Abstract:
A weather resistant pin lock with an elongated body, defining a longitudinal axis includes a shell housing a rotatable core having a keyway. An elevated pinway projects upwardly from the shell to define a linear array of pin slots containing a set of lock pins. A hood is fastened to the pinway to hold the lock pins in the pin slots and to provide a water resistant barrier. A drainway provides a channel for water to flow outwardly from the interior of the shell, the rotatable core and the keyway within the core, to a drain below the pin lock. At the proximate end, an access door rotates adjacent the keyway at an elevated position, to provide a gap along the bottom edge of the access door.

Description:
BACKGROUND 
       [0001]    Field 
         [0002]    The present invention relates to pin locks and to a method of providing weather resistant features to the pin locks, which are desirable for outdoor use. 
         [0003]    Description of the Related Art 
         [0004]    Earlier pin locks are prone to weather related failure, corrosion, water penetration and other weather related problems. U.S. patent application Ser. No. 12/004,856 filed on Dec. 21, 2007 and published under publication number 2008/0276666 is an example of one such available pin lock. 
         [0005]    See  FIGS. 1-3 and 7  of the present application which illustrate the features of one example of a prior art pin lock used in mailboxes including outdoor mailbox applications. When this lock design is installed in locations which are exposed to outdoor weather conditions, there are a number of potential weather related issues. 
         [0006]    By way of example, when installed in outdoor locations, such locks are prone to freezing particularly during weather conditions including temperature changes from rain to freezing rain or snow. With regard to the prior art drawings,  FIGS. 1-3  and particularly  FIG. 1 , water ingress is often a problem from:
   The front of the prior art pin lock between keyhole  125  and dust cover  119  and between cylinder  101  and plug cap  123 ; and   The top of the prior art pin lock at the interface between the spring retainer  117  and the surrounding edge of the prior art cylinder  101 . Furthermore, the shape of the top rear of cylinder  101  allows water dripping down from the mail compartment door to be biased towards spring retainer  117 . The spring retainer  117  is made from flat bar material. Spring retainer  117  is held in place by crimping the surrounding edge of the cylinder  101  to form an overlapping lip from the cast metal used to make the cylinder  101 . Often, tolerances are such that water can easily pass around and under the lip and around the edges of spring retainer  117 , into the pin chambers below.   
 
         [0009]    The rear of the prior art pin lock may also experience water ingress between cylinder  101  and plug  103 . The dust cover  119  frequently does not fully close when dust, dirt or ice is present. The upper and lower pivot points of dust cover  119  are square and do not promote easy or smooth pivoting of the door. Water may pool at the lower pivot point which in turn may freeze and hinder movement of the dust cover. 
         [0010]    Under these circumstances, water may freeze and render the lock inoperable. By way of further example:
   Pins  113 , retainer  126  and springs  115  may freeze in the pin chambers thus preventing the key from turning;   Ice may build up in cylinder  101  to prevent plug  103  from rotating. With regard to  FIG. 2 , stop  601  may prevent cylinder  101  from rotating if ice builds-up in stop chamber  602  which is positioned at the bottom of cylinder  101  where water and ice may accumulate;   Ice may build up in keyway  127  so that the key cannot be fully inserted; and   Ice may build up at the bottom of dust cover  119  and so that the dust cover will not open.   
 
         [0015]    In some cases, customers may bend the dust cover  119  when ice builds up at the bottom of dust cover  119  and the cover won&#39;t open when force is applied with a key. A customer faced with ice build-up may firmly push on key  111  with sufficient force to bend the door near the lower pivot point. Deformation of the dust cover may prevent the dust cover from subsequently operating correctly and it may become necessary to replace the prior art pin lock. 
         [0016]    Prior art locks may also be prone to corrosion or other water/ice related damage because of water penetration and accumulation within those locks. 
         [0017]    There is a need for a suitable mechanical pin lock with weather resistant features for use in outdoor applications. 
       SUMMARY 
       [0018]    The invention includes an improved, weather resistant pin lock. Various embodiments and aspects of the invention will be apparent to persons skilled in the art, upon reading the entirety of this specification, including the description, drawings and claims appended hereto. The following introduction is meant to provide an overview of the invention, without limiting the invention to the specific aspects and features which are described in general terms for illustration of some examples of the invention. 
