Reversible Key Blank with Rectangular Cross-Section
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Solution Overview
Problem
Existing key blanks and production methods face challenges in reducing production flexibility and costs while maintaining security, as they often require multiple blanks and extensive milling processes to create different key types.
Innovation Solution
A reversible key blank with a substantially rectangular cross-section and strategically arranged ribs and recesses allows for the production of multiple key types using a single blank, reducing material thickness and eliminating the need for additional milling, by incorporating ribs and recesses that interact to detect pin contours and facilitate the insertion of ring elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple key blanks are used to produce different key types, then key type versatility is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The key blank is designed with a universal structure that can produce multiple key types. The rectangular cross-section with broad sides and narrow sides, combined with strategically positioned recesses and ribs, allows a single blank design to serve as the basis for different key configurations through selective machining operations.
Solution Approach 2:
The key blank is pre-formed with recesses and ribs in specific positions before final key profiling. This preliminary structuring enables subsequent milling operations to efficiently create different key types by removing material around these pre-positioned features, rather than creating all features from scratch for each key type.
2Manufacturing precision
If extensive milling processes are used to create different key types, then key profile precision is improved, but production time and costs increase
Solution Approach 1:
The recesses and ribs are pre-positioned on the key blank before the final profiling milling operation. This allows the milling process to focus only on removing material to create the specific key profile, rather than having to create all geometric features during milling, thereby reducing production time while maintaining precision.
Solution Approach 2:
Different regions of the key blank are prepared with specific features (recesses on broad sides, ribs between recesses) that are then selectively machined. This localized preparation allows efficient production of different key types by varying the milling depth and pattern in specific local areas rather than re-machining the entire key profile.
3Loss of substance
If key blank thickness is reduced to save material, then material usage and costs are improved, but structural strength deteriorates
Solution Approach 1:
The key blank features non-uniform thickness distribution with thicker regions at the broad sides (where recesses are positioned) and thinner regions in between. This local variation provides enhanced strength where structural integrity is most needed (at the broad sides that engage with the lock mechanism) while reducing overall material consumption in less critical areas.
Solution Approach 2:
The key blank is effectively segmented into functional zones: broad sides with recesses for strength and feature engagement, narrow sides for reduced material, and rib structures that provide local reinforcement. This segmentation allows optimized material distribution that balances strength requirements with material efficiency.
Data Source
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Figure 2
Figure 3~4
AI summary
The present invention relates to a key blank (10) for manufacturing a key (58) for a lock cylinder (62), wherein the key blank (10) has a shaft (14) extending along a longitudinal direction (X), wherein the shaft (14) has a cross-section, in particular a substantially rectangular one, perpendicular to the longitudinal direction (X), wherein the cross-section has two wider broad sides (18) and two narrower narrow sides, wherein the key blank (10) is a reversible key blank, wherein the shaft (14) has a recess (28) with a rectangular base (32) in each of the broad sides (18), and wherein the thickness of the key blank (10) between the bases (32) of the recesses is less than 1.8 mm. Furthermore, a key (58) and a locking device, as well as a method for manufacturing a key (58), are proposed.