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`ACCO Brands
`Exhibit 1005
`
`ACCO Brands v. Think Products
`
`|PR2015—01152
`
`Ex.1005 - Page 1 of 10
`
`Ex. 1005 - Page 1 of 10
`
`ACCO Brands
`Exhibit 1005
`ACCO Brands v. Think Products
`IPR2015-01152
`
`

`

`To my sons, Daniel
`
` and Michael
`
`
`
`FIRST EDITION
`THIRD PRINTING
`
` Phillips.
`© 1991 by Bill
`
`Published
` by TAB Books.
`TAB Books
` is a division
` of McGraw-Hill,
`
`
`
`Inc.
`
`
`
`
`
` takes no
`
` The publisher
` reserved.
` All fights
` States of America.
` in the United
`
`Printed
`
`responsibility
`
` for the use of any oi: the materials
` or methods
` described
` in this book,
`nor
` for the products
`
` thereof.
`
`
`
`
`Library
`
` of Congress
`
` Cataloging-in-Publication
`
`Data
`
`
`
`
`
` techniques
`
`
`
` / by Bill Phillips.
`
`
` Bill, 1960-
`Phillips,
`
`Professional
` locksmithing
`p. cm.
`
`
`Includes
`
` index.
` (h) ISBN 0-8306-3523-8
`
`ISBN 0-8306-7523-X
`1. Locksmithing.
` I. Title.
`
`TS520.P55 1990
`683t.3--dc20
`
`
`(p)
`
`
`
`90-47231
`CIP
`
` Editor: Kimberly Tabor
`Acquisitions
`Book Editor: Cherie R. Blazer
`Director
` of Production:
` Katherine G, Brown
`Book Design: Jaclyn J. Boone
`
`
`
`
`
`Ex. 1005 - Page 2 of 10
`
`

`

`Chapter 5
`
`Pin tumbler
`locks
`
`
`
`A pin tumbler
`
` lock is
`
`any lock that has a pin
`
` is the most popular type of
`tumbler cylincter. The pin tumbler cylinder
`cylinder inuse today. It is used in key-in-knob locks, deadbolt
` locks, rim
`locks, padlocks,
` and automobile
` locks.
`The basic parts of a pin tumbler cylinder for rim and mortise locks
`include the following: cylinder case (or shell or housing or body), plug
`(or cgre), keyway, upper pin chambers,
` lower pin chambers,
` springs, top
`pins (or drivers), and bottom pins (FIG. 5-1). Pin tumbler
` cylinders for key-
`in-knob locks have a few extra parts (FIG. 5-2).
`The cylinder case houses the other basic parts. The plug rotates
`when the proper
` key is inserted into it. The keyway is an opening in the
`plug that accepts the key. The drilled holes (usually five or six) across the
`length of the plug are lower pin chambers
` that each hold a bottom pin.
`The corresponding
` drilled holes in the cylinder case directly above the
`plug.are upper pin chambers that each hold a spring and a top pin.
`
`Spring retainer
`~
`~
`~
`
`Connecting
`b.ar
`
`mug retainer
`|
`
`
`
`
`(~)] ~
`"Shell/cylinder
`
`
`
`screws
`
`5-1 Partially exploded view of a pin tumbler cylinder for a rim lock.
`
`39
`
`Ex. 1005 - Page 3 of 10
`
`

`

`40 Pin tumbler
`
`
`
` locks
`
`
`
`Bottom pins
`
`Top pin springs
`
`
`
`Top pins
`
`Cyl. plug
`
`Cyl. cap pin
`
`Cyl. body
`
`Cyl. bar JJ
`Cyl. cap
`
`5-2
`
`Exploded view of a pin tumbler cylinder for a key-in-knob lock.
`courtesy Schlage Lack Company
`
`
`
`OPERATION
`The downward
` pressure of the springs drive the top pins down into the
`¯ plug until they rest on the bottom pins. When a top pin is partially in an
`upper pin chamber
` and partially in a lower pin chamber, it prevents the
`plug from being rotated.
`
` of space between the plug and the cylinder
`There’s a small amount
`case. This space is called a shear line. Without
` a shear line, the plug could
`never be rotated, because it would fit too tightly in the cylinder case.
`When the right key is inserted into a pin tumbler lock, it lifts the bottom
`pins to the shear line, which causes the top pins to also be at the shear
`line. Figure 5-3 illustrates how the right key aligns the pins to the shear
`line.
`When all the pins are at that position, the plug is free to rotate into
`the locked or unlocked position. While the plug is rotating, the lower pin
`chambers
` separate from the upper pin chambers. The top pins then rest
`on top of the plug (FIG. 5-4),
` are the same height, but the bot-
`Usually all the top pins in a cylinder
`tom pins vary in length. In no case, however, is a bottom pin long enough
`to protrude
` into an upper pin chamber
` when no key is in the keyway. The
`key cuts can only lift the pins up, not pull them down. The depth of the
`cuts in a key must correspond
`
` to.the depths of the bottom pins for the key
`to operate the lock,
`
`REMOVING A BROKEN KEY
`Sometimes
` you might need to remove a piece of broken key from the plug
`of a pin tumbler lock. One way to accomplish this is to insert a thin
`
`Ex. 1005 - Page 4 of 10
`
`

