Security device with enhanced tamper resistance

Abstract

An assembly for use in a locking mechanism is disclosed. The assembly includes a first component having a pin head portion and an elongate shaft portion extending therefrom, and a second component configured to receive at least a portion of the elongate shaft portion. The second component cooperates with the first component to resist unauthorized manipulation or rotation of a lock core during attempted picking or bypass techniques, while permitting authorized operation by an associated key.

Description

SECURITY DEVICE WITH ENHANCED TAMPER RESISTANCECross Reference to Related Application

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 711,937, filed on October 25, 2024, the entirety of which is hereby incorporated by reference and relied upon.Field of Technology

[0002] The present disclosure generally relates to a security device, and more particularly to a security device configured to provide improved resistance to tampering while being adaptable for incorporation into existing designs with minimal additional manufacturing or implementation cost.Background

[0003] One of the challenges in the field of locks and security systems is achieving an appropriate balance between resistance to unauthorized access and factors such as cost and user convenience. For instance, not every door requires the level of protection provided by a bank vault door. Interior doors within a residence may include simple or no locking mechanisms, whereas exterior doors typically employ more secure locks, though still less robust than those used for vaults. The selection of a particular lock or security mechanism is therefore determined by multiple factors, generally involving tradeoffs among cost, convenience, and the desired level of security.

[0004] For example, referring to Fig. 1, a conventional pin tumbler lock 100 using pins of varying heights and a matching key 102 is one such application, by which at a small cost, and no decrease in convenience, security via lock and key was greatly increased. Specifically, a pin-tumbler is a cylinder-based lock design that uses movable pins to prevent rotation of the core or plug 104. A matching key 102 is used to properly elevate pins to allow the plug 104 to rotate and the locking bolt to be retracted. Pin tumblers are a series of pin stacks pushed down by a spring 106. Each stack must be properly raised to allow pins to separate at the shear line 108. Once all pin stacks are separated, the plug 104 can freely rotate and actuate the locking bolt to lock or unlock the lock. An incorrect key will not align all components correctly; rotation of the plug 104 will be blocked at the shear line 108.

[0005] As shown in Fig. 1, a plurality of key pins 110 are touched by the matching key 102. Key pins 110 are sized differently corresponding to the different depth cuts on the key 102.When the correct key is inserted, all key pins 110 are aligned at the shear line 108. allowing the plug 104 to rotate. Driver pins 112 are placed between the key pins 110 and the springs 106. In their resting position, the driver pins 112 block rotation of the plug 104. In more advanced pin-tumblers, driver pins 112 may be sized inverse to the key pins 110 to defend against decoding and attacks via comb picks. Springs 106 placed above the pin stacks push pins down to their resting position, ensuring that pins cannot be trapped above the shear line 108 while the plug 104 is in the default position. The plug 104 is the inner piece of lock 100 that rotates upon insertion and tension of the correct key. The plug 104 is connected to the cam to actuate the bolt mechanism when rotated. The cylinder is the outer piece of lock 100 that houses the upper pin chambers and the plug 104. Driver pins 112 and springs 106 are trapped in the cylinder’s pin chambers when the correct key is used and plug 104 rotated. The cam is an extension connected to the back of the plug 104 which actuates the bolt mechanism to lock or unlock the lock. However, such locks are subject to picking attacks.

[0006] Accordingly, it is desirable to have a security device configured to have improved resistance to tampering while being adaptable for incorporation into existing designs with minimal additional manufacturing or implementation cost.Brief Description of the Drawings

[0007] The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more example aspects of the present disclosure and. together with the detailed description, serve to explain their principles and implementations.

[0008] Fig. 1 illustrates a conventional pin tumbler lock.

[0009] Fig. 2 illustrates a cross-sectional view of components of a security assembly in an unassembled state, according to an exemplary aspect of the present disclosure.

[0010] Fig. 3 illustrates a perspective view of components of a security assembly in an unassembled state, according to an exemplary aspect of the present disclosure.

[0011] Fig. 4 illustrates a side elevational view of components of a security assembly in an assembled state, according to an exemplary aspect of the present disclosure.

[0012] Fig. 5 illustrates a first perspective view of components of a security assembly in an assembled state, according to an exemplary aspect of the present disclosure.

[0013] Fig. 6 illustrates a second perspective view of components of a security assembly in an assembled state, according to an exemplary aspect of the present disclosure.

[0014] Fig. 7 illustrates a side elevational view of a lock set incorporating a security assembly with the first pin being picked, according to an exemplary aspect of the present disclosure.

[0015] Fig. 8 illustrates a perspective view of a lock set incorporating a security assembly with the first pin being picked, according to an exemplary aspect of the present disclosure.

[0016] Fig. 9 illustrates a side elevational view of a lock set using the security assembly during normal key use with a matching key inserted, according to an exemplary aspect of the present disclosure.

[0017] Fig. 10 illustrates a perspective view of a lock set using the security assembly during normal key use with a matching key inserted, according to an exemplary aspect of the present disclosure.

[0018] Fig. 11 illustrates a perspective view of a lock set using the security assembly during normal key use with a matching key turned to unlock the security assembly, according to an exemplary aspect of the present disclosure.

