new positions corresponding to a new key configuration. This feature allows for easy rekeying of the lock assembly 10 without the need for disassembly or replacement of components.

[0201] In some cases, the lock assembly 10 may be manufactured using various techniques to optimize production costs and assembly. For instance, the carrier assembly 70 may be formed by joining multiple carrier elements together. This joining process may involve laser welding, which provides a robust and durable structure for the carrier assembly 70. Laser welding may be particularly advantageous due to its precision and consistency, ensuringAttorney Docket No.: 5193.004WO1 accurate and reliable operation of the lock assembly 10. Additionally, laser welding may provide further protection from shimming or other nondestructive defeat techniques.

[0202] In some embodiments, the lock assembly 10 may be designed to be reconfigured to match a new key. This reconfiguration may involve moving the key validating elements into new positions corresponding to the new key. The movement of the key validating elements into the new positions may be facilitated by the rotation and translation of the carrier assembly 70 in response to the rotation of the new key. This interaction between the key validating elements, the carrier assembly 70, and the new key allows for the reconfiguration of the lock assembly 10 to match the new key, providing a convenient method for rekeying the lock without the need for disassembly or replacement of components.

[0203] The following clauses illustrated example subject matter described herein.

[0204] Clause 1. A lock assembly, comprising: a locking module assembly extending along an actuation axis and comprising: a carrier assembly configured to rotate about and translate along the actuation axis; a spacer assembly rotationally coupled to the carrier assembly; a validation bar movable with the carrier assembly along the actuation axis; a key engaging assembly configured to interact with a key, the key engaging assembly comprising a plurality of key engaging elements arranged along the actuation axis; and a key validating assembly coupled to the carrier assembly, the key validating assembly comprising a plurality of key validating elements corresponding to the key engaging elements; a housing defining a cylindrical cavity configured to receive the locking module assembly, the housing defining a clearance slot extending parallel to the actuation axis, wherein the clearance slot is configured to accommodate movement of the validation bar and control rotation of the locking module assembly; a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly; and wherein the validation bar is configured to prevent rotation of the locking module assembly unless all key validating elements are in a validated position.

[0205] Clause 2. The lock assembly of Clause 1, wherein the spacer assembly comprises a plurality of spacers, each spacer positioned adjacent to a corresponding key validating element.

[0206] Clause 3. The lock assembly of Clauses 1 or 2, wherein the displacement mechanism comprises at least one angled surface on one of the carrier assembly or the housing, and at least one corresponding interaction surface on the other of the carrier assembly or the housing.Attorney Docket No.: 5193.004WO1

[0207] Clause 4. The lock assembly of any one of Clauses 1 through 3, wherein the key validating elements are configured to align with the key engaging elements when in a validated position.

[0208] Clause 5. The lock assembly of any one of Clauses 1 through 4, wherein, in a rekeying position, the key validating elements are axially displaced from the key engaging elements and rotatable to new positions corresponding to a new key configuration.

[0209] Clause 6. The lock assembly of any one of Clauses 1 through 5, wherein the carrier assembly comprises a cam protrusion extending from a proximal end of the locking module assembly, the cam protrusion configured to interact with a pocket in the housing to induce the relative movement.

[0210] Clause 7. A method of operation of a lock assembly, comprising: receiving a key in a locking module assembly; rotating a carrier assembly relative to a housing in response to key rotation; moving a key validating assembly relative to a key engaging assembly; separating the key validating assembly from the key engaging assembly; configuring key validating elements based on the received key; and enabling or preventing unlocking of the lock assembly based on the configuration of the key validating elements, wherein enabling or preventing unlocking comprises allowing or blocking movement of a validation bar based on the configuration of the key validating elements.

[0211] Clause 8. The method of Clause 7, wherein separating the key validating assembly from the key engaging assembly comprises translating the carrier assembly along the actuation axis during rotation.

