# US 2026/0297979 A1 · Mechanically keyed locks with isolated validation

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- Number: US 2026/0297979 A1
- Document ID: US20260297979A1
- Status: Published application
- Kind: A1
- Application number: 19/477,411
- Filed: 2024-04-19
- Published: 2026-10-01
- Earliest claimed: 2023-04-21
- Applicants: Level 6 Innovations LLC
- Inventors: Todd D. Brooks
- Web page: https://patentgrep.com/patent/US20260297979A1

## CPC

- E05B 29/0013: {with rotating plate tumblers (E05B29/0033 takes precedence; plate tumblers which are not set by inserting the key E05B21/06)}
- E05B 29/0026: {with longitudinally movable cylinder}
- E05B 29/006: {by movable rotor elements}
- E05B 29/0066: {Side bar locking}
- E05B: LOCKS; ACCESSORIES THEREFOR; HANDCUFFS

## Abstract

A mechanically keyed lock assembly with isolated validation to prevent non-destructive defeat of the mechanically keyed lock assembly, including a plurality of locking modules having a key engaging element, a spacer, a key validating element configured to establish a fixed rotational relationship between one of the key engaging element and the key validating element or the spacer and the key validating element, and a validation bar configured to achieve validation in the key validating elements only when isolated from the key engaging elements.

## Claims

### Claim 1

A lock assembly having mechanically isolated validation, comprising:
a locking module assembly extending longitudinally along an actuation axis and comprising a plurality of locking modules, each locking module comprising:
a key engaging element defining a first aperture configured to receive therethrough a key, comprising an alignment feature configured to interact the key and a first mating structure;
a spacer defining a second aperture configured to receive therethrough the key, comprising a second mating structure; and
a key validating element comprising a third mating structure configured to interface with each of the first mating structure and the second mating structure, wherein the third mating structures is configured to establish a fixed rotational relationship between one of the key engaging element and the key validating element or the spacer and the key validating element, and a validation bar receiving structure;
a carrier longitudinally translatable along a carrier axis extending parallel to the actuation axis, comprising a body portion extending along the carrier axis, defining a plurality of slots extending circumferentially orthogonal to the carrier axis and configured to receive therein at least a portion of the key validating element of each locking module, and defining a validation aperture extending longitudinally parallel to the carrier axis, and a cam protrusion extending from the body portion, defining a protrusion axis extending parallel to the carrier axis, comprising at least one cam surface that is angled relative to the protrusion axis, extending away from the body portion and toward the protrusion axis;
a validation bar disposed in the validation aperture and extending across each key validation element; and
a housing defining a cylindrical cavity to receive the locking module assembly, the carrier, and the validation bar, wherein the housing defines a clearance slot extending longitudinally parallel to the actuation axis, wherein the clearance slot is configured to receive therein the validation bar and prevent rotation of the locking module assembly unless the validation bar is in a validated position.

### Claim 2 (depends on 1)

The lock assembly of claim 1, further comprising an alignment bar configured to be retained in the alignment bar slot, wherein, when in a first rotational state prior to the validation position, the alignment bar is configured to rotationally fix each key engaging element, and wherein, when in a validated position, the validation bar is positioned within the validation bar receiving structure of each key validation element.

### Claim 3 (depends on 1)

The lock assembly of claim 1, wherein the alignment bar slot is offset from the validation aperture by about 180-degrees, wherein the housing comprises a recessed surface having ramped lateral edges defining a clearance slot.

### Claim 4 (depends on 1)

The lock assembly of claim 1, wherein the alignment feature comprises an alignment pin configured to interact with a groove defined by the mechanical key, and wherein the alignment pin extends radially into at least a portion of the aperture.

### Claim 5 (depends on 1)

The lock assembly of claim 1, wherein the alignment feature comprises a magnetic alignment feature configured to interact with a corresponding magnetic feature embedded in the key.

### Claim 6 (depends on 1)

The lock assembly of claim 1, wherein at least one of the first aperture and the second aperture define an asymmetric passage that complements and slidingly receives a cross-section of the key.

### Claim 7 (depends on 1)

The lock assembly of claim 1, wherein the first alignment bar receiving structure of the key engaging element defines a plurality of scallops aligned along a circumferential arc, each scallop configured to receive at least a portion of the alignment bar.

### Claim 8 (depends on 1)

The lock assembly of claim 1, wherein the second alignment bar receiving structure comprises an alignment bar notch configured to receive at least a portion of the alignment bar.