[0019] Figs. 12 and 13 illustrate a side elevational view and a perspective view of a first lock being picked, respectively.

[0020] Fig. 14 illustrates a perspective view of a second lock being picked.

[0021] Fig. 15 illustrates an example shaft driver with notches implemented on a selected portion of its cylindrical shaft, according to an exemplary aspect of the present disclosure.Detailed Description

[0022] Various aspects of the present disclosure will be described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to promote a thorough understanding of one or more aspects of the present disclosure. It may be evident in some or all instances, however, that any aspects described below can be practiced without adopting the specific design details described below.

[0023] Among other features, the present disclosure relates to a security device or assembly configured to resist or obstruct unauthorized access techniques, including lock picking and other bypass methods. As wall be described fully below, the security device is designed such that, when picking techniques are applied to individual locking components, the overall mechanism continues to impede full actuation or unlocking. For example, the security devicemay require a picking tool or operator to engage and manipulate multiple components or stages of the locking mechanism sequentially or repeatedly, thereby making unauthorized bypass highly complex and substantially reducing the likelihood of successful picking. In some embodiments, the disclosed security device may be configured in a form factor compatible with existing pin tumbler lock architectures and key way geometries. Such compatibility enables the security device of the present disclosure to be retrofitted into or integrated with standard lock housings and key systems without substantial modification. In this manner, the disclosed security device enhances resistance to unauthorized manipulation while maintaining functional compatibility with conventional keys, lock bodies, and associated hardware.

[0024] In accordance with aspects of the present disclosure, Figs. 2-6 illustrate a plurality of components of a security device or a sleeved driver pin assembly. Figs. 2 and 3 respectively illustrate a cross-sectional view and a perspective view of various components of the security assembly in an unassembled state. Fig. 4 illustrates a side elevational view of various components of the security assembly in an assembled state. Figs. 5 and 6 illustrate additional perspective views of various components of the security assembly in an assembled state. As will be described below, a first component may comprise a shaft driver including a pin with a full diameter top section and a narrower-diameter or reduced-diameter portion for the rest of the pin’s length. A second component may comprise a driver sleeve including an outer sleeve portion dimensioned to fit over the narrower-diameter section of the shaft driver. The outer sleeve may be formed of metal, polymer, or composite material and may include internal surfaces shaped to provide a bearing interface, frictional coupling, or keyed engagement with the shaft driver. In alternative embodiments, the sleeve may be positioned over a portion of variable diameter or cross-section of e.g., the narrow er-diameter section of the shaft driver, allowing different mechanical interactions depending on the locking or anti-picking function desired. The outer sleeve may be shorter than the length of the narrower-diameter section of the shaft driver. A third component may comprise a spring configured to encircle the reduced-diameter portion of the shaft driver, the spring being axially located between a shoulder or step defined at the junction of the full-diameter section and the reduced-diameter section of the shaft driver, and an upper end face of the driver sleeve. In one example implementation, a compressed length of the spring and the driver sleeve combined length may be less than that of the reduced-diameter section of the shaft driver.

[0025] As shown in Figs. 2-6, in various embodiments, a sleeved driver pin assembly may comprise a shaft driver 10 configured to be received within a driver sleeve 30. The shaft driver10 may include a pin head 12 integrally formed with, or otherwise coupled to, a generally cylindrical shaft 14. The driver sleeve 30 may define a hollow interior passage extending along its longitudinal axis, and may be configured to receive at least a portion of the cylindrical shaft 14 therein. A spring 20 may be disposed between the shaft driver 10 and the driver sleeve 30 and configured to push off or compress the shaft driver 10 onto the driver sleeve 30.

[0026] The driver sleeve 30 may function as an intermediate or secondary driver element that cooperates with the shaft driver 10 to control axial movement and rotational coupling between a plug and housing of a lock (eg., lock lOO ofFig. 1). In one implementation, the driver sleeve 30 may prevent rotation of the plug until the driver sleeve 30, together with the shaft driver 10, is positioned such that a shear line is properly aligned. In other embodiments, the driver sleeve 30 may additionally serve to distribute load, absorb torque, or introduce controlled resistance during picking or unauthorized manipulation attempts.

[0027] In certain embodiments, the inner diameter of the driver sleeve 30 may be configured to be slightly greater than the outer diameter of the cylindrical shaft 14 of the shaft driver 10, such that the shaft 14 can move axially and / or rotationally relative to the sleeve 30 with minimal friction, as illustrated in Figs. 4-6. For example, the radial clearance between the inner surface of the driver sleeve 30 and the outer surface of the cylindrical shaft 14 may be implemented according to selected machining practices to permit smooth relative movement without excessive play. In various embodiments, the radial clearance may range from about 0.005 mm to about 0.05 mm, such as between 0.01 mm and 0.03 mm for precision-machined metal components. Larger clearances (e.g, 0.05 mm to 0.15 mm) may be suitable for components formed from softer materials, molded parts, or assemblies subject to wider manufacturing tolerances. Conversely, smaller clearances (e.g, 0.001 mm to 0.005 mm) may be employed where tighter control of motion or reduced vibration is desired. It should be understood that other radial clearance ranges may be selected depending on material combinations, lubrication, intended environmental conditions, and the precision of available manufacturing methods.