         [0019]    In one embodiment, a pin lock extends along a longitudinal axis from an outer face at a proximate end to a distal end. The pin lock includes a shell extending between the proximate and distal ends. The shell houses a rotatable core. The core rotates within an interior chamber defined by the shell. The shell also defines an elevated pinway extending along the longitudinal axis. The elevated pinway extends upwardly to a top wall from an intermediate edge defined by the shell. The elevated pinway is bounded by first and second opposed vertical side walls and a vertical end wall extending between the first and second opposed side walls. The end wall is adjacent the distal end of the pin lock. The rotatable core defines a first linear plurality of pin slots communicating with the keyway when an operating key is inserted into the keyway. The elevated pinway defines a second linear plurality of pin slots in opposing relation to the first plurality of pin slots defined by the rotatable core. A first set of pins is held in the first linear plurality of pin slots abutting in coplanar interfacial alignment with a second set of pins in the second linear plurality of pin slots. When in the key is inserted and the lock is in the first position, the core is allowed to rotate, about the axis, within the shell. 
         [0020]    A hood is secured above the elevated pinway. The hood, which may take the form of a top cap, defines a rigid water barrier enclosing the second set of pins in the second linear array of pin slots. In this embodiment, the hood extends downwardly from the top wall to the intermediate edge, and about the vertical side walls and the end wall. Preferably, the hood is secured to the elevated pinway along a band adjacent the intermediate edge. 
         [0021]    In some aspects of the invention, a band defined by an interior surface of the hood projects inwardly to secure the hood to the elevated pinway. The band may be formed by crimping a lower edge of the hood for secure engagement along the intermediate edge of the elevated pinway. The hood may also be crimped to form the band at the intermediate edge of the elevated pinway. 
         [0022]    In some embodiments, the intermediate edge is adjacent to a bottom edge of the elevated pinway, extending along a shoulder defined by a bottom portion of the shell. 
         [0023]    Some aspects of the invention may feature an interior drainway which extends downwardly and outwardly from within the pin lock. The drainway may extend below an access door to the keyway which is pivotably mounted between the outer face and the keyway. The drainway may be provided to channel water outwardly via a drain opening. The drainway may define a pathway for water to flow outwardly from the shell, the rotatable core, the access door, and an outer face ring which covers the face of the shell while surrounding the keyway. The access door may be pivotably mounted on a post extending between a top recess in a frame and a bottom recess in the frame. The bottom of the access door may define an elevated bottom edge which travels above an adjacent surface defined by the frame or a bottom edge of a recess within the face of the rotatable core. The elevated edge may define a clearance gap above the adjacent surface when the access door pivots within the frame. The post may be rotatable relative to the frame and the access door. 
         [0024]    A detent may be featured adjacent the intermediate edge, between the interior surface of the hood and an adjacent surface of the elevated pinway to more securely fasten the hood to the elevated pinway. The hood may be crimped, press-fit, snap-fit, slide-fit or the band may be formed in another manner to provide secure engagement with the detent. 
         [0025]    By way of further example, the detent may be an elevated ridge or a recess adjacent the intermediate edge. 
         [0026]    In another aspect, the pin lock comprises an outer face ring at a proximate end. The pin lock includes a shell defining an elongated body extending along a longitudinal axis between the proximate end and the distal end. The shell houses a rotatable core adapted for connection to a driver, cam or other component of a lock mechanism. The shell defines an elevated pinway extending along the longitudinal axis. The elevated pinway extends upwardly to a top wall from an intermediate edge extending from a pair of opposed shoulders defined by the shell. The elevated pinway comprises: a first vertical side wall, a second vertical side wall opposite to the first vertical side wall, and a vertical end wall extending between the first and second side walls, the end wall being adjacent the distal end. The elevated pinway defines a first set of pins in a first linear plurality of pin slots through the top wall and vertically opposed to a second set of pins in a second linear plurality of pin slots defined by the rotatable core, the first and second linear plurality of pin slots being vertically aligned and communicating with a keyway in the rotatable core when an operating key is inserted into the keyway when the lock is in a first position. An interior drainway extends downwardly and outwardly from within the pin lock. The drainway comprises a channel along the bottom interior of the shell, and a dripway from the keyway in communication with the channel. The dripway extends along an access door to the keyway and along a proximate lower edge of the shell, for water to flow outwardly via a drain opening. The access door rotates about a post pivotably mounted within a frame between the outer face and the keyway when the access door is pushed away from the keyway upon entry of the operating key into the keyway. The access door may be elevated to define a gap upon rotation above a bottom ledge of the frame. A hood defines a rigid water barrier closing the first linear array of pin slots in the top wall. Preferably, the first set of pins are biased inwardly from a top interior surface of the hood toward the rotatable core. The hood may extend downwardly from the top wall to the intermediate edge, and about the first and second vertical side walls and the end wall, and when the hood is engaged with the elevated pinway, a band defined by an interior surface of the hood projects inwardly to secure the hood to the elevated pinway. 
