Lock cylinder and key with multiple, supplemental locking elements

A key for operating a lock comprising a housing, a plug with a keyway formed therein, wherein the plug is rotatably disposed within a bore formed in the housing, a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing, primary pin assemblies aligned with the keyway for controlling rotation of the plug within the housing and for controlling radial movement of the sidebar within the sidebar opening, one or more secondary pins disposed adjacent the keyway for controlling radial movement of the sidebar within the sidebar opening, and at least one supplemental sidebar control element for controlling radial movement of the sidebar within the sidebar opening, wherein the key comprises a key blade configured to be inserted into the keyway of the lock, the key blade comprising:

• a primary top edge having primary bittings cut therein for controlling the primary pin assemblies of the lock when the key is inserted into the keyway,
• a bottom edge,
• first and second opposed sides extending between the primary top edge and the bottom edge;
• wherein the first side includes a rib extending longitudinally along at least a portion of the length of the key blade, the rib having a secondary top edge, wherein the secondary top edge has secondary bittings cut therein for controlling the secondary pins of the lock when the key is inserted into the keyway;
• wherein the second side includes a groove opposite the rib and extending longitudinally along at least a portion of the length of the key blade;
• and
• at least one movable element disposed within the key blade,
• wherein the movable element is configured to engage a multi-level ridge projecting from a second side of the keyway and aligned with the groove as a key formed from the key blank is inserted into the keyway to move the movable element from a first position, where a second portion of the movable element extends into the groove, to a second position, where the second portion of the movable element is moved out of the groove and a first portion of the movable element extends from the first side of the key blade to actuate the supplemental sidebar control element.

A lock assembly comprising:

• a housing;
• a plug with a keyway formed therein, wherein the plug is rotatably disposed within a bore formed in the housing;
• a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• primary pin assemblies aligned with the keyway and configured to be contacted by primary bittings of a key for controlling rotation of the plug within the housing and radial movement of the sidebar within the sidebar opening;
• one or more secondary pins disposed adjacent the keyway and configured to be contacted by secondary bittings of the key for controlling radial movement of the sidebar within the sidebar opening wherein each secondary pin comprises a transversely extending projection extending into the keyway to be contacted by a secondary bitting of the key;
• and
• at least one supplemental sidebar control element disposed adjacent the keyway and configured to be contacted by a shuttle pin of the key for controlling radial movement of the sidebar within the sidebar opening and including a shuttle pin engaging portion that is laterally offset from the transversely extending portion of each secondary pin so that the supplemental sidebar control element is contacted by the shuttle pin extending from the key but is not contacted by the secondary bittings of the key.

A lock assembly comprising

• a cylindrical housing;
• a plug rotatably disposed within a bore formed in the housing;
• a keyway formed within the plug, shaped to receive a correspondingly-shaped key blade, and having a length extending longitudinally through the plug and a width extending laterally from a first side of the keyway to an opposing second side of the keyway;
• a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• and
• at least one sidebar control element disposed within the plug on the second side of the keyway and configured for movement between a locked state blocking radial movement of the sidebar within the sidebar opening and an unlocked state permitting radial movement of the sidebar within the sidebar opening,
• a multi-level ridge projecting from the first side of the keyway and extending longitudinally along at least a portion of the length of the first side of the keyway, wherein the multi-level ridge is configured to engage at least one shuttle pin disposed within a key blade inserted into the keyway, wherein the shuttle pin is configured for movement within the key blade between a first position, in which a second end of the shuttle pin extends into the groove, to a second position, in which the second end of the shuttle pin is moved out of the groove and a first end of the shuttle pin extends from the first side of the key blade to actuate movement of the sidebar control element from the first state to the second state, and wherein the multi-level ridge comprises:
• a first level extending from a front end of the keyway and configured to provide clearance for the shuttle pin located in the first position to enter the keyway within the key blade;
• a second level located further from the front end of the keyway than the first level, projecting further from the first side of the keyway than the first level, located opposite to the sidebar control element, and configured to be contacted by the shuttle pin to position the shuttle pin in the second position with the first end of the shuttle pin extending into a relief formed in the second side of the keyway opposite the second level;
• a third level located further from the front end of the keyway than the second level, projecting further from the first side of the keyway than the second level, and configured to engage a groove of the key blade;
• a first transition ramp contiguous with the first level and the second level and configured to move the shuttle pin from the first position to the second position;
• and
• a second transition ramp contiguous with the second level and the third level and configured to block the shuttle pin from progressing past the second level.