[0212] Clause 9. The method of Clauses 7 or 8, further comprising:

[0213] re through engaging the key validating assembly with the key engaging assembly.

[0214] Clause 10. The method of any one of Clauses 7 through 9, further comprising:

[0215] rotating the carrier assembly to a rekeying position; and

[0216] aligning the key validating elements with a different set of key engaging elements.

[0217] Clause 11. The method of any one of Clauses 7 through 10, wherein configuring the key validating elements comprises rotating the key validating elements to positions corresponding to a bitting of the received key.

[0218] Clause 12. A method of making a lock assembly, comprising: forming a carrier assembly by joining multiple carrier elements; arranging a plurality of key validating elements into validated positions in the carrier assembly to form a key validating assembly; aligning a plurality of key engaging elements with the plurality of key validating elements to form a key engaging assembly; positioning spacers adjacent to the validating elements; installing aAttorney Docket No.: 5193.004WO1 validation bar that interfaces with the key validating assembly; forming a housing defining a cavity and a clearance slot extending parallel to an actuation axis; positioning the carrier assembly with the key validating assembly, the key engaging assembly, and the validation bar in the cavity of the housing; integrating a displacement mechanism configured to induce relative movement between the carrier assembly and the housing structure, wherein the relative movement causes separation of the validating elements from the engaging elements during operation of the lock assembly; and configuring the validation bar to prevent rotation of the carrier assembly unless all key validating elements are in a validated position.

[0219] Clause 13. The method of Clause 12, wherein forming the carrier assembly comprises laser welding multiple carrier elements together.

[0220] Clause 14. The method of Clauses 12 or 13, wherein arranging the key validating elements comprises inserting the key validating elements into slots in the carrier assembly.

[0221] Clause 15. The method of any one of Clauses 12 through 14, wherein positioning the spacers comprises inserting a spacer adjacent to each key validating element.

[0222] Clause 16. The method of any one of Clauses 12 through 15, wherein installing the validation bar comprises inserting the bar through the clearance slot in the housing.

[0223] Clause 17. The method of any one of Clauses 12 through 16, wherein integrating the displacement mechanism comprises machining at least one angled surface on either the carrier assembly or the housing.

[0224] Clause 18. The method of any one of Clauses 12 through 17, wherein the carrier assembly, key validating elements, key engaging elements, and validation bar are formed from hardened stainless steel.

[0225] Clause 19. The method of any one of Clauses 12 through 18, wherein the housing is formed from a metal alloy through an injection molding process.

[0226] Clause 20. The method of any one of Clauses 12 through 19, wherein the spacers are formed from a low through friction polymer material.

[0227] Clause 21. A lock assembly, comprising: a locking module assembly extending along an actuation axis and comprising: a carrier assembly configured to rotate about and translate along the actuation axis; a key engaging assembly configured to interact with a key; and a key validating assembly coupled to the carrier assembly; a housing defining a cavity configured to receive the locking module assembly; and a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.Attorney Docket No.: 5193.004WO1

[0228] Clause 22. The lock assembly of Clause 21, wherein the key engaging assembly comprises a plurality of key engaging elements arranged along the actuation axis.

[0229] Clause 23. The lock assembly of any one of Clauses 21 through 22, wherein the key validating assembly comprises a plurality of key validating elements corresponding to the key engaging elements.

[0230] Clause 24. The lock assembly of any one of Clauses 21 through 23, further comprising a spacer assembly rotationally coupled to the carrier assembly.

[0231] Clause 25. The lock assembly of any one of Clauses 21 through 24, wherein the spacer assembly comprises a plurality of spacers, each spacer positioned adjacent to a corresponding key validating element.

[0232] Clause 26. The lock assembly of any one of Clauses 21 through 25, further comprising a validation bar movable with the carrier assembly along the actuation axis.

[0233] Clause 27. The lock assembly of any one of Clauses 21 through 26, wherein the housing defines a clearance slot extending parallel to the actuation axis, the clearance slot configured to accommodate movement of the validation bar and control rotation of the locking module assembly.