         [0027]    In some aspects, the band may project between the hood and the elevated pinway to secure the hood to the pinway. The hood may be glued or otherwise affixed with adhesive, crimped, press-fit, snap-fit, slide fit or assembled in some other manner, into secure engagement between the band and the elevated pinway. The band may be formed by crimping the hood into secure engagement with a detent defined by the elevated pinway. 
         [0028]    In some other aspects, the drainway may define a pathway for water to flow outwardly from the interior of the shell, the interior of the rotatable core, the access door, and an outer face ring surrounding the keyway. In some aspects, a water resistant seal is provided at the proximate end between the outer face ring and the shell or at the distal end to inhibit water ingress between the rotatable core and the shell. Preferably, the pin lock includes water resistant seals at the proximate end and the distal end to minimize water ingress. 
         [0029]    Other aspects of the invention will become apparent upon a review of the appended drawings and the following detailed description of preferred embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0030]      FIG. 1  is a drawing of an exploded view, in perspective, of the components in a prior art pin lock; 
           [0031]      FIG. 2  is a drawing in perspective, showing a core and a shell of the prior art pin lock shown in  FIG. 1 ; 
           [0032]      FIG. 3  is a drawing of a perspective view of an enlarged retainer clip provided with the prior art pin lock shown in  FIG. 1 ; 
           [0033]      FIG. 4  is a drawing of an exploded view, in perspective, of the components of an embodiment of the present invention, namely, a pin lock; 
           [0034]      FIG. 5A  is a side view of the rotatable core of the embodiment of the invention shown in  FIG. 4 ; 
           [0035]      FIG. 5B  is a frontal view of the rotatable core of the embodiment of the invention shown in  FIG. 4 ; 
           [0036]      FIG. 5C  is a side view in perspective from the distal end of the rotatable core of the embodiment of the invention shown in  FIG. 4 ; 
           [0037]      FIG. 6A  is a frontal view, in perspective, of the proximate end of the shell housing of the embodiment of the invention shown in  FIG. 4  configured for clockwise (CW) rotation of the rotatable core; 
           [0038]      FIG. 6B  is a frontal view of the shell housing of the embodiment of the invention shown in  FIG. 4  configured for clockwise (CW) rotation of the rotatable core; 
           [0039]      FIG. 6C  is a perspective view, from the distal end, of the shell housing of the embodiment of the invention shown in  FIG. 4 ; 
           [0040]      FIG. 6D  is a frontal view, in perspective, of the proximate end of the shell housing of the embodiment of the invention shown in  FIG. 4  configured for counter clockwise (CCW) rotation of the rotatable core; 
           [0041]      FIG. 6E  is a frontal view of the shell housing of the embodiment of the invention shown in  FIG. 6D  configured for counter clockwise (CCW) rotation of the rotatable core; 
           [0042]      FIG. 6F  is a perspective view, from the distal end, of the shell housing of the embodiment of the invention shown in  FIG. 6D ; and 
           [0043]      FIG. 7  is a profile view of the distal end of the prior art shell shown in  FIGS. 1 and 2 . 
       
    
    
     DETAILED DESCRIPTION 
       [0044]    A preferred embodiment of the invention is described below having regard to the preferred embodiment as illustrated in  FIGS. 4, 5A-5C, and 6A-6C . For applications in which the pin lock of the present invention will be used in retrofit installations, the shell assembly will be configured to match the existing furniture cut-out representing the available space for installation of the replacement lock. In this example, the profile of cylinder  101  is shown as  213  in  FIG. 7 . It is preferred that the shape of cylinder  101  is designed to match the existing profile in the furniture so that the lock can be retrofitted into existing furniture, for example, a storage structure having at least one locking compartment. 
