Rekeyable Lock Cylinder Without Disassembly
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Solution Overview
Problem
Conventional rekeyable lock systems require disassembly and use numerous parts, leading to a cumbersome and less-than-smooth rekeying process due to lateral meshing teeth and complex spring mechanisms.
Innovation Solution
A rekeyable lock cylinder design that eliminates teeth and springs, utilizing a plug assembly with rotatable locking bar interfaces and key followers for linear movement, allowing for rekeying without disassembly and reducing the number of parts needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional rekeyable lock systems use toothed racks and key followers with gear teeth, then the lock can be rekeyed without disassembly, but the rekeying process becomes cumbersome and less smooth due to lateral meshing teeth
Solution Approach 1:
The patent removes the toothed racks and gear teeth from the key followers, extracting the problematic lateral meshing mechanism. Instead, it uses smooth cylindrical key followers that move linearly within slots in the locking bar, eliminating the cumbersome tooth engagement during rekeying operations.
Solution Approach 2:
Rather than having teeth engage laterally during rekeying, the invention inverts the approach by using keyed slots that guide linear movement. The key followers move axially within slots defined in the locking bar, and rekeying is achieved by manipulating the locking bar's position rather than engaging teeth laterally.
2Reliability
If conventional rekeyable lock systems use multiple springs and spring catches, then the lock mechanism can maintain proper tension, but the system complexity increases with numerous parts
Solution Approach 1:
The patent removes the rack return spring, spring catches, and other spring mechanisms from the conventional system. Tension is maintained through the inherent elasticity of the locking bar material and the geometric constraints of the slot configurations, eliminating the need for multiple separate spring components.
Solution Approach 2:
The invention combines the functions of multiple springs and catches into a single integrated locking bar structure. The locking bar itself provides both the structural framework and the elastic tensioning mechanism, merging several discrete components into one unified element.
3Reliability
If conventional rekeyable lock systems use toothed racks and carriers, then the lock can maintain proper engagement, but the quantity of parts increases significantly
Solution Approach 1:
The patent eliminates the separate toothed racks and carrier components, removing these parts from the system. The engagement stability is maintained through the direct linear movement of key followers within slots in the locking bar, without requiring intermediate rack and carrier mechanisms.
Solution Approach 2:
The locking bar serves multiple functions simultaneously: it provides the structural framework, guides the key followers through its slots, maintains tension through its elasticity, and enables rekeying through its movable configuration. This multi-functionality eliminates the need for separate dedicated components.
4Adaptability or versatility
If conventional rekeyable lock systems require manual pushing of the carrier, then rekeying can be performed, but the operation requires precise manual control and time
Solution Approach 1:
The locking bar's elastic properties and slot geometry enable it to automatically return to its proper configuration after being manipulated during rekeying. The system self-corrects its position without requiring the user to manually push the carrier back, reducing both time and manual control requirements.
Solution Approach 2:
Instead of requiring manual pushing to disengage and re-engage teeth, the invention allows the locking bar to be manipulated into position and then automatically returns to its engagement state through its elastic recovery, inverting the sequence of manual intervention versus automatic action.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution simplifies the rekeying process by eliminating the need for key rotation and lateral tooth engagement, providing a faster and more reliable method with fewer components, enhancing user experience and efficiency.
Implementation Method 1
pushing at least one locking bar interface from its non-rotatable to its rotatable position against the bias of its respective key follower; rotating the interface to align a different unlocking surface with the locking bar
Implementation Method 2
pushing at least one locking bar interface from its non-rotatable to its rotatable position against the bias of its respective key follower
Data Source
AI summary
A rekeyable lock cylinder includes a cylinder body and a plug assembly, which includes key followers normally biased for linear movement into a home position. Locking bar interfaces in the plug assembly are rotatably connected to respective key followers for simultaneous linear movement with the key followers, and are movable from a non-rotatable to a rotatable position within the plug assembly. Each interface defines a plurality of angularly-spaced unlocking cavities alignable with a locking bar operatively associated with the cylinder body and plug assembly. When the user causes the interface to move into the rotatable position, it can be rotated to re-align any or all of the unlocking cavities with the locking bar. Inasmuch as each unlocking cavity is also associated with a particular elevation of the interface's respective key follower, re-aligning one or more such cavities resets the respective elevations of the key followers so that they can accept only a different valid key.