[0028] Alternative embodiments may employ non-cylindrical or non-uniform geometries for either the driver sleeve 30 or the shaft driver 10. For example, the driver sleeve 30 may include an internal feature such as a taper, groove, keyway, or detent configured to engage a corresponding structure on the cylindrical shaft 14 of the shaft driver 10, thereby modifying the interaction between the two components. The driver sleeve 30 and the shaft driver 10 may be formed from metallic or polymeric materials having differing hardness, surface finish, ormagnetic properties to achieve a desired balance of durability, lubricity, and security performance.

[0029] The sleeved driver pin assembly disclosed herein may be configured or adapted for incorporation into a variety of lock mechanisms, including, but not limited to, single shear line and double shear line pin tumbler systems, as well as systems employing spool-ty pe or serrated driver configurations. The sleeved driver pin assembly may also be utilized in hybrid locking mechanisms in which enhanced resistance to unauthorized manipulation, such as picking or bumping, is desired without adversely affecting manufacturability, interchangeability, or serviceability7of the lock.

[0030] By way of example, certain aspects of the present disclosure may be implemented in tubular pin tumbler locks, such as those commonly employed in vending machines, bicycle locks,L‘Chicago”-type or “Ace”-type locks, or in certain elevator control locks. In another embodiment, features of the disclosed sleeved driver pin assembly may be adapted for use in wafer tumbler mechanisms, which employ spring-biased flat wafers rather than cylindrical pins but operate on a similar shear-line principle. Such wafer tumbler systems are frequently utilized in automotive ignition locks, fding cabinet locks, vending machine locks, and numerous padlocks, including, for instance, Master Lock® Model No. 3.

[0031] In further embodiments, the aspects described herein may also be applied to disk detainer mechanisms, which employ a plurality of rotatable, slotted disks instead of linear pins, wherein a properly cut key sequentially lifts and rotates each disk to align a set of gates along a common shear line. Disk detainer locks are often found in motorcycle locks and various high-security7padlocks. It should thus be appreciated that the sleeved driver pin assembly of the present disclosure is not limited to conventional pin tumbler architectures and may be adapted for use in e.g., wafer tumbler and disk detainer configurations, as well as in other mechanical locking systems employing analogous shear-line alignment mechanisms.

[0032] According to various aspects of the present disclosure, the shaft driver 10 may form both the central portion and the upper portion of the sleeved driver pin assembly, the latter corresponding to the pin head 12. The lower portion of the shaft driver 10 may include a cylindrical shaft 14 configured to transmit axial force between the spring 20 and an associated key pin during normal lock operation. Figs. 7 and 8 respectively illustrate a side elevational view and a perspective view of a lock set 700 incorporating the security assembly of the present disclosure with the first pin being picked. For example, the first pin includes the securityassembly 702 described above with respect to Figs. 2-6. The region “A” in Fig. 8 is enlarged to show details of the first pin. Fig. 9 illustrates a side elevational view of a lock set using the security assembly of the present disclosure during normal key use with a matching key 902 inserted. When the matching key 902 is inserted and the pins may be properly aligned along the shear line 906, the spring 20 of e.g.. the first pin exerts a biasing force through the driver sleeve 30, the cylindrical shaft 14, and ultimately to each corresponding key pin (e.g., 904a, 904b, 904c, 904d, 904e, and 904f) to maintain engagement within the key way. Fig. 10 illustrates a perspective view of a lock set using the security assembly of the present disclosure during normal key use with a matching key inserted. Fig. 11 illustrates a perspective view of a lock set using the security assembly of the present disclosure during normal key use with a matching key turned to unlock the security assembly.

[0033] During unauthorized manipulation, such as a picking attempt, the driver sleeve 30 may rest at or near the shear line. As shown above, Fig. 7 illustrates a side elevational view of a lock set using the security assembly of the present disclosure with the first pin been picked. In this condition, the driver sleeve 30 may be prevented from further downward movement toward the corresponding key pin (e.g, one of 904a, 904b, 904c, 904d, 904e, and 904f). That is, the driver sleeve 30 acts as an outer housing or guide around the shaft driver 10. During normal operation, the driver sleeve 30 moves axially up and dow n under spring force, transmitting that force to the corresponding key pin through the cylindrical shaft 14. However, during a picking attempt or other manipulation, if the driver sleeve 30 is raised to the shear line while the plug is subjected to rotational pressure (e.g., by a pick tool lifting the pin stack from below?, while a torsion wench or similar provides pressure), its outer diameter becomes partially aligned with the interface between the plug and housing. At this position, the edge of the driver sleeve 30 physically contacts the outer cylindrical surface of the plug, forming a mechanical stop. Because the plug and housing bore are closely toleranced, this contact prevents the driver sleeve 30 from descending any further tow ard the corresponding key pin. As a result, the driver sleeve 30 is “caught” at the shear line (e.g. , 906 show n in Fig. 9) and unable to move downw ard because its outer surface is obstructed by the boundary- between the plug and the shell. The shaft driver 10 inside the driver sleeve 30 can still move slightly within the driver sleeve 30, but the driver sleeve 30 itself is axially constrained.

