Angled Stepped Bore Key Channel for Anti-Replication Security
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Solution Overview
Problem
Existing key designs for lock cylinders can be easily replicated using modern copying methods such as 3D scanners and 3D printers, compromising security.
Innovation Solution
A key with a stepped bore channel in the key shank, angled at less than 90 degrees to the central longitudinal plane, featuring a displaceable actuating pin that is difficult to reconstruct using modern copying methods, combined with an M-shaped profile for increased stability and a longitudinal groove for easy insertion, ensuring secure operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional key shaft design is used, then the key can be easily replicated using 3D scanners and 3D printers, but this compromises security
Solution Approach 1:
The key shaft is divided into multiple sections with different cross-sectional shapes (circular, square, rectangular, triangular) along its length. This segmentation creates a complex internal structure with channels and cavities that cannot be easily replicated by conventional 3D scanning and printing methods, as each section requires precise geometric matching with corresponding lock cylinder components.
Solution Approach 2:
The key shaft employs asymmetric cross-sectional shapes that change along its length, with each section having a unique geometry that does not mirror the others. This asymmetry ensures that only the correctly shaped key can be inserted and operated in the lock cylinder, preventing replication by symmetric copying methods while maintaining structural integrity for mechanical operation.
2Reliability
If a complex channel design is introduced to improve security, then replication becomes difficult, but the key shaft stability may be affected
Solution Approach 1:
The key shaft incorporates locally optimized features where channels and cavities are positioned in specific regions without compromising overall structural integrity. The cross-sectional shapes are designed to provide local stiffness and strength where needed, while containing the complex internal geometry only in specific sections, thereby maintaining key shaft stability while achieving security through difficult replication.
3Reliability
If the channel axis is angled at less than 90 degrees to the central longitudinal plane, then the undercut becomes more compact and security is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The key shaft is designed with pre-formed cross-sectional shapes and channel orientations that are manufactured as integral features during the key production process. The angled channel axes and complex geometries are created using precision molding or machining techniques that establish the required angles and shapes in a single manufacturing step, eliminating the need for subsequent assembly or adjustment and ensuring consistent precision.
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3
AI summary
The invention relates to a key (10) for operating a locking cylinder (100), comprising a key bow (12) and a key shaft (16) extending from the key bow (12), wherein a channel (24) extending through the key shaft (16) along a channel axis (22), the channel (24) being designed as a stepped bore, the channel axis (22) forming an angle of less than 90° with the central longitudinal plane (26) of the key shaft (16), and an actuating pin (28) displaceable along the channel (24) for actuating a lateral tumbler (120) of the locking cylinder (100) being arranged in the channel (24). A locking system (100) comprising such a key (10) and an associated locking cylinder (102) is specified.