Rekeyable lock cylinder with enhanced torque resistance

A rekeyable lock cylinder comprising:

• a cylinder body with a longitudinal axis including a groove;
• and
• a plug assembly disposed in the cylinder body and being rotatable about the longitudinal axis, the plug assembly including;
• a plurality of key followers, wherein at least one of the plurality of key followers includes at least one rack engaging feature at a first side, the at least one rack engaging feature being at least one of a projection and a recess, the plurality of key followers being spring-loaded;
• a plurality of racks, wherein at least one of the plurality of racks includes a plurality of key follower engaging features at a first side, the plurality of key follower engaging features being a corresponding other one of the at least one of the projection and the recess of the at least one rack engaging feature;
• wherein the at least one of the plurality of racks is selectively disengageable at the first side from the at least one of the plurality of key followers between a plurality of assignable key cut positions, the at least one of the plurality of racks also including a locking bar engaging groove at a second side, opposite the first side of the at least one of the plurality of racks;
• a locking bar being movable between a locked position in the groove of the cylinder body and an unlocked position out of the groove of the cylinder body, wherein the locking bar is positionable at least partially within the locking bar engaging groove when the at least one of the plurality of racks is positioned at both a first key cut position from an unauthorized key and a second key cut position from an authorized key, the first key cut position being consecutive with the second key cut position, wherein the first key cut position corresponds to the locked position of the locking bar, and wherein the second key cut position corresponds to the unlocked position of the locking bar;
• and
• a biasing member urging the locking bar towards the plurality of racks, wherein a spring force of the biasing member is less than a spring force of the plurality of spring-loaded key followers.

A method of operating a lock cylinder comprising:

• receiving a valid first key into a lock cylinder, the lock cylinder including:
• a cylinder body with a longitudinal axis including a groove;
• a plug assembly disposed in the cylinder body and being rotatable about the longitudinal axis, the plug assembly including;
• a plurality of key followers, wherein at least one of the plurality of key followers includes at least one rack engaging feature at a first side, the at least one rack engaging feature being at least one of a projection and a recess;
• a plurality of racks, wherein at least one of the plurality of racks includes a plurality of key follower engaging features at a first side, the plurality of key follower engaging features being a corresponding other one of the at least one of the projection and the recess of the at least one rack engaging feature;
• wherein the at least one of the plurality of racks is selectively disengageable at the first side from the at least one of the plurality of key followers between a plurality of assignable key cut positions, the at least one of the plurality of racks also including a locking bar engaging groove at a second side, opposite the first side of the at least one of the plurality of racks;
• and
• a locking bar being movable between a locked position in the groove of the cylinder body and an unlocked position out of the groove of the cylinder body;
• aligning the locking bar engaging groove of the at least one of the plurality of racks with the groove of the cylinder body, wherein when the valid first key is inserted at least partially into the plug assembly, the valid first key moves the at least one of the plurality of key followers, based on a first key cut configuration, so as to position the at least one of the plurality of racks at a first key cut position of the valid first key;
• upon positioning the at least one of the plurality of racks at the first key cut position, automatically moving the locking bar into the locking bar engaging groove of the at least one of the plurality of racks and removing the locking bar from the groove of the cylinder body wherein the locking bar is automatically urged out of the groove of the cylinder body via a biasing member urging the locking bar toward the plurality of racks;
• allowing rotation of the plug assembly with respect to the cylinder body from a home position to a first position;
• receiving an invalid second key into the lock cylinder;
• at least partially aligning the locking bar engaging groove of the at least one of the plurality of racks with the groove of the cylinder body, wherein when the invalid second key is inserted at least partially into the plug assembly, the invalid second key moves the at least one of the plurality of key followers, based on a second key cut configuration, so as to position the at least one of the plurality of racks at a second key cut position, the first key cut position consecutive with the second key cut position;
• upon positioning the at least one of the plurality of racks at the second key cut position, automatically moving the locking bar at least partially into the locking bar engaging groove of the at least one of the plurality of racks and maintaining the locking bar at least partially in the groove of the cylinder body;
• and
• preventing rotation of the plug assembly with respect to the cylinder body from the home position to the first position.

A rekeyable lock cylinder comprising:

• a cylinder body with a longitudinal axis including a groove;
• and
• a plug assembly disposed in the cylinder body and being rotatable about the longitudinal axis, the plug assembly including;
• a plurality of key followers, wherein at least one of the plurality of key followers includes at least one rack engaging feature at a first side, the at least one rack engaging feature being at least one of a projection and a recess;
• a plurality of racks, wherein at least one of the plurality of racks includes a plurality of key follower engaging features at a first side, the plurality of key follower engaging features being a corresponding other one of the at least one of the projection and the recess of the at least one rack engaging feature;
• wherein the at least one of the plurality of racks is selectively disengageable at the first side from the at least one of the plurality of key followers between a plurality of assignable key cut positions, the at least one of the plurality of racks also including a locking bar engaging groove at a second side, opposite the first side of the at least one of the plurality of racks;
• and
• a locking bar being movable between a locked position in the groove of the cylinder body and an unlocked position out of the groove of the cylinder body,
• wherein the locking bar is positionable at least partially within the locking bar engaging groove when the at least one of the plurality of racks is positioned at both a first key cut position from an unauthorized key and a second key cut position from an authorized key, the first key cut position being consecutive with the second key cut position, wherein the first key cut position corresponds to the locked position of the locking bar, and wherein the second key cut position corresponds to the unlocked position of the locking bar, wherein each consecutive assignable key cut position is separated by a key cut distance measured between centers of immediately adjacent key follower engaging features of the at least one of the plurality of racks, wherein the locking bar engaging groove has a bottom-most portion and two groove opening edges, wherein a height from the bottom-most portion to either of the groove opening edges, measured in a direction in which the at least one of the plurality of racks moves within a plug body, is greater than the key cut distance.