Cylinder Lock With Secondary Locking Element Coupled to a Primary Pin Assembly

A method for operating a lock assembly, wherein the lock assembly comprises (i) a housing, (ii) a plug rotatably disposed within a bore formed in the housing, with a keyway extending axially into the plug, (iii) a plurality of primary pin assemblies, each primary pin assembly comprising at least one top driver, a bottom pin, and a spring, wherein each primary pin assembly is disposed within aligned holes formed in the housing and the plug and wherein the spring contacts the at least one top driver within the hole formed in the housing to bias the primary pin assembly with an end of the bottom pin extending into the keyway, and (iv) at least one secondary locking element disposed within a pocket formed in the plug, each secondary locking element being associated with one primary pin assembly, wherein each secondary locking element is biased outwardly from the plug to engage a locking feature formed in an inner surface of the bore of the housing to prevent the plug from rotating within the bore of the housing, wherein a portion of the bottom pin of the associated primary pin assembly extends through the secondary locking element and into the keyway, and wherein the associated primary pin assembly is movable independently of the secondary locking element in a direction away from the keyway, and wherein each secondary locking element includes at least one control feature, wherein the method comprises:

• A. contacting a tip of the bottom pin of each primary pin assembly to manipulate each primary pin assembly into a position such that an interface between the at least one top driver and the bottom pin coincides with a shear line between the bore of the housing and the plug;
• and
• B. engaging the control feature of each secondary locking element to (i) cause the secondary locking element to move inwardly toward the plug so that the secondary locking element disengages from the locking feature or (ii) to permit the secondary locking element to be moved inwardly toward the plug so that the secondary locking element can disengage from the locking feature.

A key blank adapted to be cut into a key for operating a lock assembly, wherein the lock assembly comprises (i) a housing, (ii) a plug rotatably disposed within a bore formed in the housing, with a keyway extending axially into the plug, (iii) a plurality of primary pin assemblies, each primary pin assembly comprising at least one top driver, a bottom pin, and a spring, wherein each primary pin assembly is disposed within aligned holes formed in the housing and the plug and wherein the spring contacts the at least one top driver within the hole formed in the housing to bias the primary pin assembly with an end of the bottom pin extending into the keyway, and (iv) at least one secondary locking element disposed within a pocket formed in the plug, each secondary locking element being associated with one primary pin assembly, wherein the secondary locking element is biased outwardly from the plug to engage a locking feature formed in an inner surface of the bore of the housing to prevent the plug from rotating within the bore of the housing, wherein a portion of the bottom pin of the associated primary pin assembly extends through the secondary locking element and into the keyway, and wherein the associated primary pin assembly is movable independently of the secondary locking element in a direction away from the keyway, and wherein each secondary locking element includes at least one control feature, wherein the key blank comprises:

• a primary top edge, wherein the primary top edge is configured to receive primary bittings cut therein for contacting a tip of the bottom pin of each primary pin assembly to manipulate each primary pin assembly into a position such that an interface between the at least one top driver and the bottom pin coincides with a shear line between the bore of the housing and the plug;
• a bottom edge;
• first and second opposed sides extending between the primary top edge and the bottom edge;
• and
• at least one of a side bitting surface and a side control surface formed on at least one of the first and second opposed sides for directly or indirectly engaging the control feature of each secondary locking element (i) to cause the secondary locking element to move inwardly toward the plug so that the secondary locking element disengages from the locking feature or (ii) to permit the secondary locking element to be moved inwardly toward the plug so that the secondary locking element can disengage from the locking feature.

A method of forming a key from a key blank having a blade with a top edge, a bottom edge, and first and second opposed sides extending between the top edge and the bottom edge, wherein the key is operable for opening a lock assembly comprising (i) a housing, (ii) a plug rotatably disposed within a bore formed in the housing, with a keyway extending axially into the plug, (iii) a plurality of primary pin assemblies, each primary pin assembly comprising at least one top driver, a bottom pin, and a spring, wherein each primary pin assembly is disposed within aligned holes formed in the housing and the plug and wherein the spring contacts the at least one top driver within the hole formed in the housing to bias the primary pin assembly with an end of the bottom pin extending into the keyway, and (iv) at least one secondary locking element disposed within a pocket formed in the plug, each secondary locking element being associated with one primary pin assembly, wherein each secondary locking element is biased outwardly from the plug to engage a locking feature formed in an inner surface of the bore of the housing to prevent the plug from rotating within the bore of the housing, wherein a portion of the bottom pin of the associated primary pin assembly extends through the secondary locking element and into the keyway, and wherein the associated primary pin assembly is movable independently of the secondary locking element in a direction away from the keyway, and wherein each secondary locking element includes at least one control feature, wherein the method comprises:

• forming primary bittings on the top edge of the blade of the key blank, wherein the primary bittings are configured contacting a tip of the bottom pin of each primary pin assembly to manipulate each primary pin assembly into a position such that an interface between the at least one top driver and the bottom pin coincides with a shear line between the bore of the housing and the plug;
• and
• forming at least one of a side bitting surface and a side control surface on at least one of the first and second opposed sides, wherein the at least one of the side bitting surface and the side control surface is configured to directly or indirectly engage the control feature of each secondary locking element when the key is inserted into the keyway to (i) cause the secondary locking element to move inwardly toward the plug so that the secondary locking element disengages from the locking feature or (ii) permit the secondary locking element to be moved inwardly toward the plug so that the secondary locking element can disengage from the locking feature.