[0234] Clause 28. A method of operating a lock assembly, comprising:

[0235] receiving a key in a locking module assembly;

[0236] rotating a carrier assembly relative to a housing in response to key rotation;

[0237] moving a key validating assembly relative to a key engaging assembly;

[0238] separating the key validating assembly from the key engaging assembly; and

[0239] configuring key validating elements based on the received key.

[0240] Clause 29. The method of Clause 28, further comprising enabling or preventing unlocking of the lock assembly based on the configuration of the key validating elements.

[0241] Clause 30. The method of any one of Clauses 28 through 29, wherein separating the key validating assembly from the key engaging assembly comprises translating the carrier assembly along the actuation axis during rotation.

[0242] Clause 31. The method of any one of Clauses 28 through 30, wherein enabling or preventing unlocking comprises allowing or blocking movement of a validation bar based on the configuration of the key validating elements.

[0243] Clause 32. The method of any one of Clauses 28 through 31, further comprising:

[0244] re through engaging the key validating assembly with the key engaging assembly.

[0245] Clause 33. The method of any one of Clauses 28 through 32, further comprising:

[0246] rotating the carrier assembly to a rekeying position; andAttorney Docket No.: 5193.004WO1

[0247] aligning the key validating elements with a different set of key engaging elements.

[0248] Clause 34. The method of any one of Clauses 28 through 33, wherein configuring the key validating elements comprises rotating the key validating elements to positions corresponding to a bitting of the received key.

[0249] Clause 35. A method of making a lock assembly, comprising: forming a carrier assembly; arranging key validating elements in the carrier assembly to form a key validating assembly; aligning key engaging elements with the key validating elements to form a key engaging assembly; positioning the carrier assembly with the key validating assembly and the key engaging assembly in a housing; and integrating a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

[0250] Clause 36. The method of Clause 35, wherein forming the carrier assembly comprises joining multiple carrier elements by laser welding.

[0251] Clause 37. The method of any one of Clauses 35 through 36, wherein arranging the key validating elements comprises inserting the key validating elements into slots in the carrier assembly.

[0252] Clause 38. The method of any one of Clauses 35 through 37, further comprising:

[0253] positioning spacers adjacent to the key validating elements; and

[0254] installing a validation bar that interfaces with the key validating assembly.

[0255] Clause 39. The method of any one of Clauses 35 through 38, wherein installing the validation bar comprises inserting the validation bar through a clearance slot in the housing.

[0256] Clause 40. The method of any one of Clauses 35 through 39, wherein integrating the displacement mechanism comprises machining at least one angled surface on either the carrier assembly or the housing.

[0257] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

[0258] While the disclosure has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the disclosure is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as toAttorney Docket No.: 5193.004WO1 encompass all such modifications and equivalent structures as permitted under the law. Furthermore, it should be understood that while the use of the word preferable, preferably, or preferred in the description above indicates that feature so described may be more desirable, it nonetheless may not be necessary and any embodiment lacking the same may be contemplated as within the scope of the disclosure, that scope being defined by the claims that follow. In reading the claims it is intended that when words such as “a,” “an,” “at least one” and “at least a portion” are used, there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. Further, when the language “at least a portion” and / or “a portion” is used the item may include a portion and / or the entire item unless specifically stated to the contrary.

Claims

Attorney Docket No.: 5193.004WO1 CLAIMS What is claimed is:

1. A lock assembly, comprising: a locking module assembly extending along an actuation axis and comprising: a carrier assembly configured to rotate about and translate along the actuation axis; a spacer assembly rotationally coupled to the carrier assembly; a validation bar movable with the carrier assembly along the actuation axis; a key engaging assembly configured to interact with a key, the key engaging assembly comprising a plurality of key engaging elements arranged along the actuation axis; and a key validating assembly coupled to the carrier assembly, the key validating assembly comprising a plurality of key validating elements corresponding to the key engaging elements; a housing defining a cylindrical cavity configured to receive the locking module assembly, the housing defining a clearance slot extending parallel to the actuation axis, wherein the clearance slot is configured to accommodate movement of the validation bar and control rotation of the locking module assembly; and a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the key validating assembly from the key engaging assembly during operation of the lock assembly.

