Key Insertion Path with Segmented Angles for Lock Cylinder
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Solution Overview
Problem
Existing key designs for lock cylinders face challenges in achieving a high number of locking variants while minimizing insertion effort and avoiding copyability, with conventional designs often limiting variant options due to fixed angles of inclination and requiring long key lengths or deep notches.
Innovation Solution
The key features a concave insertion path with a small angle of inclination at the tip and a larger angle near the locking notch, along with a mirror-symmetric additional insertion path towards the key back, allowing for easy production of keys with numerous locking variants and enhanced copy protection through uneven force curves and difficult measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a large angle of inclination is used for the insertion path, then the key can be inserted with more force, but the insertion effort increases significantly
Solution Approach 1:
The insertion path is divided into two distinct segments with different angles of inclination: a first section with a small angle (5-15 degrees) for initial engagement with pin tumblers, and a second section with a large angle (45-60 degrees) for subsequent movement. This segmentation allows the key to overcome static friction easily in the first phase while maintaining controlled force in the second phase, resolving the contradiction between insertion force and insertion effort.
Solution Approach 2:
Different sections of the insertion path are assigned different local properties (angles of inclination) optimized for their specific functions. The first section uses a small angle to minimize insertion effort during the critical initial engagement phase, while the second section uses a large angle to provide sufficient force for moving pin tumblers through the locking channel. This local differentiation resolves the contradiction by matching the geometric properties to functional requirements at each stage.
2Ease of operation
If a small angle of inclination is used for the insertion path, then the insertion effort is reduced, but the locking notch must be arranged particularly deep or the insertion path must be particularly long
Solution Approach 1:
The insertion path is segmented into two sections with different angles, allowing the key to achieve both low insertion effort (first section with small angle) and compact length (second section with large angle providing efficient pin tumbler movement). This resolves the contradiction by showing that a single uniform angle cannot simultaneously optimize for both insertion effort and key length.
Solution Approach 2:
The insertion path transitions dynamically from a shallow inclination to a steep inclination, adapting the angle based on the operational phase. This dynamic adjustment allows the key to maintain short length while providing easy insertion, as the angle changes to match the operational needs at different stages of key insertion.
3Ease of manufacture
If a predetermined angle of inclination is fixed in the blank, then the manufacturing process is simplified, but the number of locking variants is limited
Solution Approach 1:
The blank is designed with a segmented insertion path featuring a first section with a small angle of inclination and a second section with a large angle of inclination. This segmentation is built into the blank structure, allowing standard manufacturing processes to produce blanks with multiple locking variants by simply adjusting the position and depth of locking notches along the pre-configured multi-angle path, thus resolving the contradiction between manufacturing simplicity and design versatility.
Solution Approach 2:
The blank incorporates variable geometric parameters (different angles of inclination) in its insertion path design, allowing the same blank to accommodate multiple locking variants by changing the positioning of locking notches. This parameter variation within the blank structure enables manufacturing simplicity while maintaining high adaptability, as the blank can be configured for different locking requirements without requiring completely different blank designs.
4Ease of manufacture
If the insertion path is designed as a continuous incline, then the manufacturing is simpler, but the copy protection is reduced
Solution Approach 1:
The insertion path is segmented into distinct sections with different angles of inclination, creating a non-uniform geometric pattern that is difficult to replicate. This segmentation provides copy protection by creating a complex geometric signature that is harder to measure and reproduce than a simple continuous incline, while still remaining manufacturable through standard machining processes that can accommodate multi-section designs.
Solution Approach 2:
The insertion path employs asymmetric angle variations (small angle followed by large angle) that create an uneven geometric profile. This asymmetry in the angle sequence creates a unique geometric signature that is difficult to copy, as copying machines struggle to replicate precise angular variations. The asymmetric design maintains manufacturability while significantly enhancing copy protection through geometric complexity.
Data Source
Figure 1~2
Figure 3~4
AI summary
The key (1) has a shaft (9), a key chest (11) arranged on the shaft and a key back (12) averted to the key chest. An angle of inclination of insertion path (14) for the longitudinal axis of the shaft at a key point (13) is smaller than an angle of inclination of the insertion path at a next closing notch (10). The insertion path has two chamfers. An independent claim is included for a blank for a key.