Rekeyable lock with small increments

A rekeyable lock cylinder comprising:

• a cylinder body defining an interior groove, the cylinder body having a longitudinal axis;
• and
• a plug assembly disposed at least partially in the cylinder body and selectively rotatably around the longitudinal axis, the plug assembly including:
• a plug body supporting at least one key follower, the at least one key follower having at least one projection and a fin;
• and
• at least one carrier subassembly including:
• a locking bar movable between a locked position engaging with the interior groove of the cylinder body for blocking rotation of the plug assembly and an unlocked position spaced apart from the interior groove of the cylinder body to allow rotation of the plug assembly;
• and
• at least one rack engaged with the at least one key follower, wherein the at least one rack controls movement of the locking bar between the locked and unlocked positions and the at least one rack is selectively disengageable from the at least one key follower to facilitate rekeying between different keys, and wherein the at least one rack defines a slot that includes a first side and an opposite second side formed from the rack and in open communication, the first side includes a first key follower engagement feature configured to engage the at least one projection of the at least one key follower and the second side includes a second key follower engagement feature configured to engage the fin of the at least one key follower.

A rekeyable lock cylinder comprising:

• a cylinder body defining an interior groove, the cylinder body having a longitudinal axis;
• and
• a plug assembly disposed at least partially in the cylinder body and selectively rotatably around the longitudinal axis, the plug assembly including:
• a plug body supporting at least one key follower, the at least one key follower having a first projection spaced apart from a second projection, the first projection having a first length measured parallel to the longitudinal axis and the second projection having a second length measured parallel to the longitudinal axis, the first length different than the second length;
• and
• at least one carrier subassembly including:
• a locking bar movable between a locked position engaging with the interior groove of the cylinder body for blocking rotation of the plug assembly and an unlocked position spaced apart from the interior groove of the cylinder body to allow rotation of the plug assembly;
• and
• at least one rack engaged with the at least one key follower, wherein the at least one rack controls movement of the locking bar between the locked and unlocked positions and the at least one rack is selectively disengageable from the at least one key follower to facilitate rekeying between different keys, and wherein the at least one rack defines a plurality of key follower recesses configured to engage any one of the first and second projections of the at least one key follower.

A method of rekeying a rekeyable lock cylinder comprising:

• inserting a first key into a keyway opening of the rekeyable lock cylinder that includes a cylinder body and a plug assembly, wherein when the first key is inserted into the keyway opening, the first key positions at least one key follower supported in a plug body of the plug assembly so that at least one rack supported in a carrier subassembly and engaged to the at least one key follower moves a locking bar towards an unlocked position and spaced apart from an interior groove defined in the cylinder body;
• rotating the plug assembly around a longitudinal axis of the rekeyable lock cylinder with the first key relative to the cylinder body when the locking bar is in the unlocked position;
• moving a carrier of the carrier subassembly that supports the at least one rack axially along the longitudinal axis and relative to the plug body so that the at least one rack disengages the at least one key follower;
• removing the first key from the keyway opening;
• inserting a different second key into the keyway opening;
• and
• rotating the plug assembly around the longitudinal axis so that the carrier axially returns along the longitudinal axis and the at least one rack engages with the at least one key follower at a location corresponding to the second key, wherein the at least one rack includes a first key follower engagement feature and a second key follower engagement feature, and the at least one key follower includes a first rack engagement feature and a second rack engagement feature, and wherein the at least one key follower and the at least one rack have an interfacing path for engagement, the first key follower engagement feature interfacing with the first rack engagement feature prior to the second key follower engagement feature interfacing with the second rack engagement feature along the interfacing path during engagement.