A plug for a lock assembly, the plug comprising

• a keyway shaped to receive a correspondingly-shaped key blade and having a width extending laterally from a first side of the keyway to an opposing second side of the keyway;
• a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• and
• at least one sidebar control element disposed adjacent the keyway and configured to be contacted by a shuttle pin of the key for controlling radial movement of the sidebar within the sidebar opening and including a shuttle pin engaging portion that is laterally offset from the transversely extending portion of each secondary pin so that the sidebar control element is contacted by the shuttle pin extending from the key but is not contacted by the secondary bittings of the key,
• a multi-level ridge projecting from the first side of the keyway and extending longitudinally along at least a portion of the length of the first side of the keyway, wherein the multi-level ridge is configured to engage at least one shuttle pin disposed within a key blade inserted into the keyway, wherein the shuttle pin is configured for movement within the key blade between a retracted position in which one end of the shuttle pin is retracted with respect to a side of the key blade opposite the multi-level ridge, to an extended position, in which the end of the shuttle pin is extended from side of the key blade opposite the multi-level ridge to actuate movement of the sidebar control element from a locked state to an unlocked state, and wherein the multi-level ridge comprises:
• a first level extending from a front end of the keyway and configured to provide clearance for the shuttle pin located in the retracted position to enter the keyway within the key blade;
• a second level located further from the front end of the keyway than the first level, projecting further from the first side of the keyway than the first level, located opposite to the sidebar control element, and configured to be contacted by the shuttle pin to position the shuttle pin in the extended position with the end of the shuttle pin extending into a relief formed in the second side of the keyway opposite the second level;
• a third level located further from the front end of the keyway than the second level, projecting further from the first side of the keyway than the second level, and configured to engage a groove of the key blade;
• a first transition ramp contiguous with the first level and the second level and configured to move the shuttle pin from the retracted position to the extended position;
• and
• a second transition ramp contiguous with the second level and the third level and configured to block the shuttle pin from progressing past the second level.

A key blank to be formed into a key for operating a lock having a cylindrical housing;

• a plug rotatably disposed within a bore formed in the housing;
• a keyway formed within the plug having a multi-level ridge with a first level, first transition ramp, second level, second transition ramp, and third level;
• a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• and at least one supplemental sidebar control element for controlling radial movement of the sidebar within the sidebar opening, the key blank comprising a key blade configured to be inserted into the keyway of the lock, the key blade comprising:
• a primary top edge, wherein the primary top edge is configured to receive primary bittings cut therein;
• a bottom edge;
• first and second opposed side extending between the primary top edge and the bottom edge;
• wherein the second side includes a groove extending longitudinally along at least a portion of a length of the key blade;
• at least one shuttle pin disposed within a through-hole extending through the key blade from the first side to the second side,
• wherein the shuttle pin is configured to engage a multi-level ridge projecting from a second side of the keyway and aligned with the groove as a key formed from the key blank is inserted into the keyway to move the shuttle pin from a first position, in which a second end of the shuttle pin extends into the groove, to a second position, in which the second end of the shuttle pin is moved out of the groove and a first end of the shuttle pin extends from the first side of the key blade to actuate the supplemental sidebar control element.

A key for operating a lock having a cylindrical housing;

