CA1238797A - Key and method of manufacture - Google Patents
Key and method of manufactureInfo
- Publication number
- CA1238797A CA1238797A CA000416795A CA416795A CA1238797A CA 1238797 A CA1238797 A CA 1238797A CA 000416795 A CA000416795 A CA 000416795A CA 416795 A CA416795 A CA 416795A CA 1238797 A CA1238797 A CA 1238797A
- Authority
- CA
- Canada
- Prior art keywords
- key
- blade
- lands
- lock
- grooves
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E05—LOCKS; KEYS; WINDOW OR DOOR FITTINGS; SAFES
- E05B—LOCKS; ACCESSORIES THEREFOR; HANDCUFFS
- E05B19/00—Keys; Accessories therefor
-
- E—FIXED CONSTRUCTIONS
- E05—LOCKS; KEYS; WINDOW OR DOOR FITTINGS; SAFES
- E05B—LOCKS; ACCESSORIES THEREFOR; HANDCUFFS
- E05B17/00—Accessories in connection with locks
- E05B17/0004—Lock assembling or manufacturing
- E05B17/0008—Lock parts made by extrusion process
Landscapes
- Lock And Its Accessories (AREA)
- Air Bags (AREA)
Abstract
Abstract of the Disclosure An improved key and an improved method of manu-facturing the key are disclosed. The key is an assembly of a handle and a blade, which are formed separately from each other. The blade is substantially flat, and includes on each of its opposite sides a plurality of parallel longitudinal lands having forwardly-facing bittings thereon, and a plurality of parallel longi-tudinal grooves which alternate with the lands and space them apart. The bittings serve to engage trans-verse rows of axially reciprocatable tumblers in a cylinder lock, and the grooves receive lock wards therein, while the distal end of the blade engages the lock to determine the depth of insertion of the key blade. The blade also is provided with a capture pin opening, and with a proximal end structure which cooperates with the handle in assembling the key. The blade is made from a length of bar stock which is rolled in order to form lands and grooves on the sides of a flat strip. The lands preferably project laterally outwardly for different distances, to provide increased security and to increase the number of possible key changes. Thereafter, the bar is stamped to form openings and recesses, and cut into individual key blade blanks. Forwardly facing bittings are provided in the lands of each blank, by milling from a distal end of the blade. The proximal end of the blade is inserted into a pocket formed in the handle, which is made of a thermoplastic material, and ultrasonic wave energy is used to soften the handle and cause the material thereof to penetrate the recesses and an opening in the proximal end of the blade, thereby forming a permanent assembly.
Description
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Description Key and ~ethod of Manufacture Technical Field This invention relates to an improvement in keys, especially those which are used ~ith axial pin tumbler locks; and it also relates to an improved method for making such keys. More particularly, the invention relates to grooved keys for use with such locks having coplanar tumblers, such as disclosed in Canadian patent application Serial No. ~07,001-1, and to the manufacture thereof.
Background Art ~lany axial pin tumbler locks have a cylinder within which tumblers are slidable in a direction parallel to the axis of the cylinder. In a large proportion of such locXs, the tumblers are arranged in a circular pattern, thus requiring a cylindrically shaped, so-called circular key to operate them. In the axial pin tumbler lock dis-closed in the above-referenced patent application, however, the tumblers are arranged in at least one planar row, so that they are operable by bittings located on a flat-bladed key.
~lat-bladed keys in general are known to the prior art. Some of them have longitudinally facing blttings adapted to cooperate with one or more rows of axially movable pin tumblers, as disclosed in U.S. Patents Nos.
3,733,963 of Toepfer, 3,604,231 of Buschi, 2,036,747 of FitzGerald, 919,259 of Simpson, 219,815 of Keil, and 180,255 of Miller. Canadian Patent No. 956,808 of Kerr and U.S. Patent No. ~50,745 o~ Lincoln are also somewhat relevant in this connectlon. But none of these keys is so designed as to take the fullest advantage of the flat blade configuration to provide maximum security, a great number of key chan~es, and minlmal expense and difficulty ~3~37~
of manufacturing commercially. Moreover, a number of the prior keys are readily duplicated, and the number of possible key changes provided by various key designs and lock and key combinations is relatively limited.
Also, the bitting arrangement of certain of the keys is such that the bittings may engage or "pick up" tumblers other than those intended.
Prior art methods of manufacturing grooved keys have involved grinding grooves in key blades. In U.S. Patent No. 3,729,965 of Gartner, it is recognized that manu-facturing keys by grinding grooves in in~ividual blades is expensive, and that a less costly approach is to ` extrude an elongated piece of blade stock with the desired grooves, thereafter cutting it to individual blade lengths. The key handles are manufactured separately, and attached to the individual blades afterwards.
Disclosure of Invention 0 The present invention provides a Xey for a lock such as disclosed in Canadian patent application Serial No. 407,001-1~ more particularly, a lock having a longitudinally extending diametral keyway and a planar transverse row of tumblers longitudinally reciprocatable in the lock with a side portion of each tumbler pro-jecting into the keyway and an outer end of such portion being accessible for engagement with the key, such lock also having at least one ward projecting transversely into the keyway. The new key of the invention includes a blade having a distal end adapted for abutting engagement with the lock to limit insertion of the key into the lock, a bitting for each of the tumblers and comprising a transverse shoulder on the blade disposed at the inner end of a recess extending longitudinally in the blade ~rom the distal end thereof and receiving the side portion o~ the tumbler ' ' -- .
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.'' ' '' , ~ ' ' ' , ' ~1.23~ 7 therein for abutting engagement of the bitting with the outer end of the side portion, and means providing at least one groove extending longitudinally in the blade from its distal end and receiving the ward therein for insertion of the key into the lock unlimited by any engagement of a ward with the key. The invention in-cludes the new key and the combination of the key and the lock.
In its preferred embodiments, the key includes at least one bitting which projects :Laterally out~ardly on the blade for a greater distance than at least one other bitting. The bittings preferably are formed on longi-tudinal lands on at least one side of the blade, and the lands alternate with longitudinal grooves in such side.
The invention provides a method of manufacturing the key, which includes the steps of providing blade stock having a length sufficient to ~orm a plurality of key blade blanks therefrom along the length thereof, rolling the stock to form compressively at least one longitudinal groove in at least one side thereof, and cutting the rolled stock transversely to form such plurality of blanks each having a longitudinal groove therein.
The new key cooperates with a lock having multiple tumblers, e.g., as many as eight pin tumblers, and also having protective wards, to provide a high degree of security, which is further enhanced by the preferred provision of disparately-si~ed bittings and lands on which the bittings are provided. The str~lcture at the same time provides for a great number of key changes.
Another feature of the invention which contributes to security in general is that the ~ey may be reproduced by others only by a time-consuming and expensive procedure, and then, with difficulty in achieving the precision that is necessary in providing grooves, pro-jections, and spacings.
~238~97 The land-and-groove structure of the key both con-tributes to security and serves to space bittlngs apart, so that there is no problem of bittings undesirably engaging tumblers adjacent to the tumblers whi,ch the bittings are intended to engage. The structuré further cooperates with the lock -to minimize key play and provide accuracy in operation.
The key may be manufacturecl commercially i~ a relativ~ly simple and economical manner, in accordance with the new method. Thus, key blades may be manu-factured conveniently and rapidly from bar stock of a desirable alloy or other suitable material, by successive rolling, stamping, and milling operations, which produce strong, accurately made blades, with little waste of material. The blades are readily assembled with handles, which preferably are constructed of thermoplastic material and are joined to the blades by heating, in a simple, - rapid, and economical procedure. As compared to keys made by prior art methods, the key blade is stronger and the blade and handle assembly is more durable when made in accordance with the present invention.
These and other features, objects and advantages of the invention will be more fully appreciated from the followinD detailed description, taken in conjunction with the accompanying drawings.
Brief Description of Drawings The drawings represent a preferred embodiment of the invention. The embodiment is merely illustrative, and the invention is not limited thereto.