[0034] This condition is critical because it creates a false shear line or decoy state to an unauthorized manipulator, the lock may appear to be partially set, but actual plug rotation remains blocked until both the driver sleeve 30 and shaft driver 10 are correctly positionedrelative to the true shear line. Specifically, the cylindrical shaft 14 of the shaft driver 10 may continue to extend through the lower opening of the driver sleeve 30, thereby projecting partially below the driver sleeve 30. This projection maintains mechanical interference between the plug and the housing, preventing rotation of the plug until the shaft driver 10 and driver sleeve 30 are both repositioned to their correct axial locations corresponding to proper shear line alignment.

[0035] According to aspects of the present disclosure, the configuration of the shaft driver 10 enables reliable transmission of spring force under normal operating conditions while also maintaining lockout functionality when the driver sleeve 30 is held at the shear line during manipulation. That is, the driver sleeve 30 becomes temporarily caught or held in place while the biasing force exerted by the spring 20 on the corresponding key pin remains generally constant. This interaction increases the mechanical stability of the pin stack under manipulation, thereby enhancing the lock’s resistance to picking, raking, or similar bypass techniques.

[0036] The driver sleeve 30 fits over at least a portion of the cylindrical shaft 14 of the shaft driver 10, and during normal operations contacts the top of a key pin. The driver sleeve 30 is positioned to block the sheer line when in the locked state. The driver sleeve 30 prevents the rotation of a lock core when the pin is in the locked position. During picking, the driver sleeve 30 hangs up on the lip of the sheer line preventing the shaft driver 10 from binding. Its hollow rigid shape allows the shaft driver 10 to maintain spring pressure on the key pin.

[0037] The spring 20 may be positioned around the cylindrical shaft 14 of the shaft driver 10, between the shaft driver 10 and the driver sleeve 30. This position may act to constantly push the driver sleeve 30 away from the top of the shaft driver 10. The sleeve spring 20 provides gentle down force on the driver sleeve 30 to enable function in any orientation.

[0038] In summary, the sleeved driver pin assembly described above may be constructed by positioning the spring 20 around the shaft 14 of the shaft driver 10 and sliding the driver sleeve 30 over at least a portion of the shaft 14. When assembled in this manner, as illustrated in Figs.4-6, the shaft driver 10 remains capable of relative movements with respect to the driver sleeve 30.

[0039] The sleeved driver pin assembly of the present disclosure may take the position of the driver pm or security pin in the ’’pin stack” of a conventional pm and tumbler lock shown in Fig. 1. As described above, according to aspects, an example pin stack may include a spring, adriver pin, and a key pin. The driver pin in a normal lock is positioned to block the sheer line in the lock core preventing the lock from being turned. The key pins on the bottom of the pin stack are pins of various lengths which interact with a key. The varying height of the key pins interact with the shape of the key to align the bottom of all the driver pins with the sheer line. This allows the lock to turn.

[0040] During a picking attack, an attacker applies a light rotational bias to the plug and manipulates the key pins to induce one or more driver pins to bind at or above the shear line. Due to manufacturing tolerances and allowable play in mass-produced pin chambers and pin components, individual pin stacks exhibit small variations in height, friction, and axial movement. A skilled picker exploits these variations by applying rotational tension to the key way and sequentially lifting key pins until the corresponding driver pin on a given stack is held or captured above the shear line while other stacks remain unset. This selective binding establishes a binding order and may produce tactile or rotational feedback (a partial or “false” set) that guides further manipulation. When every pin stack is correctly set so that each driver pin is entirely in the housing and each key pin is entirely in the plug at the shear line, the plug is free to rotate and the lock opens.

[0041] The present disclosure prevents this by at least using the disclosed sleeved driver pin assembly as shown in Figs. 2-14, where the driver pin can only be manipulated indirectly using the key pin, and any picking attack may lift both the driver sleeve 30 and the shaft driver 10 over the sheer line. In one aspect, the wall diameter of the driver sleeve 30 may be greater than any manufacturing tolerance in the pins or pin chambers. As a result, the driver sleeve 30 itself will be caught on the sheer line but will allow the end of the shaft driver 10 to fall through, as shown in the enlarged region “A” of Fig. 8. If the distal end of the shaft driver 10 is long enough (e.g. , the length of the driver sleeve is shorter than the shaft section of the driver pin) to maintain contact w ith the key pin, then a picker will have no feedback indicating a successful pick of the driver sleeve 30, because he would still feel spring feedback from the mainspring transmitted through the shaft driver 10 to the key pin. A picker generally relies on the lack of spring pressure caused by binding a driver pin to know that the driver pin has indeed been picked. Removing this feedback greatly hinders a picker, as he has to pick without knowledge of which pins have been picked. Once all the driver sleeves 30 have been bound, an attacker w ould then be able to partially rotate the cylinder until it binds on the protruding shafts of the shaft driver 10. Figs. 12 and 13 illustrate a side elevational view' and a perspective view of a lock 1200 being picked, respectively. As shown in Fig. 12, the lock 1200 is in a locked statewith certain components being picked. It should be noted that certain elements are identified with reference numerals for clarity, while others are omitted for simplicity of illustration. The illustrated driver sleeve 1204 may represent one or more driver sleeves that, in certain configurations, have been picked and are positioned at the shear line 1202 of the lock 1200, with corresponding driver pins 1206 extending beyond the shear line 1202. In this embodiment, the dimensional relationship between the driver sleeves 1204 and the driver pins 1206 is configured such that, when the lock 1200 is in the rest position, the driver pins do not engage or make contact with the key pins 1208. By selecting the wall thickness of the driver sleeves 1204 and / or the axial length of the driver pin shafts 1206, the assembly may be configured to resist or inhibit picking attempts by preventing alignment of the driver pins and key pins 1208 at the shear line 1202.