         [0045]    With reference to  FIGS. 4 and 6C , the preferred pin lock of the present invention includes a shell configured as a generally U-shaped cylinder  208  which defines a chamber housing rotatable core  207 , preferably made from stainless steel. The shell head  401  of the shell  208  is configured to securely accommodate protective shell scalp  201 . The shell  208  is provided with shoulders  410 ,  411  extending to intermediate edge  412  which defines the transition between the shoulders  410 ,  411  and vertical sidewalls  407 ,  407 A and vertical end wall  408  joining the sidewalls  407  and  407 A. In this embodiment, the elevated pinway is illustrated as a modified pin chamber area  404  configured to accept snug fitting top cap  209 . The top edges of sidewalls  407 ,  407 A and end wall  408  are preferably beveled to permit a hood, for example, the top cap  209 , to be more easily placed and properly aligned with the elevated pinway during assembly of the preferred pin lock. 
         [0046]    Preferably, the top cap  209  is crimped such that a band of the top cap  209  is formed to engage with groove  405  to securely hold the top cap  209  in place, closing the second linear array of pin slots  450 , after the crimping operation. The top cap  209  functions as a pin slot closure and a water resistant hood which inhibits water from entering the pin slots  450  and  250  and freezing the pins  217 , retaining pin  218 , springs  216  . The top cap  209  will be made from a suitable material, preferably a metal suitable for the manufacturing process, such as crimping, in the preferred embodiment, and to meet other product specifications. 
         [0047]    In other embodiments, the top cap  209  may be configured so that the top cap is fastened to an elevated pinway using another manufacturing technique. For example, the top cap may be press-fit, snap-fit, or slide-fit into place so that a preformed band on the top cap engages a detent on the elevated pinway. By way of further example, the detent may be a ridge or a depression formed on the elevated pinway, preferably adjacent the intermediate edge  412 . Upon reading this specification, it will be apparent to persons skilled in the art that other techniques and features may be used to secure a hood to an elevated pinway of the present invention. 
         [0048]    In the preferred embodiment of an assembled pin lock, a drainway is provided to channel water outwardly from the interior of the lock so that the water is removed to avoid, for example, freezing which may damage or render the lock inoperable. In the preferred embodiment as illustrated in  FIGS. 5B and 6A-6C , the drainway comprises a drainage channel  212  at the bottom of the shell interior which extends from its distal end  212 B, toward the proximate end of the shell  208 , over drip edge  222 . Drainage channel  212  is configured so that water drains from the distal end  212 B forward to drain through drainage holes  403 ,  203 A and  201 A. 
         [0049]    As shown in  FIG. 5B , a lower cavity  302  is also provided in the proximate face of the rotatable core  207  so that water may vacate more easily away from the keyway, and thus preventing ice build-up behind an access door such as the illustrated dust shutter door  204 . Preferably, the lower cavity  302  is positioned so that, when the lock is in the locked position, the lower cavity  302  is positioned above drainage hole  403  and shell drainage hole  201 A. The funnel-like shape (with inwardly sloped side walls) and position of the lower cavity  302  below the dust shutter door  204  also creates a gap below the lower edge of the shutter door  204  to permit less restrictive rotational movement of the dust shutter door  204  when it is pushed open with a customer&#39;s key  219 . 
         [0050]    The proximate face of the rotatable core  207  is configured to mount and receive the components of the dust shutter assembly  206 . The recesses are adequately shaped and dimensioned to allow the opposite ends of dust shutter pin  202  to engage pin pockets  301 A,  301 B while supporting dust shutter door  204  and torsional spring  205  within the bracket arms of shutter face plate  203 . 
         [0051]    The torsional spring  205  is preferably configured as a dual arm spring urging the dust shutter door  204  toward its closed position, to block debris from entering the opening to the keyway when the lock is not being operated with a key  219 . The dust shutter pin  202  is preferably round to support the preferred, stronger dual arm torsion spring  205  to improve the closing operation of the dust shutter door  204  particularly when the dust shutter door is impeded by dirt, dust, water or ice. The rounded pin  202  should also rotate more easily even when the dust shutter door or the rounded pin is impeded by dirt or ice. 
         [0052]    It is also preferable to avoid accumulation of any water near the rotational range interface defined by, for example, stop  215  which travels within a rotational track defined by cavity  402  as illustrated in  FIGS. 5A and 6B . 