Like elements are identified by like reference characters in each of the views of the d~awings, wherein:
FIG. 1 is a perspective view of a key constructed in accordance with this invention, together with the lock for which it is adapted;
FIG. 2 is an enlarged exploded side elevational , : :
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view of the key;
FIG. 3 is n cross-sectional view of the key blade, taken on the line 3-3 of FIG. 2;
FIG. ~ is a side elevational view of the key;
FIG. 5 is a front elevational view of the key;
FIG, 6 is a front elevational view of a ~acing plate in the lock of FIG. l;
FIG. 7 is a further enlargled front and side perspec-tive view of a spacer in the lock;
FIG. 8 is a similarly enlarged front elevational view of the lock, with a cap thereof removed and parts broken away to reveal internal structure;
FIG. 9 is a longitudinal sectional view of the lock, taken substantially on line 9-9 of FIG. 8, together with a fragmentary side elevational view of the key in position to be inserted into the lock;
FIG. 10 is a view similar in all respects to FIG. 9 except that the key is inserted into the lock;
FlG. 11 is a top plan view of the lock and key, in the same positions as in FIG. 10, with parts broken away and sectioned for clarity o~ illustration;
; FIG. 12 is a perspective view of a portion of a piece of elongated flat blade stock which can be employed in manufacturing the blade of the key according to the method of this invention;
FIG. 13 is a perspective view of a portion o~ the same piece o~ stock after it has been rolled, in accord-ance with the method of this invention, to form lands and grooves thereon;
FIG. 14 is a perspective view of two individual key blade blanks cut from the rolled blade stock of FIG. 13 a~ter stamping and/or punching the same, in accordance with the method;
FIG. 15 is a perspective view of one of the blanks of FIG. 14 after forwardly-facing bittings have been .
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formed on the lands thereof in accordance with this invention, to provide the key blade illustrat~d in earlier views; and FIG. 16 is an enlarged perspective view of a tumbler in the lock.
Best Mode for Carrying Out the Illvention _ FI&. 1 shows the lock 10 of International Appli-cation No. PCT/US82/00914 ? having~ a keyway lOA7 and a key 12 according to this invention which is designed to operate a lock of that type. The lock includes a tubular barrel 14, at one end of which is a closure cap 16 and a facing plate 1~. At the opposite end of the barrel 14 is a locking arm 20. A mounting nut 22 is threaded to the tubular barrel 14 for the purpose of securing the lock 10 to some type of enclosura (not shown). The locking arm 20 is secured to a threaded extension 24a of a lock cylinder 24 (FIGS. 8-11) by a nut 21 J and projects at an angle from the lock to prevent the door of the enclosure from being opened. In order to unlock the door, it is necessary to turn the lock cylinder 24, which is rotatable ~ithin the tubular barrel 14. This cylinder 24 cannot be turned, however, unless a number of pin tumblers 26 (FIGS. 9, 10 and 16) are moved precisely the correct distances in a direction parallel to the common longi-tudinal axis of the tubular barrel 14 and of the lock cylinder 24. This is the function which is performed by the key 12 of the invention, by insertion into the keyway lOA.
In order to admit the key 12 to the interior of the lock 10, the generally circular facing plate 18 is provided with an elongated key-receiving opening 18A.
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The key-receiving opening 18A constitutes an outermost or first portion of the longitudinally extending, diametral or transverse keyway 10A. On both sides of this opening 18A, a plurality o~ wards 18B project inwardly into the opening, and they define grooves 18C
alternating with them, as best seen in FIG. ~.
FIGS. 7 and 9-11 illustrate a cylindrically-shaped spacer 28, which is located directly behind the facing plate 18. This spacer is provided with an elongate longitudinal key-receiving opening 28A, which is aligned or registers with the key-receiving opening 18A of the facing plate 18, and constitutes an intermediate or second portion of the keyway 10A. Wards 28B extend into the key-receiving opening 28A of the spacer and are aligned with certain wards 18B in the face plate. The width of the spacer opening 28A is equal to the greatest width of the opening 18A in the facing plate 18 in any of the alternative configurations of the opening, described hereinafter.
The spacer 28 also has two arcuate front lugs 28D and two rectangular rear lugs 28F on respective -front and rear faces thereof. The facing plate 18 has two arcuate recesses 18D in its periphery, which recesses are adapted to receive the front lugs 28D of the spacer 28, for the purpose of preventing relative rotation between the facing plate and the spacer.
The spacer 28 is provided with two diametrically opposed, counterboredJ radial, pin-receiving openings 28E, which extend from its outer periphery to its key-receiving opening 28A. As illustrated in FIGS. 9-11, a capture or retention pin 3~ of similar configuration is mounted in the spacer 28 -for reciprocal radial movement in each opening 28E, under the outward bias of a capture pin spri.ng 35.
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37~'7 Referring to ~IGS. 8-11, the lock cylindor 24 includes a cylinclrical body 24B having a ~ront face 24C, which body rotates within 1;he barre~ 14 and is integral with the extension 24A. Two longitudinal grooves 2~D (FIG. 11) are provided iD the surface o~
the lock cylinder 2~, and they extend rearwardly ~rom the front ~ace 24C in diametrically spaced apart parallel rela-tion. The grooves 24D receive respective rear lugs 28F o~ the spacer 28, to prevent relative rotation between the spacer and the c~lincler. Thus, owing to the engagement o~ the spacer ~ront and rear lugs 28D and 28I with the ~acing plate 18 and the lock cylinder 24, respectively, the ~acing plate, the spacer, and the cylinder are lnterconnected ~o~ rotating as a unit in the barrel 14.
The lock cylinder 24 is provided wi-th two spaced apart parallel planar transverse rows of spaced apart cylindrical blind tumbler bores 24E extending ~rom the ~ront ~ace 24C in parallel relation in the direction oi' the longitudinal axis o~ the cylinder. A coil compression tumbler spring 52 and a tumbler 26 are received in each o~ the bores 24E, for reciprocal longitudinal movement of the tumbler therein.
A diametral key-receiving ælot 24F (FIGS. 8 and 11~
25 - extends rearwardly in the axial direction ~rom the ~ront ~ace 24C of the lock cylinder 24 ~or a minor portion of the length o~ the cylinder body 24~. The slot 24F is aligned or registers wi-th the key-receiving openings 18A
and 28A in the ~acing plate 18 and the spacer 2~, raspectively, and the slot 24F constitutes an innermost or third portion o~ the keyway lOA. The slot 24F
intersects the walls of the tumbler bores 24E, whereby an angularly minor section o-~ the wall o~ each bore is removed, on the inside o~ its row o~ hores. A corres-3S ponding section o~ each tumbler 26 is exposed in the ' ~
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,~
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--9--slot 24F (see FIG. g).
Re~erring to FIG. 16, each tumbler 26 inc].udes a cylindrically shaped body 26A and a cylindrical stem 26B
o~ reduced diameter extending axially froo a rear end o~
tha body. The body 26A ~s provided with one or more shallow peripheral grooves 26C, and a relatively deep peripheral groove 26D, for operating purposes, as : described in the above-identi~led application. Brie~ly, the shallow ~rooveæ 26C constitute ~alse picking grooves, while the deep groove 26D constitutes an unlockirg groove. As illustrated in FIG. 9, the tumbler stems 26B
are received in the springs 52 and the tumbler bodies 26A are seated on the springs, so that the tumblers are urged outwardly, with their outer or ~ront ends 26E
in abutting engagement with the spacer 28 in the lockillg condi-tion o~ the lock 10.
As seen in FIG. 3, an angularly minor side portion or scction o~ each tumbler body 26A projects transversely ; into the portion o~ the keyway 10A ~orm~d by the cylinder slot 24F. The outer end of such tumbler body portion, being a p~rt of the tumbler outer end 26~, is accessible for engagement with a blAde 30 o~ the key 12. The wardæ
18B o~ the facing plate 18 and the wards 28B of the ; spacer 28 also project transversely into the ~eyway 10A, and, in general, they are disposed in common longitudinal planes with the portions o~ the cylinder body 24B which exist between the tumbler bores 24E.
In accordance with this invention, the key 12 is aæsembled ~rom two separate components, a metal blade 30 or shank and a plastic handle 32 (FIG. 2). The blade haæ
a distal or operating end 30A and a proximal end 30B.
The handle is ~ormed with a pocket 32A, best seen in FIGS. 2 and 11, which is adapted to receive the proximal end 30B o the blade. The handle is provided with 3~ serrations 32B along one edge only, 80 that the user can ~ ' '' :
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determine by ~eel the ~anner in which to orient the key ~or insertion into the keyway lOA of the lock 10. The handle 3~ also is provided with a Xeychatn hole 32C.
The key 1~ is what is known as a "~lat" key, having a generally Plat blacle 30, as distingulshed -from a "round"
or "circular" key~ having a generally cireular tubular shank. Referring to FXG. 3, the blade 30 is provided with a plurality o~ parallel longituclinal alternating lands and grooves on each of its sides, there being ~our lands 36-39 interspersed with three grooves 4S-~7 on one side, ~ncl ~our lands 40-43 interspersed with three grooves 48-50 on the opposite side. In the illustrative pre~erred embodiment, the locations oP the lands and grooves on the opposite sides are alike, so that they are arranged in back-to-back relation on the blade. Two o~ the lands on one side of the embodiment, numbered 36 and 39, project laterally outwardly ~rom the blade bofly ~or gr~ter distances than or beyond -the remaining lands 37 and 38~
i.e., are enlarged with respect to the remaining lands.