`

`5-3 The right key aligns the top and
`bottom pins to the shear line
`so the plug is free to rotate,
`
`Rekeying 41
`
`Spring
`
`Driver
`Plug
`
`No key
`
`Right key
`
`5-4 When the plug is rotated, the
`top pins rest on its surface.
`
` and catch the
` down,
` hook pointing
` piece of wire into the keyway,
`hooked
`end of the broken
` key (FIG. 5-5). Sometimes
` it’s easier to use a thin saw
`blade to poke the broken
` key and manipulate
`
` it out of the plug (FIG. 5-6).
`If part
` of the broken
` key is prot~:uding
` out of the plug, you might
` be
`able to use a pair of pliers to pull it out. Locksmith
` supply houses
` sell a
`wide variety of broken
` key extractor
`
` tools.
`
`
`REKEYllqG
`
` the
` the device retaining
` first remove
` cylinder,
`To rekey a pin tumbler
`plug--which
` will be a retainer
` clip, cam, or cylinder
` cap. The device var-
`ies among different
` pin tumbler
` cylinders.
`
`
`Ex. 1005 - Page 5 of 10
`
`

`

`42 Pin tumbler
`
`
`
` locks
`
`
`
`thin hooked tool can be used to remove a piece of broken key from a cylinder.
`
`Keyway
`
`5-6
`
`
`~%.~~~
`Sometimes a saw blade can be used to manipulate a piece of broken key out of a
`Sawblade
`
`cylinder.
`
`
`
`
` it off with a small screw-
` by prying
` clip can be removed
`A retainer
`
`driver.
` A cam can be removed
` by unscrewing
` the two small
` screws
` hold-
`.ing it in place.
`
` the
` locks), depress
`
` cap (found on key-in-knob
`To remove
` a cylinder
` then rotate the cap
`cap pin with an awl or edge of a small screwdriver,
`counterclockwise
` until it comes
`
` off (FIG. 5-7). Remove
` both the cap pin
`and the small
` spring beneath
`
` it from the plug.
`
` or counterclockwise.
`Rotate the plug about 15 degrees
` clockwise
`The easiest
` way to do this is by using a key. If no key is available,
` you’ll
`need to pick or shim the lock. Be sure not to pull the plug forward
` while
`rotating
` it.
` the back of
` bar firmly against
` or following
`Now hold a plug follower
`the plug (FIG. 5-8). Push the tool through
`
` the cylinder
` body.
` Make sure the
`
`
`
`
`
`Ex. 1005 - Page 6 of 10
`
`

`

`Rekeying 43
`
` with the back of the plug; if the plug
` contact
`plug follower is in constant
`and plug follower separate too soon, the top pins and springs will fall out
`of the upper pin chambers.
`
`
`After the plug is pushed out of the cylinder body, set the cylinder
`body aside and set the plug into a plug holder, sometimes
` called a holding
`fixture (FIG. 5-9). It isn’t essential
` to use a plug holder, but using one makes
`rekeying cylinders easier.
`Remove the pins from the plug. Insert a new key. Then add appropri-
`ate size pins into the plug. Use bottom pins that reach the shear line of the
`plug with the new key in place. Figure 5-10 shows how the pins should be
`aligned.
`
` pins to use. One is by
`There are three ways you can find the correct
`comparing the key bitting numbers written on the bows of some factory
`original
` keys to the cross-reference
` charts listed on most key pinning kits.
`
`
`
`5-7 Depress the cylinder cap pin and rotate the cylinder cap counterclockwise to
`remove the cap. Schl~g, ~ck Comparg
`
`Follower
`
` bar
`
`5-8 Use a plug follower to hold the springs and top pins in place while removing the
`plug. Scht~ge
`L~ck Compa~.
`
`Holding
`
` fixture
`
`
`
`5-9 A plug holder can be used to
`hold the plug you’re working
`O(1. Schlage Imck Company
`
`Ex. 1005 - Page 7 of 10
`
`