2. The lock assembly of claim 1, wherein the spacer assembly comprises a plurality of spacers, each spacer positioned adjacent to a corresponding key validating element.

3. The lock assembly of claim 1 or 2, wherein the displacement mechanism comprises at least one angled surface on one of the carrier assembly or the housing, and at least one corresponding interaction surface on the other of the carrier assembly or the housing.

4. The lock assembly of any one of claims 1 through 3, wherein the key validating elements are configured to remain aligned rotationally with the key engaging elements when in a validated position.

5. The lock assembly of any one of claims 1 through 4, wherein the validation bar is configured to prevent rotation of the locking module assembly unless all key validating elements are in a validated position.Attorney Docket No.: 5193.004WO1 6. The lock assembly of any one of claims 1 through 5, wherein, in a rekeying position, the key validating elements are axially displaced from the key engaging elements and rotatable to new positions corresponding to a new key configuration.

7. A method of operation of a lock assembly, comprising: receiving a key in a locking module assembly; moving a key validating assembly relative to a key engaging assembly; rotating a carrier assembly relative to a housing in response to key rotation; separating the key validating assembly from the key engaging assembly; and configuring key validating elements based on the received key.

8. The method of claim 7, further comprising enabling or preventing unlocking of the lock assembly based on the configuration of the key validating elements.

9. The method of claim 8, wherein enabling or preventing unlocking comprises allowing or blocking movement of a validation bar based on the configuration of the key validating elements.

10. The method of any one of claims 7 through 9, wherein separating the key validating assembly from the key engaging assembly comprises translating the carrier assembly along an actuation axis during the key rotation.

11. The method of any one of claims 7 through 10, further comprising re-engaging the key validating assembly with the key engaging assembly.

12. A method of making a lock assembly, comprising: forming a carrier assembly by joining multiple carrier elements; arranging a plurality of key validating elements into validated positions in the carrier assembly to form a key validating assembly; aligning a plurality of key engaging elements with the plurality of key validating elements to form a key engaging assembly; positioning spacers adjacent to the validating elements; installing a validation bar that interfaces with the key validating assembly; forming a housing defining a cavity;Attorney Docket No.: 5193.004WO1 positioning the carrier assembly with the key validating assembly, the key engaging assembly, and the validation bar in the cavity of the housing; and integrating a displacement mechanism configured to induce relative movement between the carrier assembly and the housing, wherein the relative movement causes separation of the validating elements from the engaging elements during operation of the lock assembly.

13. The method of claim 12, wherein forming the carrier assembly comprises laser welding multiple carrier elements together.

14. The method of claims 12 or 13, wherein arranging the key validating elements comprises inserting respective key validating elements into slots of respective carrier elements of the carrier assembly.

15. The method of any one of claims 12 through 14, wherein positioning the spacers comprises inserting a spacer adjacent to each key validating element.

16. The method of any one of claims 12 through 15, wherein installing the validation bar comprises inserting the bar through a clearance slot in the housing.

17. The method of any one of claims 12 through 16, wherein integrating the displacement mechanism comprises forming at least one angled surface on either the carrier assembly or the housing.

18. The method of any one of claims 12 through 17, wherein the carrier assembly, key validating elements, key engaging elements, and validation bar are formed from hardened stainless steel.

19. The method of any one of claims 12 through 18, wherein the housing is formed from a metal alloy through an injection molding process.

20. The method of any one of claims 12 through 19, wherein the spacers are formed from a low-friction polymer material.

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