         [0053]    In the prior art pin lock as shown in  FIG. 2 , stop  601  rotates clockwise from the 3-to-6 o′clock position in stop cavity  602 . The stop cavity is near the bottom of cylinder  101 . Because of its orientation when the prior art lock is in the locked position, this cavity configuration is prone to buildup of ice adjacent the top of the shell. In a lock of the present invention designed for clockwise (CW) rotation of the core from a locked to an unlocked position, as illustrated in  FIGS. 6A, 6B and 6C , the preferred solution is to move the stop  215  to the 12 o′clock position shown in  FIGS. 5A, 5C . In the preferred embodiment of the present invention, the stop  215  rotates clockwise (CW) from a position starting at 12 o′clock and rotating to 3 o′clock. Stop cavity  402  is correspondingly placed at the top of the interior of shell  208  so that ice cannot build up along the interior ceiling of shell  208 . In another variant of the invention illustrated in  FIGS. 6D, 6E and 6F  in which the lock is designed for counter clockwise (CCW) rotation of the core from a locked to an unlocked position, the preferred solution is to provide a configuration in which the stop  215  rotates counter clockwise (CCW) from a position starting at  12  o′clock and rotating to 9 o′clock. 
         [0054]    In addition to the preferred drainway which may be provided to drain any penetrating water from within the pin lock, it is also preferable to provide water resistant seals to inhibit the inward flow of rain or other water surrounding the pin lock. 
         [0055]    For example, the rotatable core may be lengthened to provide additional mounting space shown as O-ring groove  214  to hold a rubber O-ring  211  as a barrier to inhibit water ingress from the distal end between rotatable core  207  and shell  208 . For example, the rubber O-ring  211  may be mounted within O-ring groove  214  prior to assembly. 
         [0056]    A shell scalp  201  is shown as a rigid protective shroud to be fastened over the proximate face of the shell  208 . The shell scalp is configured to hold the dust shutter assembly  206  in place and to inhibit water ingress from the proximate end, which is often exposed to the elements when the lock is used in outdoor installations. A front gasket  210  may also be added adjacent the proximate end of the pin lock, between the pin lock shell and a surrounding wall of a storage structure such as a lock box. The gasket material is preferably selected to satisfy a product specification for outdoor use. These are only two examples of the various kinds or seals which may be provided to inhibit water ingress. 
       Preferred Materials Choices 
       [0057]    While it will be understood that persons skilled in the art will have reasons to select from a wide variety of construction materials, the following materials are preferred for the present invention. 
         [0058]      201  Scalp—preferably stainless steel; 
         [0059]      206  Dust Shutter Assembly ( 202 - 205 )—preferably stainless steel; 
         [0060]      207  Core—preferably stainless steel, preferably MIM (Metal Injection Molded) hardened to appropriate manufacturing specifications selected for the product installation(s); 
         [0061]      208  Shell—preferably cast from zinc; 
         [0062]    Hex Nut  105 , Retaining Clip  505  are preferably plated in Zinc Nickel Alloy (automotive grade plating) to reduce rusting; and 
         [0063]    Pins  113  and Retaining Pin  126  are preferably made of stainless steel. 
         [0064]    Preferably, the lock is treated with lubrication during assembly. 
         [0065]    Persons skilled in the art will appreciate that the foregoing description was directed to specific embodiments of the invention. However, many other variations and modifications of the invention are also possible. A preferred embodiment of the invention has been described with regard to the appended drawings. It will be apparent to those skilled in the art that additional embodiments are possible and that such embodiments will also fall within the scope of the appended claims. 
       PARTS LIST (OF THE PREFERRED EMBODIMENT DESCRIBED HEREIN) 
       [0066]    In which “SS” indicates stainless steel.  201 —SS Shell Scalp  201 A—Shell Drainage Hole  202 —SS Dust Shutter Pin  203 —SS Dust Shutter Face Plate  203 A—Dust Shutter Drainage Hole  204 —SS Dust Shutter Door  205 —Dual Arm Torsion Spring  206 —Dust Shutter Assembly (Shown as  202 - 205 )  207 —SS MIM Core  208 —Shell  209 —Top Cap  210 —Front Gasket  211 —Rear O-Ring  212 —Shell Drainage Channel  212 —distal end of shell drainage channel  213 —Hex Nut  214 —O-Ring Groove  215 —stop  250 —first linear array of pin slots  301 —dust shutter cavity  301 A—pin pocket  301 B—pin pocket  302 —lower cavity  401 —shell head  402 —stop cavity  403 —drainage hole  404 —pin chamber area  405 —groove  407 ,  407 A—vertical sidewalls  408 —vertical end wall  410 , 411 —shoulders  412 —intermediate edge  415 —elevated pinway  450 —second linear array of pin slots  601 —stop  602 —stop cavity