Tool-less rekeyable lock cylinder

1. A rekeyable lock cylinder comprising:

a cylinder body with a longitudinal axis;

a plug assembly disposed in the cylinder body and being rotatable about the longitudinal axis, the plug assembly including a plug body, a key follower disposed in the plug body, and a rack corresponding to the key follower, wherein the rack is selectively disengageable from the key follower to facilitate rekeying to a new key; and

a locking bar movable between a locked position for blocking rotation of the plug assembly with respect to the cylinder body and an unlocked position to allow rotation of the plug assembly with respect to the cylinder body, wherein a plug face of the plug body is spaced apart from the cylinder body to allow longitudinal movement of the plug body relative to the cylinder body, and the plug face is configured to provide means for blocking longitudinal movement of the plug body relative to the cylinder body when the rekeyable lock cylinder is in a locked state and for allowing longitudinal movement of the plug body relative to the cylinder body for performing a rekey operation when the rekeyable lock cylinder is in an unlocked state.

2. The rekeyable lock cylinder of claim 1 , wherein the plug face is formed to define a standoff extending from the plug face toward the cylinder body, wherein the standoff is engaged with a front end of the cylinder body to block longitudinal movement of the plug body relative to the cylinder body when the rekeyable lock cylinder is in the locked state, and wherein the cylinder body is formed to include a recess in the front end configured to receive the standoff and allow longitudinal movement of the plug body relative to the cylinder body when the rekeyable lock cylinder is in the unlocked state.

3. The rekeyable lock cylinder of claim 1 , further comprising a spring configured to engage with the cylinder body and plug face to bias the plug face away from the cylinder body.

4. The rekeyable lock cylinder of claim 3 , wherein the spring is one of a spring washer, wave spring washer, or coil spring.

5. The rekeyable lock cylinder of claim 1 , wherein the locking bar is formed to define a notch and the cylinder body is formed to define a catch, and wherein longitudinal movement of the plug body relative to the cylinder body engages the notch with the catch to block longitudinal movement of the rack relative to the cylinder body.

6. A rekeyable lock cylinder comprising:

a cylinder body with a longitudinal axis and including a groove;

a plug assembly disposed in the cylinder body and being rotatable about the longitudinal axis, the plug assembly including a plug body, a carrier extending alongside the plug body, a key follower disposed in the plug body, and a rack disposed in the carrier and corresponding to the key follower, wherein the carrier is longitudinally movable relative to the plug body between a set position where the rack is engaged with the key follower and a learn position where the rack is disengaged from the key follower to facilitate rekeying to a new key; and

a locking bar movable between a locked position engaged with the groove of the cylinder body for blocking rotation of the plug assembly with respect to the cylinder body and an unlocked position spaced apart from the groove of the cylinder body to allow rotation of the plug assembly with respect to the cylinder body, wherein the rack controls movement of the locking bar between the locked and unlocked positions,

wherein a plug face of the plug body is spaced apart from the cylinder body to allow longitudinal movement of the plug body relative to the cylinder body, and the carrier moves from the set position to the learn position in response to longitudinal movement of the plug body relative to the cylinder body.

7. The rekeyable lock cylinder of claim 6 , wherein the plug face is formed to define a standoff extending from the plug face toward the cylinder body, wherein the cylinder body is formed to include a recess, wherein the standoff is rotationally offset from the recess when the lock cylinder is in a locked state to block longitudinal movement of the plug body relative to the cylinder body, and wherein the standoff is rotationally aligned with the recess when the lock cylinder is in an unlocked state to allow the standoff to be received in the recess and allow longitudinal movement of the plug body relative to the cylinder body.

8. The rekeyable lock cylinder of claim 7 , further comprising a spring configured to engage with the cylinder body and plug face to bias the plug face away from the cylinder body.

9. The rekeyable lock cylinder of claim 8 , wherein the spring is one of a spring washer, wave spring washer, or coil spring.

10. The rekeyable lock cylinder of claim 6 , wherein the locking bar is formed to define a notch and the cylinder body is formed to define a catch, and wherein longitudinal movement of the plug body relative to the cylinder body engages the notch with the catch to block longitudinal movement of the carrier relative to the cylinder body.

11. A method for rekeying a rekeyable lock cylinder comprising the steps of:

providing a cylinder body with a longitudinal axis and a groove;

providing a plug assembly disposed in the cylinder body, the plug assembly including a plug body, a carrier extending alongside the plug body, a key follower disposed in the plug body, and a rack disposed in the carrier and corresponding to the key follower, wherein the carrier is longitudinally movable relative to the plug body between a set position where the rack is engaged with the key follower and a learn position where the rack is disengaged from the key follower to facilitate rekeying to a new key;

providing a locking bar movable between a locked position engaged with the groove of the cylinder body for blocking rotation of the plug assembly with respect to the cylinder body and an unlocked position spaced apart from the groove of the cylinder body to allow rotation of the plug assembly with respect to the cylinder body, wherein the rack controls movement of the locking bar between the locked and unlocked positions;

while the plug assembly is in a home position, inserting a valid key into the plug assembly and rotating the plug assembly;

moving a plug face of the plug body toward the cylinder body such that the plug assembly moves longitudinally relative to the cylinder body;

moving the plug face of the plug body away from the cylinder body such that the plug assembly moves longitudinally relative to the cylinder body and the carrier moves from the set position to the learn position;

while the carrier is in the learn position, removing the valid key and inserting a replacement key; and

rotating the plug assembly to the home position.

12. The method of claim 11 , wherein the plug face is spaced apart from the cylinder body, wherein the plug face is formed to define a standoff extending from the plug face toward the cylinder body, wherein the cylinder body is formed to include a recess, wherein the standoff is rotationally offset from the recess when the lock cylinder is in a locked state to block longitudinal movement of the plug body relative to the cylinder body, and wherein the standoff is rotationally aligned with the recess when the lock cylinder is in an unlocked state to allow the standoff to be received in the recess and allow longitudinal movement of the plug body relative to the cylinder body.

13. The method of claim 11 , wherein a spring is configured to engage with the cylinder body and plug face to bias the plug face away from the cylinder body.

14. The method of claim 13 , wherein the spring is one of a spring washer, wave spring washer, or coil spring.

15. The method of claim 11 , wherein the locking bar is formed to define a notch and the cylinder body is formed to define a catch, and wherein longitudinal movement of the plug body relative to the cylinder body engages the notch with the catch to block longitudinal movement of the carrier relative to the cylinder body.