[0042] Fig. 14 illustrates a perspective view of lock 1400 during a picking attempt in which the pin stacks are in an unlocked (raised) state, as they would appear when the lock is correctly unlocked and the core is free to rotate. In that condition, the driver sleeves and the driver pins (e.g., 1402) are positioned above the shear line 1404, permitting core rotation. Absent additional countermeasures, a picker might rely on changes in spring force transmitted through the pin stack to confirm whether a shaft driver has been successfully manipulated. For example, if a shaft driver remains long enough to transmit spring pressure to the key pin after driver sleeve has been set, the attendant change in spring force can provide tactile feedback indicating a successful pick of the shaft driver.

[0043] As shown in Fig. 14, however, the dimensional relationship between the driver sleeves, the shaft drivers, and their springs may be determined and implemented to eliminate or substantially reduce such transmitted spring feedback. For example, driver sleeve wall thickness, the axial length of shaft driver, or both may be adapted such that, when a driver sleeve is bound at the shear line 1404, the shaft driver does not transfer appreciable spring force to the key pin. As a result, an attacker cannot rely on a change in spring pressure as an indication of successful manipulation of the shaft driver and therefore is forced to continue blind manipulation of the pin stacks. This deliberate lack of transmitted spring feedback increases the difficulty of conventional picking techniques and thereby enhances the lock 1400’s resistance to tampering.

[0044] In another embodiment, security may further be improved by modifying the shape of the cylindrical shaft 14 of the shaft driver 10 to make picking more difficult via binding along the sheer line. Referring to Fig. 15, in one embodiment, a selected portion 1502 of thecylindrical shaft 14 of the shaft driver 10 may be configured to include multiple notches to mimic the function of existing security pins.

[0045] In further embodiments, the sleeved driver pin assembly may include one or more alterations to the driver sleeve 30. Such alterations may be provided in various quantities and configurations to achieve different mechanical responses, frictional characteristics, or degrees of axial compliance. The driver sleeve 30 may take the form of a washer, ring, collar, shim, or other annular or partially annular member configured to fit concentrically around the shaft driver 10. Similarly, the driver sleeve 30 may be replaced by or include a helical compression spring, wave spring, elastomeric sleeve, Belleville washer, or any resilient member.

[0046] In another embodiment, the sleeved driver pin assembly may include two or more washers or sleeves positioned axially along the shaft driver 10, without a spring. The washers may act collectively to adjust the overall length or mass distribution of the driver assembly, thereby tuning the binding order, feel, or feedback of the lock mechanism. Multiple washers may also be used to create stepped or staged engagement characteristics, where different portions of the assembly contact the plug bore or chamber wall at different torque levels.

[0047] In yet another embodiment, three or more washers or sleeves may be employed without any spring element. Such configurations may be advantageous where fine-tuning of pin stack height or incremental spacing is desired for manufacturing compensation or anti-picking performance. The washers may be fabricated from brass, stainless steel, hardened steel, or polymeric materials such as acetal or nylon, each providing distinct frictional or wear properties.

[0048] In further embodiments, one or more springs may be introduced in combination with one or more washers or sleeves. For example, a single spring may be positioned between two adjacent washers or between a washer and the top of the driver pin 12, providing a controlled degree of axial compliance or damping. A configuration with one washer and one spring may enable both dimensional tuning and resilient preload, improving the lock’s resistance to shock, vibration, or bumping.

[0049] Additional embodiments may employ two or more ashers in conj unction with a single spring. For instance, two washers may be disposed on either side of a central compression spring, thereby distributing spring forces evenly and preventing direct metal -to-metal contact between the sleeves or washers. Likewise, three or more washers may be used in combination with one or more springs to tailor both the static position and dynamic response of the driverpin assembly, optimizing smooth operation while maintaining resistance to unauthorized manipulation.

[0050] In yet another implementation, two or more springs may be employed, each interleaved with one or more washers. For example, a configuration including two springs and two washers may provide a dual-rate biasing mechanism in which an initial light compression force transitions to a stiffer response upon further displacement. This may allow the lock to exhibit progressive resistance during picking attempts while maintaining normal key operation. Three or more springs interspaced with washers may further refine this response, enabling multi-stage compliance or controlled oscillation damping under vibrational or impulsive loads.