; 20 Referring to FI~S, 2, 4, 5 and 15, the several lands 36-~3 have respective forwardlyfacing bittings 36A~43A
thereon. The bittin~s comprise transverse shoulders on the lands 36-43, disposed at the inner ends of recesses, such as those numbered 36B-39B in ~IGS. 2 and 15, wh:ich extend longitudinally in the lands from the distal end 30A o~ the blade 30, for various selected distances.
The recesses 36B-39B, and corresponding recesses on the opposite side o~ the blade, having the shape o~ a ~ection of a cylinder, ~or receiving therein the above-describefl tumbler body side portions which project into the keyway lOA, with the outer ends o~ the side portions7 at 26D, abuttingly engaging respective bittings 36A-43A. Various key changes are achieved by dif~erent combinations o~
bitting locations on the lands 36-43.
In the preferred embodiments o~ the invention, the .
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~3~7~7 number o~ Icey changes is increase~ by ~rranginF ~or one or more o~ the :lands o~ the key blade 30 to be enlarged with respect to ~i.e,, more prominent than) the others, Thus, ~or example, the top and bottom lands 36 and 39 in the illustrative embodiment are enlarged with respect to the other lands (see FIGS, 3 and 5). The elongate open-ing 18A in the ~acing plate 18 is deslgned to accommodate the enlarged key blade lands 36 and 39, with correspondin~
grooves 18C which are deeper than the grooves 13C at the locations which accommodate the remainlng lands oi' the key blade. Such a ~acing plate can only accommodate a key blade which does not have an enlarged land in any position where a relatively shallow groove 18C appears in the ~acing plate opening 18A, Thus, in orcler to open the lock 10, the lsey blade 30 must have a land con~ig-uration which is not excluded ~rom entering the cylinder ,~ 24 by the groove configuration o~ the ~acing plate 18, in addition to having a bitting con~iguration which matches the code for the tumblers 26, i.~., the locations o~ the unlocking grooves 26D, as described in the above-identi~ied application.
SiIIce the facing plate 13 is external to the spacer 28 in the lock 10, and excludes those key blades which have enlarged lands in the wrong places, the elongate opening 28A in the spacer need only have a con~iguration which is capable o~ accepting any key blade, That is to say, the width o~ the elongate spacer opening 28A at all locations, except where there are wards 2~B, is great enough to accept a Icey blade 30 having an enlarged land, such as those numbered 36 and 39, at any land location.
Re~erring to FIG. 2, a capture or retentlon opening 30C in the blade 30 provides pin-receiving recesses on opposite sides o~ the blade, adjacent to and spaced ~rom the blade distal end 30A, approximately midway between its side edges, The central blade grooves 46 and ~9 on , -: "
the oppo~ite slde~ o~ tha blacle are aligned ~ith the capture openin~ 30C.
For ~ssembly purposes, described hereina~ter, a handle-retaining or anchoring hole 30D is provlded in the blade 30, adjacent to and æpa&ed LCrom the blade proximal end 30B. A
plurality of ker~s 30E is ~ormecl on each edge o~ t,he blade 30 adjacent to its proxim~l end 30B. The kerIs 30E ~re deIined by sawtooth-type anchor teeth 30F, which provide s0rr~t~d edges ~t the proxim~l end 30B. An inner, rect~ngul~r e~tra olle o~
the ~er~s 30E ~s prorided on one edg~, i'or orlentillg the bl~de 30 by locatlng such ker~ adjacont to the handle serration~ 32B.
Re~erring to FIGS. 2-ll, the key blade 30 i8 elosely r~-ceived w~thin tha key-receiving openlng l~A o~ the ~acing plate 18, wlth the la~ds 36-43 received in the grooves 18C o~ the ~acing plate and the wards 18B o~ the ~ac~ng pl~te received in the groove~ 45-50 o~ the blade. The key blade 30 iæ re-ceived within the key-receiving opening 28h oi' the spacer 28, with the wards 28B o~ the spacer received in the outer grooves 45, 47, and 48, 50 o~ opposite sldes o~ the blade. The key blade is received in the diametral key-receiving slot 24F in the cylinder 24, and the distal blade end 30A ls adapted ior abutting engagement w~th the lock cylinder 24 at the base o~
the slot 24F. Thus, the di~tal blade end 30A bottoms in the slot 24F, as seen in FIGS. 10 and ll, to limit insertion o~
the key into the lock. When the key is thu~ inserted, the lands 36-43 and the groovos 45-~0 e~tend lo~gitudlnally out-wardly beyo~d the ~eyway lOA. The side portions o~ the tum-bler~ 26 are received in the blade recesses 36B~39B ~nd cor-responding recesses on the opposite sid~ o~ the blade, a~d ~but on the bittings 36A-43A, as described above.
In u~e, the blade 30 of the key 12 is inserted i~to the lock keyway lOA, ~y manipulating the handle 32, until the dis-tal end 30A of the blade bottoms in the cylinder slot 24F.
During the insertion, the outer ends 26E o~ the tumblers 26 engage the bittings 36A-43A, as described above, whereby the ~?
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tumblers are moved lnwardly against the blas o~ the spring~
52. Upon bvttoming o~ the blade, the tumbler~ 26, particul~r-ly tbe deep grooves therein, such a~ the groove 26D7 are ~o disposed as to enable the facing plate 18, the ~pacer 28, and the lock cylinder 24 to be rotated to an unlocking condition by turning the k0y 1~. In thl~ connection, it will be noted that the wards 18B o~ the ~aclng plake 18, and th0 ward~ 2~B
o~ the ~pacer 28 are received in corresponding grooves 45-50 in the blade 30, the grooves extendlng outwardly beyond tha keyway lOA, without llmiting t~he insertlon o~ the key by any engagement o~ a ward therewith.
A~ the bl~de 30 is ln~erlted, the inner ends o~ the cap-ture plns 34 on oppo~lte side~ o~ the blade are received in the central blade grooves 46 and 49, respcctively, to permit insertion o~ the bl~de. When the blade 30 i~ ~ully ln~erted, the pin~ 34 are aligned with the capture opening 30C in the blade, which permitæ movement o~ the pin~ inwardly agalnst the bias o~ their springs 35. When tha key 12 is turned, the pin~
34 are moved inwardly into the capture opening 30C by cam~ing engagement of their outer snds with the barrel 14, as des-cribed in the9 above-identi~ied applieation. In the absence o~ sultabl~ recess means9 such as provided by the capture o-pening 30C, the pins 3~ would interlock with the b~rrel 14, to prevent rotation o~ the lock cylinder 24. After rota~lng the lock cylinder to an unlocking condltion, and ln thc ab-sence oP any relie~ area in the ~all o~ the barrel 14, the 1nner ends o~ the pins 34 remain within the capture openlng 30C, to hold the Xey 12 captlve in the lock 10, until the lock cylinder ~ ~ res~ored to ~ts locking conditlon .
The illustrat~ve preferred combin~tion o~ the key 12 and the lock 10 employ~ eight pin tumblers 26 and key ~, ' " , ~, . . ` ` ~ .
' ,, ' 3~' bittings 36A-~3A, which is one more than certain widely used "circular key" locks, thereby increaslng the loclc security and the number o~ ker changes af:eorded. A1-ternatively, a lesser number o~ tumbler~ and bittings may be employed for either or both tumbler rows, especially where a smaller, more compac-t lock is desired.
The preferred structure embodies at least one row of a ; minimum of three tumblers, and a double row structure surh as illustrated i~ much pre~erred ~or exceptlonal security. While the tumblers in each row pre~erably face the corresponding tumblers in the other row, they may be disposed in other relationships, such as sta~gered, with the key lands, grooves and bittings cooperatively disposed on the key blade.
The Isey grooves 45-50 cooperate with the lock wards 18B and 2~B in providing additional lock security and -~ precision in operation, and the grooves also serve to space the lands 36-43 and their bittings 36A-43A apart from adjacent ones, so -that there is no problem of the ; 20 bittings engaging or "picking up" tumblers 26 adjacent to the proper ones, upon insertion of the key. Further, key duplication is made difficult by the need ~or the lands, grooves, and bittings, especially in their back-to-back relationship.
