Rekeyable Lock Cylinder Plug Assembly with Movable Rack Components

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Solution Overview

Problem

Existing lock cylinders require replacement when a key is changed, leading to high replacement costs and inconvenience.

Innovation Solution

A rekeyable lock cylinder system that allows for key changes without replacing the lock cylinder, using a plug assembly with movable rack components and a guide bar to disengage and reengage pins, enabling the use of new keys without altering the lock cylinder.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a lock cylinder is replaced when changing keys, then security is maintained, but cost and convenience deteriorate

Engineering Contradiction:

ImprovesecurityVSAvoidconvenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The lock cylinder is divided into separable components: the plug body containing movable rack components can be independently accessed and reconfigured while the outer cylinder body remains in place. This segmentation allows key reconfiguration without complete lock replacement.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The pin assemblies incorporate movable rack components that can shift between engaged and disengaged states. This dynamic mechanism enables the lock to accept different key configurations by moving the rack components transversely, maintaining security while allowing key changes.

Inventive Principle:

Principle #15Dynamics

2Reliability

If a lock cylinder is replaced when changing keys, then security is maintained, but cost deteriorates

Engineering Contradiction:

ImprovesecurityVSAvoidcost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Instead of discarding the entire lock cylinder when changing keys, the invention recovers and retains the cylinder body while only replacing or reconfiguring the internal pin assemblies and rack components. This selective recovery significantly reduces material loss and replacement cost.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The cylinder body is designed as a universal component that can accommodate multiple different key configurations through its interchangeable pin assemblies. This multi-functionality allows a single cylinder body to serve multiple keying purposes, eliminating the need for multiple complete lock cylinders.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If rack components are made movable to enable rekeying, then adaptability improves, but device complexity increases

Engineering Contradiction:

Improverekeying capabilityVSAvoidstructure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The rack components are designed to be movable rather than fixed, allowing them to shift transversely between engaged and disengaged states. This dynamic capability enables the lock to adapt to different key configurations while the movement is constrained to simple linear paths guided by the guide bar.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The guide bar serves as an intermediary component that mediates the movement of multiple rack components. By providing a centralized guiding structure, the guide bar simplifies the complexity of coordinating multiple moving parts, ensuring they all move in unison along the transverse axis.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Adaptability or versatility

If pin assemblies are made movable to enable rekeying, then adaptability improves, but manufacturing precision requirements increase

Engineering Contradiction:

Improverekeying capabilityVSAvoidengagement precision

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The guide bar acts as a precision intermediary that ensures all rack components move along the same transverse path. This centralized guidance mechanism maintains manufacturing precision by providing fixed reference surfaces and constrained movement paths, reducing the need for high-precision machining of each individual rack component.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The pin assemblies are segmented into modular units with standardized interfaces. This segmentation allows for precision to be achieved through repeated modular components with standardized tolerances rather than requiring high precision across the entire assembly, making manufacturing more feasible.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS7624606B1Rekeyable lock cylinder, plug assembly of the same and method for rekeying the same

Publication Date: 2009.12.01 TAIWAN FU HSING INDUSTRIAL CO LTD

AI summary

A rekeyable lock cylinder comprises a cylinder body and a plug assembly disposed within the cylinder body. The plug assembly comprises a plug body, a plurality of pin assemblies and a guide bar. The plug body has a longitudinal axis, a transverse axis perpendicular to the longitudinal axis and a tool-receiving hole. Each of the pin assemblies is movably disposed in the plug body and comprises a first rack component and a second rack component selectively engaging with the first rack component. The guide bar is coupled to the plug body and has a plurality of pin runners for engaging with the first rack components and a tool-receiving portion exposed by the tool-receiving hole. The guide bar is capable of moving along transverse axis-direction of the plug body to disengage the first rack components from the second rack components.