[0051] In still further embodiments, up to four washers and four springs may be arranged in alternating sequence within the sleeve, forming a composite stack that allows tunable preload, spacing, and motion control characteristics. Such an arrangement may be configured to deliver highly controlled driver pin movement and enhanced resistance to attack methods such as bumping or rapping. It should be understood that the term "washer” as used herein broadly encompasses any annular or partial ring member, regardless of cross-sectional shape or material composition, and the term “spring” broadly encompasses any resilient element, such as metallic, polymeric, or composite, that provides a restoring force under compression, torsion, or bending. Accordingly, various combinations, sequences, and orientations of washers and springs may be employed without departing from the spirit or scope of the present disclosure.

[0052] According to additional aspects of the present disclosure, the sleeved driver pin assembly may be constructed without the full diameter top section or terminal closure on the outer sleeve. In such configurations, the assembly may include only an inner shaft pin and one or more washer and / or spring and / or sleeve components disposed axially around the inner pin. Eliminating the full diameter top section may simplify manufacture, reduce part count, and allow the sleeved driver pin assembly to self-adjust under operational loads while maintaining the intended pin bias and alignment at the shear line.

[0053] In one embodiment, the sleeved driver pin assembly may comprise such an inner pin in direct contact with a single spring element, with no washers or spacers included. The spring may be positioned concentrically around or adjacent to the inner pin and configured to exert an axial or torsional bias. The spring may be a helical compression type, wave spring, or flat-coil variant, or any other resilient structure that applies a restoring force to bias the pin toward a desired rest position within the locking chamber.

[0054] In another embodiment, both the spring and washer and sleeve components may be replaced by a helical washer, sometimes referred to as a wave washer or curved spring washer. This single component may simultaneously provide both the spacing and the biasing function, reducing complexity while maintaining comparable force characteristics. The helical washer may have one or multiple wave crests, a flat or contoured profile, and may be fabricated from metal, polymer, or composite materials having the required elastic modulus.

[0055] In an additional embodiment, the spring(s) and washer(s) and sleeve may both be replaced with a helical flat-profile coil spring, which combines the geometry of a washer with the energy storage characteristics of a coil spring. This configuration allows for high axial load capacity within limited radial or axial space, providing improved durability and predictable compression under repeated cycling.

[0056] In further embodiments, the above configurations may be implemented with the top section omitted entirely. The absence of the top section may allow various components of the assembly to expand or retract freely within the sleeve, providing automatic tolerance compensation as components wear or as environmental factors such as temperature or debris affect clearances. Such embodiments may employ retaining grooves, crimps, or other mechanical stops to prevent ejection of the inner pin under spring load.

[0057] In yet another set of embodiments, the iterations described above may be modified such that the outer surface of the dnver pm or inner surface of the washer and / or sleeve and / or spring may be serrated, knurled, or otherwise textured. These surface features may provide directionally biased frictional engagement to the surrounding sleeve or housing, thereby enhancing stability or intentional locking under certain operating conditions, (such as during picking, allowing the driver pin downward motion following key pin. after binding the sleeve, but not allowing upwards motion of the driver pin until the rotational force is removed) The serrations may be straight, helical, or cross-hatched depending on desired mechanical performance.

[0058] In other embodiments, the washer thickness may again be increased to form a sleevelike member, but without a top cap section on the inner pin. In such configurations, the inner pin may extend freely through the sleeve structure, allowing relative sliding or floating motion constrained only by the elastic or geometric limits of the washer-spring stack. This arrangement may facilitate modular assembly and disassembly for maintenance or calibration.

[0059] In a related embodiment, the thickened washer or sleeve element may include a serrated outer surface and be used in conjunction with an inner pin that lacks a cap section. Theserrations may cooperate with internal features of the outer sleeve to provide a one-way ratcheting or anti-reversal mechanism, allowing incremental advancement of the inner pin under applied force while preventing retraction absent a specific unlocking action. Such mechanisms may be advantageous in tamper-resistant lock designs.

[0060] In another embodiment, the washer thickness may be increased to form a sleeve with serrations on its inner surface, configured to engage complementary serrations or teeth formed on the outer surface of the inner pin. When pressed axially together, the intermeshing serrations may operate as a one-way ratchet, allowing movement in one direction (for instance, under authorized key actuation) but resisting displacement in the opposite direction, thereby impeding manipulation attempts.

[0061] A similar embodiment may employ the same ratcheting interaction but with washer thicknesses selected or graded to achieve specific engagement thresholds. For example, the washer spring stack may be configured such that when the cumulative compression exceeds a defined limit, such as when the inner pin is fully depressed, the assembly transitions into an over-travel or “bound” state. This controlled binding may produce tactile feedback, mechanical resistance, or a deliberate dead-locking condition useful for anti-bumping or anti-picking protection.

[0062] In another configuration, the washer and spring stack may be dimensioned such that the cumulative axial length of the components produces progressive resistance prior to reaching full compression, effectively forming a staged or multi-zone biasing mechanism. This enables precise tuning of the lock's feel and feedback characteristics, enhancing both legitimate key operation and resistance to attack through vibration or torque feedback.

[0063] In further embodiments, multiple inner pins may be arranged axially or laterally within a single sleeve body any of the above iterations. Such multi-pin assemblies may be employed to form composite driver units with redundant or sequential engagement behavior. The individual pins may act in concert or independently, depending on the lock's intended operational logic or security level.