• a plug rotatably disposed within a bore formed in the housing and having a front face and end face;
• a keyway formed within the plug having a multi-level ridge with a first level, first transition ramp, second level, second transition ramp, and third level;
• a sidebar disposed within a sidebar opening formed in the plug and configured for lateral movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• and at least one supplemental sidebar control element for controlling radial movement of the sidebar within the sidebar opening, wherein the key comprises a key blade configured to be inserted into a keyway of the lock, the key blade comprising:
• a primary top edge having primary bittings cut therein for controlling the primary pin assemblies of the lock when the key is inserted into the keyway;
• a bottom edge;
• a first side and a second opposed side extending between the primary top edge and the bottom edge;
• wherein the second side includes a groove extending longitudinally along at least a portion of the length of the key blade;
• at least one shuttle pin disposed within a through-hole extending through the key blade from the first side to the second side,
• wherein the shuttle pin is configured to engage a multi-level ridge projecting from a second side of the keyway and aligned with the groove as a key formed from the key blank is inserted into the keyway to move the shuttle pin from a first position, in which a second end of the shuttle pin extends into the groove, to a second position, in which the second end of the shuttle pin is moved out of the groove and a first end of the shuttle pin extends from the first side of the key blade to actuate the supplemental sidebar control element.

A lock assembly comprising

• a cylindrical housing;
• a plug rotatably disposed within a bore formed in the housing;
• a keyway formed within the plug, shaped to receive a correspondingly-shaped key blade, and having a length extending longitudinally through the plug and a width extending laterally from a first side of the keyway to an opposing second side of the keyway;
• a sidebar disposed within a sidebar opening formed in the plug and configured for radial movement with respect to an axis of rotation of the plug for engaging a sidebar groove formed in a wall of the bore formed in the housing for controlling rotation of the plug within the housing;
• and
• a first sidebar control element and a second sidebar control element disposed within the plug on the second side of the keyway and configured for movement between a locked state blocking radial movement of the sidebar within the sidebar opening and an unlocked state permitting radial movement of the sidebar within the sidebar opening,
• a multi-level ridge projecting from the first side of the keyway and extending longitudinally along at least a portion of the length of the first side of the keyway, wherein the multi-level ridge is configured to engage a first shuttle pin and a second shuttle pin disposed within a key blade inserted into the keyway, wherein
• the first shuttle pin is configured for movement within the key blade between a first position, in which a second end of the first shuttle pin extends into the groove, to a second position, in which the second end of the first shuttle pin is moved out of the groove and a first end of the first shuttle pin extends from the first side of the key blade to actuate movement of the first sidebar control element from the locked state to the unlocked state, and
• the second shuttle pin is configured for movement within the key blade between a first position, in which a second end of the second shuttle pin extends into the groove, to a second position, in which the second end of the second shuttle pin is moved out of the groove and a first end of the second shuttle pin extends from the first side of the key blade to actuate movement of the second sidebar control element from the locked state to the unlocked state, and wherein the multi-level ridge comprises:
• a first section comprising:
• a first section first level extending from a front end of the keyway and configured to provide clearance for the first shuttle pin and second shuttle pin located in the first position to enter the keyway within the key blade;
• a first section second level located further from the front end of the keyway than the first section first level, wherein the first section second level projects further from the first side of the keyway than the first section first level, is located opposite to the first sidebar control element, and is configured to be contacted by the first shuttle pin to position the first shuttle pin in the second position with the first end of the first shuttle pin extending into a first relief formed in the second side of the keyway opposite the first section second level;
• a first section first transition ramp contiguous with the first section first level and the first section second level and configured to move the first shuttle pin and second shuttle pin from the first position to the second position as the key is inserted into the keyway;
• and
• a regression ramp contiguous with the first section second level and configured to move the second shuttle pin from the second position to the first position;
• and
• a second section located further from the front end of the keyway than the first section, and comprising:
• a second section first level configured to provide clearance for the second shuttle pin located in the first position to enter the second section;
• a second section second level located further from the front end of the keyway than the second section first level, wherein the second section second level projects further from the first side of the keyway than the second section first level, is located opposite to the second sidebar control element, and is configured to be contacted by the second shuttle pin to position the second shuttle pin in the second position with the first end of the second shuttle pin extending into a second relief formed in the second side of the keyway opposite the second section second level;
• a third level located further from the front end of the keyway than the second section second level, projecting further from the first side of the keyway than the second section second level, and configured to engage a groove of the key blade;
• a second section first transition ramp contiguous with the second section first level and the second section second level and configured to move the second shuttle pin from the first position to the second position;
• and
• a second transition ramp contiguous with the second section second level and the third level and configured to block the second shuttle pin from progressing past the second section second level and to prevent the key from further insertion.