25 - The provision in the lock of the capture pins 34 adds to the security and complicates picking and key duplication efforts, inasmuch as key blade grooves are required, as previously de~cribed, which will align with the pins and permit the blade 30 to be inserted into the lock. Then, the capture opening 30C must be provided in the correct position in the blade 30, to enable the lock cylinder to be rotated.
The prior art has recognized that ~t is more economical to manu~acture a grooved Icey blade separately from the key handle, because the grooves for a number o~
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individual key blades can be ~ormed simultaneously along the length o~ a piece o~ bar stock, and a plurality o-~
individual blades then can be made ~rom the grooved bar ~ stock. Similarly, in the present invention) the ; 5 manu~acture o~ key blades 30 begins with an elon~a-ted piece o~ metal bar stoclc 60 or the like, which is longer than any one blade) h~ving a length su~icient to ~orm a plurality oP lcey blade blanks there~rom along the length thereof. The desired lands 36-~3 and grooves ~5-50 are ~ormed on the sides o~ the bar stock, as seen in FIG. 13.
It is part o-P this invention, however, that the ~ormation o~ the lands and grooves is done by a process o~
rolling, rather than by the procedures previously employed ~or malcing key blades, such as milling and extrusion.
Rolled blade stock ~s much stronger than a structure ~ormed by milling away su~icient metal to de~ine the grooves, or one which is ~ormed by passing the stock through an extrusion d~e of appropriate con~iguration to de~ine the desired lands and grooves. The rolling procedure compresses and strengthens the metallic material of the bar 60 in the areas which are depressed to ~orm the grooves 45-50 Such compressing and strengthening also occurs~ although to a lesser extent, in those areas which are partlally compressed to ~orm the smaller lands 37, 38 and 40-43. Unlike the prior milling, no metal is removed, so that there is virtually no waste.
The rolling procsss may commence with bar stock o~
any suitable cross section. It is convenient to start with round bar stock, which first is rolled to a generally ~lat elongated bar or strip, such as the bar 60 o~ FIG 12. Then,the lands and grooves are ~ormed by rolling, to produce the rolled, contoured, generally Plat bar 60A o~ FIG. 13, having the lands 36-43 and the grooves 45-50 Pormed therein.
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~16-Blade blal~ks such as those numberecl 30.1 and 30.2 o~ FIG. 1~ next are stamped or punched and cut from the contoured bar 60A. In onQ preferred procedure, the operat~ons are performed by a progressive clie, which punches -the openings 30C and 30D, stamps out the ker~s 30E, and severs the blanks 30.1 and 30.2. Therea~tar, the blan~s are encl-m:illed from the distal e~d 30A, to form the cylindrically rounded recesses 36B-39B in the lands 36-39 on one side, and similar recesses in the lands ~0-43 on the opposite side. The transverse ~la-t ~rcuate hittings 36A~-L3A are provlded thereby, at the rear or inner ends of the recesses, as illustrated in I~IGS. 5 and 15.
The ker~s 30E, cut to ~orm serrated opposite edges adjacent to the proximal end 30~ of the blade, and the handle-retaining hole 30D permit the ~astening of the handle 32 to the blade 30 by a novel, convenient, and economical method. The handle 32 is formed o~ a con-ventional thermoplastic material which softens under suitable heating. The depth o~ the pocket 32A in the handle is such that when the proximal end 30B o the blade is inserted thereinto, both the retaining hole 30D
and the ker~s are recelved completely within the pocket.
Then, the assembly of the handle and the blade pre~erably is subjected to ultrasonic wave energy, which is exter-nally directed to the handle and the proximal blade end therein. ~s a result, the plastic material of the handle 32 is heated to its so~tening point adjacent to the blade end, and then ~lows into the ~erfs 32~ and -the ~0 hole 32D, in intimate, securing engagement with the blade end. The thermoplastic material is allowed to cool and harden whereupon the handle 32 and the key blade 30 form an interpenetrating and there~ore permanent assembly.
Previously, keys had been manufactured by holding key blades in a die, and in~ection-molding plastic handles ~3~7~
thereon, such procedure bein~ re~erred to as insert molding. The key assembly methotl oP the present invention is ~aster and less expensive than the con-ventional insert molding, and more secure and longer-lastin~ than other conventional approaches, such asriveting or ~ use of a eriction ~it, a press ~it, or a snap ~it.
The key manu:eacturlng method of the present in-vention thus provicles a stronger blade, and the assemblv method is more economical, and i'orms a more lasting assembly Oe the blade and the handle, than prior methods While preferred embofliments of the s-tructure ancl method O:e the invention have been illustrated and described, it will be spparent to those skilled in the art that various changes and modifications may be made therein, within the spirit and scope of the invention.
It is intended that such changes and modi~eications be included within the scope of the appended claims.
,
Description Key and ~ethod of Manufacture Technical Field This invention relates to an improvement in keys, especially those which are used ~ith axial pin tumbler locks; and it also relates to an improved method for making such keys. More particularly, the invention relates to grooved keys for use with such locks having coplanar tumblers, such as disclosed in Canadian patent application Serial No. ~07,001-1, and to the manufacture thereof.
Background Art ~lany axial pin tumbler locks have a cylinder within which tumblers are slidable in a direction parallel to the axis of the cylinder. In a large proportion of such locXs, the tumblers are arranged in a circular pattern, thus requiring a cylindrically shaped, so-called circular key to operate them. In the axial pin tumbler lock dis-closed in the above-referenced patent application, however, the tumblers are arranged in at least one planar row, so that they are operable by bittings located on a flat-bladed key.
~lat-bladed keys in general are known to the prior art. Some of them have longitudinally facing blttings adapted to cooperate with one or more rows of axially movable pin tumblers, as disclosed in U.S. Patents Nos.
3,733,963 of Toepfer, 3,604,231 of Buschi, 2,036,747 of FitzGerald, 919,259 of Simpson, 219,815 of Keil, and 180,255 of Miller. Canadian Patent No. 956,808 of Kerr and U.S. Patent No. ~50,745 o~ Lincoln are also somewhat relevant in this connectlon. But none of these keys is so designed as to take the fullest advantage of the flat blade configuration to provide maximum security, a great number of key chan~es, and minlmal expense and difficulty ~3~37~
of manufacturing commercially. Moreover, a number of the prior keys are readily duplicated, and the number of possible key changes provided by various key designs and lock and key combinations is relatively limited.
Also, the bitting arrangement of certain of the keys is such that the bittings may engage or "pick up" tumblers other than those intended.
Prior art methods of manufacturing grooved keys have involved grinding grooves in key blades. In U.S. Patent No. 3,729,965 of Gartner, it is recognized that manu-facturing keys by grinding grooves in in~ividual blades is expensive, and that a less costly approach is to ` extrude an elongated piece of blade stock with the desired grooves, thereafter cutting it to individual blade lengths. The key handles are manufactured separately, and attached to the individual blades afterwards.
Disclosure of Invention 0 The present invention provides a Xey for a lock such as disclosed in Canadian patent application Serial No. 407,001-1~ more particularly, a lock having a longitudinally extending diametral keyway and a planar transverse row of tumblers longitudinally reciprocatable in the lock with a side portion of each tumbler pro-jecting into the keyway and an outer end of such portion being accessible for engagement with the key, such lock also having at least one ward projecting transversely into the keyway. The new key of the invention includes a blade having a distal end adapted for abutting engagement with the lock to limit insertion of the key into the lock, a bitting for each of the tumblers and comprising a transverse shoulder on the blade disposed at the inner end of a recess extending longitudinally in the blade ~rom the distal end thereof and receiving the side portion o~ the tumbler ' ' -- .
.~ . . - .
.'' ' '' , ~ ' ' ' , ' ~1.23~ 7 therein for abutting engagement of the bitting with the outer end of the side portion, and means providing at least one groove extending longitudinally in the blade from its distal end and receiving the ward therein for insertion of the key into the lock unlimited by any engagement of a ward with the key. The invention in-cludes the new key and the combination of the key and the lock.
In its preferred embodiments, the key includes at least one bitting which projects :Laterally out~ardly on the blade for a greater distance than at least one other bitting. The bittings preferably are formed on longi-tudinal lands on at least one side of the blade, and the lands alternate with longitudinal grooves in such side.
The invention provides a method of manufacturing the key, which includes the steps of providing blade stock having a length sufficient to ~orm a plurality of key blade blanks therefrom along the length thereof, rolling the stock to form compressively at least one longitudinal groove in at least one side thereof, and cutting the rolled stock transversely to form such plurality of blanks each having a longitudinal groove therein.