`

`44 Pin tumbler
`
` locks
`
`Top pins
`
`Cyl. body
`
`courtesy
`
` Schlage Lock CompaW Cyl. plug
`
`5-10 When a properly cut key is inserted into a cylinder, all the pins are raised to the
`shear line.
`
` you can use a key gauge or a caliper
` have such a number
`If the key doesn’t
`to measure tl~e cuts of the key, then compare your readings with the infor-
`mation listed on your key pinning kit.
`Another
` way to find the right pins is by trial and error. Look at the
`key and compare
` the depths of the cuts to one another. The deeper
`the cut in the key, the longer the pin for that cut must be. After finding the
`right pin for the first cut, use the size of that pin as a reference point for
`locating the other sizes you need.
`Ideally, you should find pins that fit perfectly in the plug. In an emer-
`gency, you might want to use bottom pins that are too long and file them
`down with a fine mill file. Be sure to use the key to rotate the plug while
`filing, so you don’t flatten the top of the plug (FIG. 5-11). Most locksmiths
`consider
` it unprofessional
`
` to file pins down.
`After fitting the pins to the plug, insert the plug into the face of the
`cylinder
` body. Push the back of the plug against the plug follower
` until
`the tool comes out of the cylinder
` (FIG. 5-12). Do not allow the plug and
`the plug follower
` to separate from each other.
` slip out of the
`Hold the plug and cylinder
` body so the plug doesn’t
`body, and test the new key. Make sure the plug rotates easily and the key
`smoothly slides in and out of the plug (FIG. 5-13). If there is a problem at
`
`
`
`
`
`Rotate while filing
`
`Round not flat
`
`5-11
`
`When filing pins, don’t file the plug.
`
`Ex. 1005 - Page 8 of 10
`
`

`

`Replacing
`
` top pins 45
`
`Cyl. body
`
`Follower
`
` bar
`
`plug
`
`5- I ~2 Push the plug against the plug follower. Schtag~
`
`Lock Company
`
`this point, use the plug follower to remove the plug, and check the
`heights of the pins. Then put the plug back into the housing and test the
`key again.
` body,
`After the key is working properly with the plug in the cylinder
`slowly remove the key. Don’t pull hard enough for the plug to slip out of
`the cylinder
` body. Then reassemble the cylinder
` by reversing the proce-
`dure you used to disassemble it (FIG. 5-14).
`
`REPLACING TOP PINS
`
` purposely remove the springs and top pins every time
`Many locksmiths
`they rekey locks. This allows the locksmith to clean the upper pin cham-
`bers and to replace any worn or broken top pins.
`To reload the upper pin chambers,
` use a pair Of tweezers or similar
`device to hold pins. With this device and a plug follower, you can easily
`replace the springs and top pins (FIG. 5-15). However, it takes a little prac-
`tice. The first time you try loading upper pin chambers, you’ll probably
`frequently drop pins and springs.
`
`
`C~yl. body
`
`Plug
`
`\
`
`5-13 Test the new key after rekeying a cylinder. Schlage
`
`Lock Comp,ny
`
`Ex. 1005 - Page 9 of 10
`
`

`

`46 Pin tumbler
`
` locks
`
`TUBULAR KEY LOCKS
`
`The tubular key lock is basically a pin tumbler
` lock that has its tumblers
`arranged in a circle. Like any other pin tumbler
` lock, it has springs, top
`pins, and bottom pins. The tubular key has notches of varying sizes to
`correspond
`
` to the lengths of the pins. When the key is inserted into the
`keyway, it pushes the pins to the shear line so the plug can rotate.
`
` cylinder
`Depress
`cap pin
`
`
`
`!
`
`Make sure cap or cam
`is properly adjusted
`
`5-14 Put the retaining device back in place after rekeying the cylinder, schlag~
`
`L~e< Compa~
`
`cam screws
`
`Follower
`
` bar
`
`Spring
`
`5-.15
`
`It takes a little practice to feel comfortable replacing springs and top pins.
`
`Ex. 1005 - Page 10 of 10
`
`