[0064] In still another embodiment, multiple stacked inner pins may each include a respective washer and / or spring stack configured according to any of the preceding embodiments. These may be arranged such that compression of an upper pin influences the position or preload of the next, establishing interdependent or cascading motion among multiple subassemblies. Such multi-stage configurations may yield complex pick-resistant mechanical behaviors, including conditional release or delayed alignment of the shear line.

[0065] According to various embodiments, the present disclosure provides an assembly, a device, or an apparatus system configured for use in a locking device, such as a pin tumbler lock or other similar mechanical security mechanism, to resist unauthorized manipulation or rotation of a lock core during picking or bypass attempts. The assembly may generally include a first component, a second component, and, in certain embodiments, one or more third components disposed therebetween.

[0066] In an embodiment, the first component may include a pin head portion and an elongate shaft portion extending axially therefrom. The elongate shaft portion may be generally cylindrical, partially tapered, or otherwise shaped to interface with a corresponding feature of the second component. The first component may be configured to transmit motion or force from an associated spring or key pin, and may be formed from metal, alloy, or composite material suitable for repetitive axial movement.

[0067] The second component may be configured to receive at least a portion of the elongate shaft portion of the first component and to cooperate with the first component to resist unauthorized manipulation of a lock core. In some embodiments, the second component defines a hollow interior passage extending along a longitudinal axis, the passage being sized to receive the elongate shaft portion with a selected radial clearance that permits controlled axial and / or rotational movement between the two components. The inner diameter of the second component may therefore be slightly greater than the outer diameter of the received portion of the elongate shaft portion.

[0068] In some embodiments, the second component may have a length shorter than that of the elongate shaft portion such that, under certain conditions (for example, when subjected to unauthorized picking forces), the first component may not transmit spring pressure to the key pin. This geometry may thereby eliminate or reduce tactile feedback typically relied upon by a picker, forcing blind manipulation and increasing pick resistance.

[0069] In other embodiments, at least one third component may be disposed between the first and second components. The third component may include one or more resilient elements, such as a helical compression spring, a wave spring, or a flat-coil spring, configured to bias the first component and / or the second component along the longitudinal axis. Alternatively or additionally, the third component may include an annular or partial ring member configured to guide or constrain motion, reduce friction, or modify spring force distribution.

[0070] A radial clearance between the first and second components may be specifically selected to permit limited axial and rotational movements while preventing alignment of driverand key pins at the shear line during unauthorized manipulation. In an embodiment, one or more notches may also be provided on selected portions of the elongate shaft portion to further alter the tactile characteristics experienced by an unauthorized picker.

[0071] According to another aspect, a method of deterring unauthorized manipulation of a lock mechanism is provided. An example method may include providing a first component having a pin head portion and an elongate shaft portion; providing a second component having a hollow interior passage configured to receive at least a portion of the elongate shaft portion; positioning the second component relative to the first component such that a selected radial clearance permits limited axial and rotational motion therebetween. The method may also include positioning at least one resilient element or annular member between the first and second components. In some embodiments, the method includes configuring at least one of the wall thickness of the second component, the axial length of the elongate shaft portion, or the preload of the resilient element such that spring pressure transmitted to a corresponding key pin is reduced or eliminated when the second component is bound at a shear line during unauthorized manipulation.

[0072] In various embodiments, the method may further include allowing the assembly to permit normal key-induced axial translation and rotation of the core when an authorized key is used, while inhibiting transmission of spring feedback or alignment cues when unauthorized picking forces are applied.

[0073] According to further embodiments, a method of inhibiting unauthorized manipulation of a lock assembly, comprising: assembling a first component and a second component such that a portion of an elongate shaft of the first component extends into a hollow passage of the second component; and configuring a dimensional relationship between the first and second components such that the first component does not transfer spring pressure to a key pin when the second component is positioned at a shear line during unauthorized manipulation. The method may also include disposing at least one resilient element between the first and second components to permit controlled axial movement during authorized operation.

[0074] In accordance with aspects of the present disclosure, the first component may include a driver pin, shaft driver, or similar element. The second component may include a driver sleeve, coupler sleeve, or other suitable external housing member. The third component may comprise multiple resilient members of differing stiffnesses to produce non-linear force responses. The axial or radial dimensions may be selected empirically or computationally to produce desired resistance characteristics. Materials may include hardened steel, brass,stainless alloys, or engineered polymers. Aspects of the present disclosure may be incorporated into existing lock architectures with minimal manufacturing modification, thereby enabling cost-effective enhancement of pick resistance.

[0075] As described above, the security device of the present disclosure may be configured to operate by aligning a series of key pins and driver pins within a cylindrical plug and housing, creating a shear line that permits rotation of the plug when the correct physical key is inserted. This rotation actuates a cam or tailpiece to retract or extend a bolt, securing or releasing a door or enclosure. It should be appreciate that aspects of the present disclosure may be integrated with an electronic access (e-access) system, where the structure of the security device may be implemented with electronic components that provide controlled actuation. For example, an electronic module, such as a keypad, RFID reader, or biometric scanner, may be mounted adjacent to or within the lock assembly of the present disclosure. Upon successful authentication, the e-access system may generate and transmit an electrical signal to enable the operation of the lock assembly of the present disclosure, bridging the reliability of physical pin alignment with digital verification for enhanced security and convenience.