The new key cooperates with a lock having multiple tumblers, e.g., as many as eight pin tumblers, and also having protective wards, to provide a high degree of security, which is further enhanced by the preferred provision of disparately-si~ed bittings and lands on which the bittings are provided. The str~lcture at the same time provides for a great number of key changes.
Another feature of the invention which contributes to security in general is that the ~ey may be reproduced by others only by a time-consuming and expensive procedure, and then, with difficulty in achieving the precision that is necessary in providing grooves, pro-jections, and spacings.
~238~97 The land-and-groove structure of the key both con-tributes to security and serves to space bittlngs apart, so that there is no problem of bittings undesirably engaging tumblers adjacent to the tumblers whi,ch the bittings are intended to engage. The structuré further cooperates with the lock -to minimize key play and provide accuracy in operation.
The key may be manufacturecl commercially i~ a relativ~ly simple and economical manner, in accordance with the new method. Thus, key blades may be manu-factured conveniently and rapidly from bar stock of a desirable alloy or other suitable material, by successive rolling, stamping, and milling operations, which produce strong, accurately made blades, with little waste of material. The blades are readily assembled with handles, which preferably are constructed of thermoplastic material and are joined to the blades by heating, in a simple, - rapid, and economical procedure. As compared to keys made by prior art methods, the key blade is stronger and the blade and handle assembly is more durable when made in accordance with the present invention.
These and other features, objects and advantages of the invention will be more fully appreciated from the followinD detailed description, taken in conjunction with the accompanying drawings.
Brief Description of Drawings The drawings represent a preferred embodiment of the invention. The embodiment is merely illustrative, and the invention is not limited thereto.
Like elements are identified by like reference characters in each of the views of the d~awings, wherein:
FIG. 1 is a perspective view of a key constructed in accordance with this invention, together with the lock for which it is adapted;
FIG. 2 is an enlarged exploded side elevational , : :
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', :~
1238~
view of the key;
FIG. 3 is n cross-sectional view of the key blade, taken on the line 3-3 of FIG. 2;
FIG. ~ is a side elevational view of the key;
FIG. 5 is a front elevational view of the key;
FIG, 6 is a front elevational view of a ~acing plate in the lock of FIG. l;
FIG. 7 is a further enlargled front and side perspec-tive view of a spacer in the lock;
FIG. 8 is a similarly enlarged front elevational view of the lock, with a cap thereof removed and parts broken away to reveal internal structure;
FIG. 9 is a longitudinal sectional view of the lock, taken substantially on line 9-9 of FIG. 8, together with a fragmentary side elevational view of the key in position to be inserted into the lock;
FIG. 10 is a view similar in all respects to FIG. 9 except that the key is inserted into the lock;
FlG. 11 is a top plan view of the lock and key, in the same positions as in FIG. 10, with parts broken away and sectioned for clarity o~ illustration;
; FIG. 12 is a perspective view of a portion of a piece of elongated flat blade stock which can be employed in manufacturing the blade of the key according to the method of this invention;
FIG. 13 is a perspective view of a portion o~ the same piece o~ stock after it has been rolled, in accord-ance with the method of this invention, to form lands and grooves thereon;
FIG. 14 is a perspective view of two individual key blade blanks cut from the rolled blade stock of FIG. 13 a~ter stamping and/or punching the same, in accordance with the method;
FIG. 15 is a perspective view of one of the blanks of FIG. 14 after forwardly-facing bittings have been .
~3~7~
formed on the lands thereof in accordance with this invention, to provide the key blade illustrat~d in earlier views; and FIG. 16 is an enlarged perspective view of a tumbler in the lock.
Best Mode for Carrying Out the Illvention _ FI&. 1 shows the lock 10 of International Appli-cation No. PCT/US82/00914 ? having~ a keyway lOA7 and a key 12 according to this invention which is designed to operate a lock of that type. The lock includes a tubular barrel 14, at one end of which is a closure cap 16 and a facing plate 1~. At the opposite end of the barrel 14 is a locking arm 20. A mounting nut 22 is threaded to the tubular barrel 14 for the purpose of securing the lock 10 to some type of enclosura (not shown). The locking arm 20 is secured to a threaded extension 24a of a lock cylinder 24 (FIGS. 8-11) by a nut 21 J and projects at an angle from the lock to prevent the door of the enclosure from being opened. In order to unlock the door, it is necessary to turn the lock cylinder 24, which is rotatable ~ithin the tubular barrel 14. This cylinder 24 cannot be turned, however, unless a number of pin tumblers 26 (FIGS. 9, 10 and 16) are moved precisely the correct distances in a direction parallel to the common longi-tudinal axis of the tubular barrel 14 and of the lock cylinder 24. This is the function which is performed by the key 12 of the invention, by insertion into the keyway lOA.
In order to admit the key 12 to the interior of the lock 10, the generally circular facing plate 18 is provided with an elongated key-receiving opening 18A.
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The key-receiving opening 18A constitutes an outermost or first portion of the longitudinally extending, diametral or transverse keyway 10A. On both sides of this opening 18A, a plurality o~ wards 18B project inwardly into the opening, and they define grooves 18C
alternating with them, as best seen in FIG. ~.
FIGS. 7 and 9-11 illustrate a cylindrically-shaped spacer 28, which is located directly behind the facing plate 18. This spacer is provided with an elongate longitudinal key-receiving opening 28A, which is aligned or registers with the key-receiving opening 18A of the facing plate 18, and constitutes an intermediate or second portion of the keyway 10A. Wards 28B extend into the key-receiving opening 28A of the spacer and are aligned with certain wards 18B in the face plate. The width of the spacer opening 28A is equal to the greatest width of the opening 18A in the facing plate 18 in any of the alternative configurations of the opening, described hereinafter.
The spacer 28 also has two arcuate front lugs 28D and two rectangular rear lugs 28F on respective -front and rear faces thereof. The facing plate 18 has two arcuate recesses 18D in its periphery, which recesses are adapted to receive the front lugs 28D of the spacer 28, for the purpose of preventing relative rotation between the facing plate and the spacer.
The spacer 28 is provided with two diametrically opposed, counterboredJ radial, pin-receiving openings 28E, which extend from its outer periphery to its key-receiving opening 28A. As illustrated in FIGS. 9-11, a capture or retention pin 3~ of similar configuration is mounted in the spacer 28 -for reciprocal radial movement in each opening 28E, under the outward bias of a capture pin spri.ng 35.
- : .
37~'7 Referring to ~IGS. 8-11, the lock cylindor 24 includes a cylinclrical body 24B having a ~ront face 24C, which body rotates within 1;he barre~ 14 and is integral with the extension 24A. Two longitudinal grooves 2~D (FIG. 11) are provided iD the surface o~
the lock cylinder 2~, and they extend rearwardly ~rom the front ~ace 24C in diametrically spaced apart parallel rela-tion. The grooves 24D receive respective rear lugs 28F o~ the spacer 28, to prevent relative rotation between the spacer and the c~lincler. Thus, owing to the engagement o~ the spacer ~ront and rear lugs 28D and 28I with the ~acing plate 18 and the lock cylinder 24, respectively, the ~acing plate, the spacer, and the cylinder are lnterconnected ~o~ rotating as a unit in the barrel 14.
The lock cylinder 24 is provided wi-th two spaced apart parallel planar transverse rows of spaced apart cylindrical blind tumbler bores 24E extending ~rom the ~ront ~ace 24C in parallel relation in the direction oi' the longitudinal axis o~ the cylinder. A coil compression tumbler spring 52 and a tumbler 26 are received in each o~ the bores 24E, for reciprocal longitudinal movement of the tumbler therein.
A diametral key-receiving ælot 24F (FIGS. 8 and 11~
25 - extends rearwardly in the axial direction ~rom the ~ront ~ace 24C of the lock cylinder 24 ~or a minor portion of the length o~ the cylinder body 24~. The slot 24F is aligned or registers wi-th the key-receiving openings 18A
and 28A in the ~acing plate 18 and the spacer 2~, raspectively, and the slot 24F constitutes an innermost or third portion o~ the keyway lOA. The slot 24F
intersects the walls of the tumbler bores 24E, whereby an angularly minor section o-~ the wall o~ each bore is removed, on the inside o~ its row o~ hores. A corres-3S ponding section o~ each tumbler 26 is exposed in the ' ~
'. ' ' . :
,~
. .
, ' 7~
--9--slot 24F (see FIG. g).