### Claim 9 (depends on 1)

The lock assembly of claim 1, wherein the first mating structure and the second mating structure comprise a plurality of arcuately arranged teeth, and wherein the third mating structure comprises one or more corresponding arcuately arranged teeth.

### Claim 10 (depends on 1)

The lock assembly of claim 1, wherein the key validating element defines an arcuate structure corresponding to a first arcuate surface defined by the first mating structure of the key engaging element and the second mating structure of the spacer.

### Claim 11 (depends on 1)

The lock assembly of claim 1, wherein the carrier further comprises a guide protrusion extending from the body portion along the carrier axis, and wherein the cam protrusion and the guide protrusion may be located at opposed ends of the body portion.

### Claim 12 (depends on 1)

The lock assembly of claim 1, wherein the validation bar defines a plurality of validation features configured to selectively engage the locking module assembly.

### Claim 13 (depends on 1)

The lock assembly of claim 1, wherein the validation bar comprises a solid metal rod.

### Claim 14 (depends on 1)

The lock assembly of claim 1, wherein the validation bar defines a first isolation feature comprising a radial inward protrusion configured to be received within the validation bar receiving structure of at least one spacer, wherein at least one spacer defines a second isolation feature comprising a radial outward protrusion configured to support at least a portion of the validating bar, wherein the first isolation feature and the second isolation feature are configured to, when not in a validation position, mechanically isolate the validation bar from each key validating element.

### Claim 15 (depends on 1)

The lock assembly of claim 1, further comprising a proximal cap fixed to a first end of the housing and defining an access port configured to receive therethrough the key and a pocket to receive the cam protrusion, wherein rotation of the locking module causes the cam protrusion to traverse out of the pocket and translate the carrier along the carrier axis.

### Claim 16 (depends on 1)

The lock assembly of claim 1, further comprising a distal cap fixed to a second, opposing end of the housing, wherein the distal cap defines a pocket configured to complement and slidingly accept at least a portion of the cam protrusion.

### Claim 17

A method of assembling a lock assembly, wherein the method comprises:
aligning on a retaining fixture extending longitudinally along an actuation axis an alternating plurality of key engaging elements and plurality of spacers;
welding each spacer to at least one adjacent spacer of the plurality of spacers;
arranging each of a plurality of key validating element in a respective slot of a plurality of slots defined by a body portion of a carrier extending along a carrier axis;
coupling, in longitudinally translatable engagement, the carrier and the plurality of key validating elements with the plurality of key engaging elements and plurality of spacers to define a lock assembly and a carrier, wherein the carrier axis extends parallel to the actuation axis;
positioning a validation bar within a validation aperture defined by the carrier and extending along the carrier axis, wherein each a validation bar receiving structure defined by each key validating element of the plurality of key validating elements is positioned to receive the validation bar therein; and
positioning an alignment bar within a first alignment bar receiving structure defined by each key engaging element of the plurality of key engaging elements and a second alignment bar receiving structure defined by each spacer of the plurality of spacers.

### Claim 18 (depends on 17)

The method of claim 17, wherein the method further comprises inserting into a housing coupled locking assembly and the carrier, the validation bar, and the alignment bar, and wherein the housing defines a cylindrical cavity having an alignment bar slot and a clearance slot, each extending longitudinally parallel to the actuation axis.

### Claim 19 (depends on 18)

The method of claim 18, wherein the clearance slot receives therein the respective alignment bar in a rekey configuration, and wherein the method further comprises:
inserting a key into the locking assembly to encode the locking assembly to a code of the key; and
rotating the locking assembly to a locked configuration to set the code of the key.

### Claim 20 (depends on 17)

The method of claim 17, wherein:
the body portion of the carrier extends along the carrier axis and defines the plurality of slots extending circumferentially orthogonal to the carrier axis, and wherein the carrier further defines the validation aperture extending longitudinally parallel to the carrier axis and a cam protrusion extending from the body portion, defining a protrusion axis extending parallel to the carrier axis, comprising at least one cam surface that is angled relative to the protrusion axis, extending away from the body portion and toward the protrusion axis;
each key engaging element of the plurality of key engaging elements comprises an alignment feature configured to interact the key, a first mating structure, and a first alignment bar receiving structure;
each spacer of the plurality of spacers comprises a second mating structure and a second alignment bar receiving structure; and
each key validating element of the plurality of key validating elements comprises a third mating structure configured to interface with each of the first mating structure and the second mating structure, wherein the third mating structures is configured to establish a fixed rotational relationship between one of the key engaging element and the key validating element or the spacer and the key validating element.