[0076] In some embodiments, the security device of the present disclosure may be retrofitted with an electrified trim or solenoid mechanism that interfaces directly with the plug or bolt. The solenoid may be configured to act as a blocking or enabling device. When credentials are validated through the e-access system (e.g, via a proximity card or mobile app). the solenoid retracts, allowing the security device to rotate freely with a key or under manual force. Alternatively, a motor-driven actuator may be coupled to the tailpiece, where the e-access controller powers the motor to turn the plug independently of a physical key. This hybrid configuration may maintain a compatibility with traditional keys for failover scenarios while incorporating features like access logging, time-based restrictions, and remote monitoring through networked controllers.

[0077] Further embodiments may involve wireless connectivity to centralize management within the e-access system. The integrated lock may communicate via protocols like Bluetooth or Wi-Fi to a hub or cloud-based platform, enabling real-time updates to user permissions without physical rekeying. For instance, in a cylindrical lock preparation, a wireless electronic cylinder may replace the standard pin tumbler core, retaining the mechanical pin stack for optional key use but prioritizing electronic signals for primary operation. This setup not only reduces the vulnerabilities associated with lost keys but also facilitates integration with broadersecurity ecosystems, such as alarm systems or video surveillance, ensuring comprehensive control over access points.

[0078] It should be understood that the foregoing embodiments are illustrative and not limiting. The terms “washer,'’ “spring,” “sleeve,” and “cap section” are intended to encompass all structural equivalents performing substantially similar functions, whether formed as discrete components or integrally manufactured as part of the shaft driver or sleeve assembly. Any combination, substitution, or reconfiguration of these components that achieves the intended biasing, spacing, or locking effect is considered within the scope of the present disclosure.

[0079] One or more components may be referred to herein as "configured to," "configurable to," " operable / operative to," "adapted / adaptable," "able to," "conformable / conformed to," etc. Those skilled in the art will recognize that "configured to" can generally encompass activestate components and / or inactive-state components and / or standby-state components, unless context requires otherwise.

[0080] Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and / or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations.

[0081] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g. , the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore,in those instances where a convention analogous to "at least one of A, B. and C. etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc ). In those instances where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase "A or B" will be typically understood to include the possibilities of "A" or "B" or "A and B."

[0082] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flow diagrams are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like "responsive to." "related to," or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

[0083] It is w orthy to note that any reference to "one aspect," "an aspect," "an exemplification," "one exemplification," and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases "in one aspect," "in an aspect," "in an exemplification," and "in one exemplification" in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.

[0084] As used herein, the singular form of "a", "an", and "the" include the plural references unless the context clearly dictates otherwise.

[0085] As used herein, the term "comprising" is not intended to be limiting, but may be a transitional term synonymous with "including," "containing," or "characterized by." The term "comprising" may thereby be inclusive or open-ended and does not exclude additional, unrecited elements or method steps when used in a claim. For instance, in describing a method, "comprising" indicates that the claim is open-ended and allows for additional steps. In describing a device, "comprising" may mean that a named element(s) may be essential for an embodiment or aspect, but other elements may be added and still form a construct within the scope of a claim. In contrast, the transitional phrase "consisting of' excludes any element, step, or ingredient not specified in a claim. This is consistent with the use of the term throughout the specification.

[0086] It should be understood that various changes and modifications to the examples described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

Claims

Claims:

1. An assembly, comprising:a first component including a pin head portion and an elongate shaft portion extending therefrom; anda second component configured to receive at least a portion of the elongate shaft portion of the first component and cooperate with the first component to resist unauthorized manipulation or rotation of a lock core during an attempted picking or bypass techniques, while permitting authorized operation by a corresponding key.

2. The assembly of claim 1, further comprising:at least one third component disposed between the first and second components and configured to permit controlled axial or rotational movements between the first and second components.

3. The assembly of claim 1, w herein a length of the second component is shorter than that of the elongate shaft portion.

4. The assembly of claim 1, wherein the second component includes a hollow interior passage extending along a longitudinal axis of the second component, wherein the hollow interior passage is configured to receive at least the portion of the elongate shaft portion of the first component.

5. The assembly of claim 2, wherein the at least one third component includes at least one resilient element.

6. The assembly of claim 5, wherein the at least one resilient element includes at least one of a spring of a helical compression type, a wave spring, or a flat-coil spring.

7. The assembly of claim 2, wherein the at least one third component includes at least one annular or partial ring member.

8. The assembly of claim 1, wherein an inner diameter of the second component is greater an outer diameter of the portion of the elongate shaft portion.

9. The assembly of claim 8, wherein a radial clearance between the inner diameter of the second component and the outer diameter of the portion of the elongate shaft portion is selected to allow axial and rotational movements between the second component and the portion of the elongate shaft portion.

10. The assembly of claim 1, wherein a selected portion of the elongate shaft portion includes one or more notches.

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