Re~erring to FIG. 16, each tumbler 26 inc].udes a cylindrically shaped body 26A and a cylindrical stem 26B
o~ reduced diameter extending axially froo a rear end o~
tha body. The body 26A ~s provided with one or more shallow peripheral grooves 26C, and a relatively deep peripheral groove 26D, for operating purposes, as : described in the above-identi~led application. Brie~ly, the shallow ~rooveæ 26C constitute ~alse picking grooves, while the deep groove 26D constitutes an unlockirg groove. As illustrated in FIG. 9, the tumbler stems 26B
are received in the springs 52 and the tumbler bodies 26A are seated on the springs, so that the tumblers are urged outwardly, with their outer or ~ront ends 26E
in abutting engagement with the spacer 28 in the lockillg condi-tion o~ the lock 10.
As seen in FIG. 3, an angularly minor side portion or scction o~ each tumbler body 26A projects transversely ; into the portion o~ the keyway 10A ~orm~d by the cylinder slot 24F. The outer end of such tumbler body portion, being a p~rt of the tumbler outer end 26~, is accessible for engagement with a blAde 30 o~ the key 12. The wardæ
18B o~ the facing plate 18 and the wards 28B of the ; spacer 28 also project transversely into the ~eyway 10A, and, in general, they are disposed in common longitudinal planes with the portions o~ the cylinder body 24B which exist between the tumbler bores 24E.
In accordance with this invention, the key 12 is aæsembled ~rom two separate components, a metal blade 30 or shank and a plastic handle 32 (FIG. 2). The blade haæ
a distal or operating end 30A and a proximal end 30B.
The handle is ~ormed with a pocket 32A, best seen in FIGS. 2 and 11, which is adapted to receive the proximal end 30B o the blade. The handle is provided with 3~ serrations 32B along one edge only, 80 that the user can ~ ' '' :
. .
9~
determine by ~eel the ~anner in which to orient the key ~or insertion into the keyway lOA of the lock 10. The handle 3~ also is provided with a Xeychatn hole 32C.
The key 1~ is what is known as a "~lat" key, having a generally Plat blacle 30, as distingulshed -from a "round"
or "circular" key~ having a generally cireular tubular shank. Referring to FXG. 3, the blade 30 is provided with a plurality o~ parallel longituclinal alternating lands and grooves on each of its sides, there being ~our lands 36-39 interspersed with three grooves 4S-~7 on one side, ~ncl ~our lands 40-43 interspersed with three grooves 48-50 on the opposite side. In the illustrative pre~erred embodiment, the locations oP the lands and grooves on the opposite sides are alike, so that they are arranged in back-to-back relation on the blade. Two o~ the lands on one side of the embodiment, numbered 36 and 39, project laterally outwardly ~rom the blade bofly ~or gr~ter distances than or beyond -the remaining lands 37 and 38~
i.e., are enlarged with respect to the remaining lands.
; 20 Referring to FI~S, 2, 4, 5 and 15, the several lands 36-~3 have respective forwardlyfacing bittings 36A~43A
thereon. The bittin~s comprise transverse shoulders on the lands 36-43, disposed at the inner ends of recesses, such as those numbered 36B-39B in ~IGS. 2 and 15, wh:ich extend longitudinally in the lands from the distal end 30A o~ the blade 30, for various selected distances.
The recesses 36B-39B, and corresponding recesses on the opposite side o~ the blade, having the shape o~ a ~ection of a cylinder, ~or receiving therein the above-describefl tumbler body side portions which project into the keyway lOA, with the outer ends o~ the side portions7 at 26D, abuttingly engaging respective bittings 36A-43A. Various key changes are achieved by dif~erent combinations o~
bitting locations on the lands 36-43.
In the preferred embodiments o~ the invention, the .
: ' '' ' : :
. .
~3~7~7 number o~ Icey changes is increase~ by ~rranginF ~or one or more o~ the :lands o~ the key blade 30 to be enlarged with respect to ~i.e,, more prominent than) the others, Thus, ~or example, the top and bottom lands 36 and 39 in the illustrative embodiment are enlarged with respect to the other lands (see FIGS, 3 and 5). The elongate open-ing 18A in the ~acing plate 18 is deslgned to accommodate the enlarged key blade lands 36 and 39, with correspondin~
grooves 18C which are deeper than the grooves 13C at the locations which accommodate the remainlng lands oi' the key blade. Such a ~acing plate can only accommodate a key blade which does not have an enlarged land in any position where a relatively shallow groove 18C appears in the ~acing plate opening 18A, Thus, in orcler to open the lock 10, the lsey blade 30 must have a land con~ig-uration which is not excluded ~rom entering the cylinder ,~ 24 by the groove configuration o~ the ~acing plate 18, in addition to having a bitting con~iguration which matches the code for the tumblers 26, i.~., the locations o~ the unlocking grooves 26D, as described in the above-identi~ied application.
SiIIce the facing plate 13 is external to the spacer 28 in the lock 10, and excludes those key blades which have enlarged lands in the wrong places, the elongate opening 28A in the spacer need only have a con~iguration which is capable o~ accepting any key blade, That is to say, the width o~ the elongate spacer opening 28A at all locations, except where there are wards 2~B, is great enough to accept a Icey blade 30 having an enlarged land, such as those numbered 36 and 39, at any land location.
Re~erring to FIG. 2, a capture or retentlon opening 30C in the blade 30 provides pin-receiving recesses on opposite sides o~ the blade, adjacent to and spaced ~rom the blade distal end 30A, approximately midway between its side edges, The central blade grooves 46 and ~9 on , -: "
the oppo~ite slde~ o~ tha blacle are aligned ~ith the capture openin~ 30C.
For ~ssembly purposes, described hereina~ter, a handle-retaining or anchoring hole 30D is provlded in the blade 30, adjacent to and æpa&ed LCrom the blade proximal end 30B. A
plurality of ker~s 30E is ~ormecl on each edge o~ t,he blade 30 adjacent to its proxim~l end 30B. The kerIs 30E ~re deIined by sawtooth-type anchor teeth 30F, which provide s0rr~t~d edges ~t the proxim~l end 30B. An inner, rect~ngul~r e~tra olle o~
the ~er~s 30E ~s prorided on one edg~, i'or orlentillg the bl~de 30 by locatlng such ker~ adjacont to the handle serration~ 32B.
Re~erring to FIGS. 2-ll, the key blade 30 i8 elosely r~-ceived w~thin tha key-receiving openlng l~A o~ the ~acing plate 18, wlth the la~ds 36-43 received in the grooves 18C o~ the ~acing plate and the wards 18B o~ the ~ac~ng pl~te received in the groove~ 45-50 o~ the blade. The key blade 30 iæ re-ceived within the key-receiving opening 28h oi' the spacer 28, with the wards 28B o~ the spacer received in the outer grooves 45, 47, and 48, 50 o~ opposite sldes o~ the blade. The key blade is received in the diametral key-receiving slot 24F in the cylinder 24, and the distal blade end 30A ls adapted ior abutting engagement w~th the lock cylinder 24 at the base o~
the slot 24F. Thus, the di~tal blade end 30A bottoms in the slot 24F, as seen in FIGS. 10 and ll, to limit insertion o~
the key into the lock. When the key is thu~ inserted, the lands 36-43 and the groovos 45-~0 e~tend lo~gitudlnally out-wardly beyo~d the ~eyway lOA. The side portions o~ the tum-bler~ 26 are received in the blade recesses 36B~39B ~nd cor-responding recesses on the opposite sid~ o~ the blade, a~d ~but on the bittings 36A-43A, as described above.
In u~e, the blade 30 of the key 12 is inserted i~to the lock keyway lOA, ~y manipulating the handle 32, until the dis-tal end 30A of the blade bottoms in the cylinder slot 24F.
During the insertion, the outer ends 26E o~ the tumblers 26 engage the bittings 36A-43A, as described above, whereby the ~?
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.
'' ' ' ' ' ' ~ '' :
tumblers are moved lnwardly against the blas o~ the spring~
52. Upon bvttoming o~ the blade, the tumbler~ 26, particul~r-ly tbe deep grooves therein, such a~ the groove 26D7 are ~o disposed as to enable the facing plate 18, the ~pacer 28, and the lock cylinder 24 to be rotated to an unlocking condition by turning the k0y 1~. In thl~ connection, it will be noted that the wards 18B o~ the ~aclng plake 18, and th0 ward~ 2~B
o~ the ~pacer 28 are received in corresponding grooves 45-50 in the blade 30, the grooves extendlng outwardly beyond tha keyway lOA, without llmiting t~he insertlon o~ the key by any engagement o~ a ward therewith.
A~ the bl~de 30 is ln~erlted, the inner ends o~ the cap-ture plns 34 on oppo~lte side~ o~ the blade are received in the central blade grooves 46 and 49, respcctively, to permit insertion o~ the bl~de. When the blade 30 i~ ~ully ln~erted, the pin~ 34 are aligned with the capture opening 30C in the blade, which permitæ movement o~ the pin~ inwardly agalnst the bias o~ their springs 35. When tha key 12 is turned, the pin~
34 are moved inwardly into the capture opening 30C by cam~ing engagement of their outer snds with the barrel 14, as des-cribed in the9 above-identi~ied applieation. In the absence o~ sultabl~ recess means9 such as provided by the capture o-pening 30C, the pins 3~ would interlock with the b~rrel 14, to prevent rotation o~ the lock cylinder 24. After rota~lng the lock cylinder to an unlocking condltion, and ln thc ab-sence oP any relie~ area in the ~all o~ the barrel 14, the 1nner ends o~ the pins 34 remain within the capture openlng 30C, to hold the Xey 12 captlve in the lock 10, until the lock cylinder ~ ~ res~ored to ~ts locking conditlon .
The illustrat~ve preferred combin~tion o~ the key 12 and the lock 10 employ~ eight pin tumblers 26 and key ~, ' " , ~, . . ` ` ~ .
' ,, ' 3~' bittings 36A-~3A, which is one more than certain widely used "circular key" locks, thereby increaslng the loclc security and the number o~ ker changes af:eorded. A1-ternatively, a lesser number o~ tumbler~ and bittings may be employed for either or both tumbler rows, especially where a smaller, more compac-t lock is desired.
The preferred structure embodies at least one row of a ; minimum of three tumblers, and a double row structure surh as illustrated i~ much pre~erred ~or exceptlonal security. While the tumblers in each row pre~erably face the corresponding tumblers in the other row, they may be disposed in other relationships, such as sta~gered, with the key lands, grooves and bittings cooperatively disposed on the key blade.
The Isey grooves 45-50 cooperate with the lock wards 18B and 2~B in providing additional lock security and -~ precision in operation, and the grooves also serve to space the lands 36-43 and their bittings 36A-43A apart from adjacent ones, so -that there is no problem of the ; 20 bittings engaging or "picking up" tumblers 26 adjacent to the proper ones, upon insertion of the key. Further, key duplication is made difficult by the need ~or the lands, grooves, and bittings, especially in their back-to-back relationship.
25 - The provision in the lock of the capture pins 34 adds to the security and complicates picking and key duplication efforts, inasmuch as key blade grooves are required, as previously de~cribed, which will align with the pins and permit the blade 30 to be inserted into the lock. Then, the capture opening 30C must be provided in the correct position in the blade 30, to enable the lock cylinder to be rotated.
The prior art has recognized that ~t is more economical to manu~acture a grooved Icey blade separately from the key handle, because the grooves for a number o~
- ' ' , ' ' . .
individual key blades can be ~ormed simultaneously along the length o~ a piece o~ bar stock, and a plurality o-~
individual blades then can be made ~rom the grooved bar ~ stock. Similarly, in the present invention) the ; 5 manu~acture o~ key blades 30 begins with an elon~a-ted piece o~ metal bar stoclc 60 or the like, which is longer than any one blade) h~ving a length su~icient to ~orm a plurality oP lcey blade blanks there~rom along the length thereof. The desired lands 36-~3 and grooves ~5-50 are ~ormed on the sides o~ the bar stock, as seen in FIG. 13.
It is part o-P this invention, however, that the ~ormation o~ the lands and grooves is done by a process o~
rolling, rather than by the procedures previously employed ~or malcing key blades, such as milling and extrusion.
Rolled blade stock ~s much stronger than a structure ~ormed by milling away su~icient metal to de~ine the grooves, or one which is ~ormed by passing the stock through an extrusion d~e of appropriate con~iguration to de~ine the desired lands and grooves. The rolling procedure compresses and strengthens the metallic material of the bar 60 in the areas which are depressed to ~orm the grooves 45-50 Such compressing and strengthening also occurs~ although to a lesser extent, in those areas which are partlally compressed to ~orm the smaller lands 37, 38 and 40-43. Unlike the prior milling, no metal is removed, so that there is virtually no waste.
The rolling procsss may commence with bar stock o~
any suitable cross section. It is convenient to start with round bar stock, which first is rolled to a generally ~lat elongated bar or strip, such as the bar 60 o~ FIG 12. Then,the lands and grooves are ~ormed by rolling, to produce the rolled, contoured, generally Plat bar 60A o~ FIG. 13, having the lands 36-43 and the grooves 45-50 Pormed therein.
.:, ' : - , : . :, . :
' ~
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. ~ , 3 ~
~16-Blade blal~ks such as those numberecl 30.1 and 30.2 o~ FIG. 1~ next are stamped or punched and cut from the contoured bar 60A. In onQ preferred procedure, the operat~ons are performed by a progressive clie, which punches -the openings 30C and 30D, stamps out the ker~s 30E, and severs the blanks 30.1 and 30.2. Therea~tar, the blan~s are encl-m:illed from the distal e~d 30A, to form the cylindrically rounded recesses 36B-39B in the lands 36-39 on one side, and similar recesses in the lands ~0-43 on the opposite side. The transverse ~la-t ~rcuate hittings 36A~-L3A are provlded thereby, at the rear or inner ends of the recesses, as illustrated in I~IGS. 5 and 15.
The ker~s 30E, cut to ~orm serrated opposite edges adjacent to the proximal end 30~ of the blade, and the handle-retaining hole 30D permit the ~astening of the handle 32 to the blade 30 by a novel, convenient, and economical method. The handle 32 is formed o~ a con-ventional thermoplastic material which softens under suitable heating. The depth o~ the pocket 32A in the handle is such that when the proximal end 30B o the blade is inserted thereinto, both the retaining hole 30D
and the ker~s are recelved completely within the pocket.
Then, the assembly of the handle and the blade pre~erably is subjected to ultrasonic wave energy, which is exter-nally directed to the handle and the proximal blade end therein. ~s a result, the plastic material of the handle 32 is heated to its so~tening point adjacent to the blade end, and then ~lows into the ~erfs 32~ and -the ~0 hole 32D, in intimate, securing engagement with the blade end. The thermoplastic material is allowed to cool and harden whereupon the handle 32 and the key blade 30 form an interpenetrating and there~ore permanent assembly.
Previously, keys had been manufactured by holding key blades in a die, and in~ection-molding plastic handles ~3~7~
thereon, such procedure bein~ re~erred to as insert molding. The key assembly methotl oP the present invention is ~aster and less expensive than the con-ventional insert molding, and more secure and longer-lastin~ than other conventional approaches, such asriveting or ~ use of a eriction ~it, a press ~it, or a snap ~it.
The key manu:eacturlng method of the present in-vention thus provicles a stronger blade, and the assemblv method is more economical, and i'orms a more lasting assembly Oe the blade and the handle, than prior methods While preferred embofliments of the s-tructure ancl method O:e the invention have been illustrated and described, it will be spparent to those skilled in the art that various changes and modifications may be made therein, within the spirit and scope of the invention.
It is intended that such changes and modi~eications be included within the scope of the appended claims.
,
Claims (9)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A key for operating a cylinder lock having:
a longitudinally extending diametral keyway terminating at an inner end in a key abutment which determines the depth of insertion of the key into the lock, for operating the lock; a planar transverse row of at least three tumblers longitudinally reciprocatable in the lock with a side portion of each tumbler projecting into the keyway and an outer end of such portion accessible for engagement with the key; and at least one ward projecting transversely into said keyway between the longitudinal axes of a pair of adjacent tumblers; said key comprising:
a substantially flat one-piece integral blade insert-able in said keyway and having a distal end abutting on said key abutment and a proximal end extending longitudi-nally outwardly beyond said keyway when the key is fully inserted into the keyway, said blade having a longitudinal rolled land on one side of the blade for each of said tumblers, and a rolled groove extending longitudinally in the blade between each pair of adjacent lands, said lands and said grooves extend-ing from said distal end to said proximal end, said ward being received in one of said grooves for insertion of the key into the lock unlimited by any engagement of a ward with the key, said blade including a bitting for each of said tumblers and each bitting comprising a transverse shoulder on one of said lands disposed at the inner end of a recess extending longitudinally in the land for a predetermined distance from said distal end of the blade corresponding to the tumbler code, said recess receiving said side portion of a tumbler therein for abutting engagement of the bitting with said outer end of the side portion.
a longitudinally extending diametral keyway terminating at an inner end in a key abutment which determines the depth of insertion of the key into the lock, for operating the lock; a planar transverse row of at least three tumblers longitudinally reciprocatable in the lock with a side portion of each tumbler projecting into the keyway and an outer end of such portion accessible for engagement with the key; and at least one ward projecting transversely into said keyway between the longitudinal axes of a pair of adjacent tumblers; said key comprising:
a substantially flat one-piece integral blade insert-able in said keyway and having a distal end abutting on said key abutment and a proximal end extending longitudi-nally outwardly beyond said keyway when the key is fully inserted into the keyway, said blade having a longitudinal rolled land on one side of the blade for each of said tumblers, and a rolled groove extending longitudinally in the blade between each pair of adjacent lands, said lands and said grooves extend-ing from said distal end to said proximal end, said ward being received in one of said grooves for insertion of the key into the lock unlimited by any engagement of a ward with the key, said blade including a bitting for each of said tumblers and each bitting comprising a transverse shoulder on one of said lands disposed at the inner end of a recess extending longitudinally in the land for a predetermined distance from said distal end of the blade corresponding to the tumbler code, said recess receiving said side portion of a tumbler therein for abutting engagement of the bitting with said outer end of the side portion.
2. A key as defined in claim 1 wherein said blade is provided with a key-capture pin-receiving recess there-in, and one of said grooves in said blade is aligned with the latter recess.
3. A key as defined in claim 1 or 2 wherein at least one of said lands projects laterally outwardly on said blade for a greater distance than at least one other land.
4. A key for operating a cylinder lock having:
a longitudinally extending diametral keyway terminating at an inner end in a key abutment which determines the depth of insertion of the key into the lock, for operating the lock; two parallel planar transverse rows of at least three tumblers longitudinally reciprocatable in the lock, said rows being disposed on opposite sides of said keyway and each tumbler having a side portion projecting into the keyway and an outer end of such portion accessible for engagement with the key; and a ward projecting trans-versely into said keyway substantially midway between the longitudinal axes of each pair of adjacent tumblers in each of said rows; said key comprising:
a substantially flat one-piece integral blade insert-able in said keyway and having a distal end abutting on said key abutment and a proximal end extending longitudi-nally outwardly beyond said keyway when the key is fully inserted into the keyway, said blade having a longitudinal rolled land on one side of the blade for each of said tumblers in one row and a longitudinal rolled land on the opposite side of the blade for each of said tumblers in the remaining row, and a rolled groove extending longitudinally in the blade between each pair of adjacent lands on each side of the blade, said lands and said grooves extending from said distal end to said proximal end, said wards being received in respective ones of said grooves for insertion of the key into the lock unlimited by any engagement of a ward with the key, said blade including a bitting for each of said tumblers and each bitting comprising a transverse shoulder on one of said lands disposed at the inner end of a recess extending longitudinally in the land for a predetermined distance from said distal end of the blade corresponding to the tumbler code, said recess receiving said side portion of a tumbler therein for abutting engagement of the bitting with said outer end of the side portion.
a longitudinally extending diametral keyway terminating at an inner end in a key abutment which determines the depth of insertion of the key into the lock, for operating the lock; two parallel planar transverse rows of at least three tumblers longitudinally reciprocatable in the lock, said rows being disposed on opposite sides of said keyway and each tumbler having a side portion projecting into the keyway and an outer end of such portion accessible for engagement with the key; and a ward projecting trans-versely into said keyway substantially midway between the longitudinal axes of each pair of adjacent tumblers in each of said rows; said key comprising:
a substantially flat one-piece integral blade insert-able in said keyway and having a distal end abutting on said key abutment and a proximal end extending longitudi-nally outwardly beyond said keyway when the key is fully inserted into the keyway, said blade having a longitudinal rolled land on one side of the blade for each of said tumblers in one row and a longitudinal rolled land on the opposite side of the blade for each of said tumblers in the remaining row, and a rolled groove extending longitudinally in the blade between each pair of adjacent lands on each side of the blade, said lands and said grooves extending from said distal end to said proximal end, said wards being received in respective ones of said grooves for insertion of the key into the lock unlimited by any engagement of a ward with the key, said blade including a bitting for each of said tumblers and each bitting comprising a transverse shoulder on one of said lands disposed at the inner end of a recess extending longitudinally in the land for a predetermined distance from said distal end of the blade corresponding to the tumbler code, said recess receiving said side portion of a tumbler therein for abutting engagement of the bitting with said outer end of the side portion.
5. A key as defined in claim 4 wherein said tumblers in each row face respective tumblers in the other row, and said lands and grooves on each side of said blade are disposed in back-to-back relation to respective lands and grooves on the opposite side of the blade.
6. A key as defined in claim 4 wherein at least one of said lands projects laterally outwardly on said blade for a greater distance than at least one other land on the same side of the blade.
7. A key as defined in claim 4, 5, or 6 wherein said blade is provided with a key-capture pin-receiving recess therein, and at least one of said grooves is aligned with the latter recess.
8. A key as defined in claim 1 or 2 in combination with said cylinder lock.
9. A key as defined in claim 4, 5, or 6 in combina-tion with said cylinder lock.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US36088682A | 1982-03-23 | 1982-03-23 | |
| US360,886 | 1982-03-23 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1238797A true CA1238797A (en) | 1988-07-05 |
Family
ID=23419797
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000416795A Expired CA1238797A (en) | 1982-03-23 | 1982-12-01 | Key and method of manufacture |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0104181A4 (en) |
| CA (1) | CA1238797A (en) |
| WO (1) | WO1983003439A1 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4735069A (en) * | 1982-03-23 | 1988-04-05 | Chicago Lock Co. | Cylinder lock and key |
| DE3618074C1 (en) * | 1986-05-29 | 1988-01-07 | Meissner Peter E Dipl Ing | Lock cylinder with key |
| KR100202832B1 (en) * | 1995-05-19 | 1999-06-15 | 송창준 | Key clip |
| DE202009014283U1 (en) * | 2009-10-16 | 2010-08-19 | Assa Abloy Sicherheitstechnik Gmbh | Lock-key system |
Family Cites Families (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US1088917A (en) * | 1913-02-10 | 1914-03-03 | Sarkis Meledonian | Trunk-fastener. |
| US1899739A (en) * | 1929-02-26 | 1933-02-28 | Mehren Lock Co Inc | Key |
| GB614387A (en) * | 1943-01-30 | 1948-12-15 | Spiku Trust | Cylinder lock |
| US2391834A (en) * | 1943-11-12 | 1945-12-25 | Yale & Towne Mfg Co | Cylinder lock |
| CH277918A (en) * | 1947-11-18 | 1951-09-30 | Limited Code Designs | Cylinder lock. |
| US2687638A (en) * | 1950-08-08 | 1954-08-31 | Clyde G Abernathy | Cylinder lock |
| US2772557A (en) * | 1955-06-06 | 1956-12-04 | Audicio Adolfo Fernandez | Cylinder lock mechanism |
| US3464294A (en) * | 1966-12-09 | 1969-09-02 | Chicago Lock Co | Method of forming a key for an axial tumbler type lock |
| CH542348A (en) * | 1971-08-18 | 1973-09-30 | Magnus Horst | Cylinder lock with key |
| US3786659A (en) * | 1972-11-15 | 1974-01-22 | Schlage Lock Co | Lock key |
| FR2278882A1 (en) * | 1974-03-01 | 1976-02-13 | Antivols Simplex Sa | Manufacture of key symmetrical about one axis - using pressed metal toothed shank inserted in groove in rubber head |
| GB1512628A (en) * | 1975-05-23 | 1978-06-01 | Squire H & Sons | Key blanks |
| GB1549199A (en) * | 1975-07-08 | 1979-08-01 | Barnsdale A D | Insert |
| US4325242A (en) * | 1977-08-25 | 1982-04-20 | Zeiss Ikon Ag Goerzwerk | Multi-level lock system and method |
| US4203693A (en) * | 1978-07-27 | 1980-05-20 | Taylor Lock Company | Duplicating machine for tubular keys |
| FR2450928A1 (en) * | 1979-03-05 | 1980-10-03 | Profalux | Key for lock with axial bits - has lock actuating bits in form of radial ribs on round section shaft with different heights and start points |
-
1982
- 1982-12-01 CA CA000416795A patent/CA1238797A/en not_active Expired
- 1982-12-28 EP EP19830900402 patent/EP0104181A4/en not_active Withdrawn
- 1982-12-28 WO PCT/US1982/001796 patent/WO1983003439A1/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| WO1983003439A1 (en) | 1983-10-13 |
| EP0104181A1 (en) | 1984-04-04 |
| EP0104181A4 (en) | 1985-04-25 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |