Abstract:
Door lock apparatus, comprising in combination an elongated housing having input code selectors on the housing, to enable door locking and/or unlocking via a locking element, a locking handle protruding from the housing, a coupling in the housing having parts that interfit to enable force transmission between said handle and element, and first means responsive to code selection to control coupling of the parts.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This application claims priority from provisional application Ser. No. 61/208,680, filed Feb. 25, 2009. 
         [0002]    This invention relates generally to electronically or electronically controlled locks, such as door locks. More particularly, it concerns improvements in control mechanisms located between handle input, and latch or bolt outputs of such devices. 
         [0003]    There is need for simplicity, reliability, and effectiveness of such control mechanisms, including improvements in structure, functioning and results associated with operation of such mechanisms. 
       SUMMARY OF THE INVENTION 
       [0004]    It is a major object of the invention to provide improvements meeting the above needs. Basically, the invention is embodied in the following, in combination:
       a) an elongated housing having input code selectors on the housing, to enable door locking and/or unlocking via a locking element,   b) a locking handle protruding from the housing,   c) a coupling in the housing having parts that interfit to enable force transmission between said handle and element,   d) and first means responsive to code selection to control coupling of said parts.       
 
         [0009]    As will be seen, said means include an electronic motor in the housing to effect controlled displacement of one or more of said parts. 
         [0010]    Another object include provision of second means to compensate for interfit misalignment of said parts and to automatically overcome said misalignment. 
         [0011]    That second means may advantageously include a spring or springs biasing at least one of said parts to interfit another of said parts in response to relative rotation of said parts. 
         [0012]    Another object is to provide means to resist handle turning at selected handle turn angles, and also allow handle turning in response to override force transmitted via handle turning, for handle re-positioning relative to the housing. 
         [0013]    A further object include provision of handle force resisting structure that includes a rotor, an elongated spring, and at least one set of interengaged balls that transmit spring force to the rotor with mechanical advantage. 
         [0014]    Yet another object is to provide coupling parts, and a spring or springs biasing at least one of said parts to interfit another of said parts in response to relative rotation of said parts. One of such springs may be compliant fork-shaped leaf spring urging the coupling against tips of the pins. 
         [0015]    A further object is to provide means to compensate and overcome misalignment of coupling pins and slots in a coupler. 
         [0016]    An additional object is to provide means to allow release of a battery cover, including a one-piece elongated shifter basically movable in response to key input turning of a control rotor. 
         [0017]    Also, the housing may include a battery compartment lid, there being a retention fastener, an override bracket blocking access to the fastener from the exterior, and having a position in which such access is unblocked, there being means blocking movement of the bracket to said position in response to unauthorized such access. 
         [0018]    An additional object is to provide apparatus multiple improvements as disclosed herein. 
         [0019]    These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which: 
     
    
     
       DRAWING DESCRIPTION 
         [0020]      FIG. 1  is a perspective view of lock apparatus incorporating the invention; 
           [0021]      FIG. 2  is a diagram showing a system of elements carried within the apparatus housing, to effect operation of the lock in response to handle turning; 
           [0022]      FIG. 3  is a perspective view of a handle re-positioning clutch mechanism; 
           [0023]      FIG. 4  is an axial section taken through  FIG. 3 ; 
           [0024]      FIG. 5  is a view like  FIG. 1 , but with the handle turned to show length direction, the same as housing length; 
           [0025]      FIGS. 6-8  show coupling mechanisms; 
           [0026]      FIG. 9  shows a configuration of motion translation elements between the coupling and the latch or dead bolt; 
           [0027]      FIG. 10  is a view like  FIG. 9 , but showing shifted position of elements; 
           [0028]      FIG. 11  is a side view showing installation of an override bracket for blocking access to a fastener that secures a battery compartment lid; 
           [0029]      FIG. 12  is a frontal view of  FIG. 11  elements; 
           [0030]      FIG. 13  is a perspective view of the override bracket; 
           [0031]      FIG. 14  is a perspective view of the battery compartment lid; 
           [0032]      FIG. 15  is a perspective view of a sensor plate. 
           [0033]      FIG. 16  shows Hall Effect mechanism; 
           [0034]      FIG. 17  is a schematic view of override bracket and compliant spring positioning. 
       
    
    
     DETAILED DESCRIPTION 
       [0035]    Referring first to  FIG. 1 , it shows the lock assembly in the form of an elongated housing,  100  with a key pad  101  including multiple coding selectors at  102  on the housing outer side  103 . A handle  104  is carried for turning as between  FIG. 1  and  FIG. 5  positions. Batteries within the housing are accessible after removal of lid or cover plate  105 , in response to insertion of a key into the housing via slot  106  and turning of the key, which releases the plate. 
         [0036]    Referring to the system schematic diagram seen in  FIG. 2 , it shows handle input displacement, such as turning, at  107 , to a slip clutch  108  assembly. The assembly shown includes a shaft  1  mechanism  110  allowing handle slip, and output pins  5 . Referring to the  FIG. 3  description of the clutch assembly, it includes a clutch plate  2 , two compression springs  3 , four steel balls  4 , two coupling  5 , an override set screw  6   a,  and various other pins. The handle connects to the output shaft  1 . A coupling mechanism  111  (see  FIG. 2 ) couples the coupling pins  5  to the drive mechanism of the unit that finally drives the deadbolt or dead latch device. A latch device is shown at  112  in  FIG. 2 . The slip clutching mechanism  108  seen in  FIG. 2  is designed to allow slippage of the handle relative to the unit mechanism at a torque lower than would be required to destroy or damage the unit mechanism but at a torque significantly higher than normally required to operate a latch or deadbolt device. In such capacity, the clutching mechanism acts as a mechanical “fuse” if for instance the deadbolt is “jammed” or misaligned with its mating strike plate. The clutch plate  2  has ball detent pockets every 45 degrees, about the axis of plate rotation. The output shaft  1  has a plurality (two, as shown) of vertical holes drilled to house long compression springs  3 . These holes are intersected by perpendicular holes at the bottom of the output shaft  1  radiating out from output shaft  1  centerline or axis. The compression springs push downwards against steel balls oriented to push outwards against a second set of steel balls at a shallow pressure angle. The second set of steel balls protrude out of the perpendicular holes in the output shaft  1  and engage detent pockets  113  in the clutch plate  2 . In this way, the orientation of the balls relative to their mating balls allow the springs to be located in perpendicular relation to the necessary direction of final force application for the clutch and situated in an orientation where more space is available. Note that the direction of spring elongation is parallel to the length direction of the housing  100 . Furthermore, the shallow pressure angle and friction between the ball pairs creates a mechanical advantage that allows a lower spring force to create a higher clutching torque. This allows the mechanism to be more compact and lower cost than would otherwise be feasible.  FIG. 4  shows a section view of the clutching mechanism. 
         [0037]    Besides acting as a mechanical fuse, the orientation, lengthwise of the housing clutching mechanism provides other benefits. With the battery lid  105  removed, the handle can be rotated to a detent position 90 degrees from the normal operating position of the handle as shown in  FIG. 5 . This allows the unit to be shipped in a compact configuration with the handle already attached. This in turn minimizes packaging size/cost and freight charges. 
         [0038]    Furthermore, the clutching mechanism allows the unit to be “rehanded” in the field, quickly and easily. For instance, some applications require the handle to point right and others require that it point left. When the unit is removed from packaging, the handle can be rotated two detent positions clockwise if the handle heeds to point left or two detent positions CC to point right. The unit can be “rehanded” any time in the field if there is a desire to remount the unit in a different location requiring opposite handling. 
         [0039]    Coupling mechanism is provided to couple the handle to drive mechanism, as via the slip clutch  108 . See for example in  FIG. 2 , coupler  120  receiving input via pins  5  of the slip clutch  108 , and transmitting rotary drive at  125  to drive mechanism  126 . Such mechanism effects such coupling in response to operation of an electrical motor  127  controlled by the selectors  102  of the keypad  101  control. In this regard, means is provided to compensate for input misalignment of the coupling parts (typically pins  5  and slots  5   a  in the coupler, such misalignment typically being rotary), and to automatically overcome such misalignment to enable effective coupling, for operation of the latch by the handle. 
         [0040]    As shown in  FIGS. 6-8 , a keypad operated gear motor  6  drives a cam  7  that pushes on a cam follower assembly  8 . The cam follower assembly  8  pivots around a mounting pin  9 . The cam  7  follower assembly  8  consists of a body  10 , a cam follower pin  11 , and a fork shaped leaf spring  12 . The fork shaped leaf spring  12  pushes against a coupler  13  that is biased against the fork shaped leaf spring  12  with a light compression spring  12   a.  The spring constant and preload of the leaf spring  12  is significantly higher than that of the compression spring. When the high side lobe of the cam  7  pushes down against the cam follower pin  11 , the cam follower assembly  8  pivots around the pin  9 . The fork shaped leaf spring  12  pushes against the coupler  13  causing it to move upwards until the coupling pins  5  engage slots  5   a  in the coupler  13 . With the handle in its rest position 3 or 9 O&#39;clock, the coupler pins  5  are aligned with slots  5   a  in the coupler  13  and the fork shaped leaf spring  12  only has to deflect a minute amount to compress the compression spring biasing the coupler  13  downwards. If for instance a user has the handle turned while operating the coupler and the coupler pins  5  do not align with the slots in the coupler  13 , the fork shaped leaf spring  12  bends more and pushes the coupler  13  against the tips of the coupler pins  5 . Once the handle has released to the 3 or 9 O&#39;clock position, the force from the fork shaped leaf spring  12  will push the coupler pins  5  into the coupler  13  slots  5   a.  Thus, the fork shaped leaf spring  12  provides enough rigidity to overcome the compression spring but enough compliance so the mechanism does not lock up or stall with the handle moved out of normal position. 
         [0041]    In the event that the unit&#39;s batteries die at a position where the lock is left in an unlocked position, the unit handle can be removed and the override set screw  6  tightened until the coupler  13  is no longer engaged to the coupler pins  5 . Thus the unit is returned to a locked position. The compliance of the fork shaped leaf spring  12  allows this to happen without permanent damage to the unit. When the batteries are replaced the override set screw  6  can be backed off to allow normal operation. 
         [0042]    Referring to  FIGS. 8 and 9 , the coupler  13  has a square shaped shaft  13   a  that keys either to an input gear  14  or to a butterfly shaped cam  15  depending on whether the unit will operate a deadbolt or dead latch, respectively. The square feature of the shaft  13   a  allows it to translate up and down and also transmit torque through its entire range of motion. 
         [0043]    The alternative deadbolt mechanism consists of three gears, an input gear  14 , an idler gear  16 , and an output gear  17 . The output gear  17  has a rectangular opening that accepts a sheet metal “tailpiece”. The “tailpiece” couples the output gear  17  to the deadbolt device. A small magnet  18  holds the tailpiece in place while the unit is being assembled to the door. 
         [0044]    Typically, deadbolts require two directions of output to operate the bolt. One direction of rotation locks the deadbolt while the opposite direction of rotation unlocks the deadbolt. The illustrated gear train mechanism provides two directions of output rotation for two directions of handle rotation. 
         [0045]    The required direction can be clockwise or counterclockwise depending on whether door lock is right or left handed. Therefore, the dead latch version needs to be able to rotate either direction, but only one direction at a time. 
         [0046]    Referring to  FIG. 9 , the butterfly shaped cam  15  keys to the coupler  13 . The butterfly shaped cam  15  interacts with a slider crank  19 . The slider crank is biased to the left by two compression springs  19   a.  When the butterfly shaped cam  15  is coupled to the handle through the coupler  13 , either direction of handle rotation causes the slider crank  19  to be moved to the right due to the butterfly shaped cam  15  dual lobe symmetry. The slider crank  19  has a slot  20  that receives a pin  21  from an output shaft  22 . Translation of the slider crank  19  causes clockwise rotation of the output shaft  22 . The output shaft  22  couples to a dead latch through a tailpiece inserted into its inner cross shape. As with the dead bolt version, a small magnet in the output shaft  22  helps hold the tailpiece in place during assembly. Furthermore, a user can insert a straight blade screwdriver into the cross and rotate clockwise against the two compression springs until the output shaft  22  goes “over center” and the pin  21  ends up on the opposite side of the slider crank  19  slot  20  as shown in  FIG. 10 . 
         [0047]    In this case, translation of the slider crank  19  causes counterclockwise rotation of the output shaft  22 . In this way, the unit can be quickly and easily adjustably rehanded for right or left hand doors. Besides being an assisting feature for insert, this provides cost and logistics advantages to have one configuration work for either handling requirement. 
         [0048]    As illustrated above, the deadbolt and dead latch versions share most parts and only differ in the last several parts in their respective mechanism chains. The relatively small differences are adapted to by the different output motion requirements. However, sharing of most components has a positive effect on keeping cost and complexity down. 
         [0049]    As will all locks, security is of utmost concern. The present device has a battery lid  105  that allows access to the battery compartment. This compartment also allow access to two mounting screws at the bottom of the unit. With these screws removed, the unit can be unclipped from a hook that holds the top of the unit secured to the door. By using such method of securing the unit to a door, all fasteners are hidden. For many architects, this is an important feature. It is therefore of importance that access to the battery compartment be controlled to maintain security. The battery lid has a sheet metal tang that is screwed to the unit base. Access to this screw is provided by a small hole  24  in the top of the unit. Referring to  FIG. 11 , override bracket  25  has a feature  26  that blocks access to the battery lid  105  screws through this small hole  24 . The override bracket  25  interacts with the unit cylinder cam. Rotating the key to an unlocked position accomplishes two things: 1) a cam surface  27  on the back of the override bracket pushes down on the cam follower pin  11  of the cam follower assembly coupling the handle to output and allowing access. 2) The override bracket  25  moves lengthwise to a position where it no longer blocks the battery lid screw and thus allows the battery lid to be removed. If a person were to insert a small sharp object such as a pick into the battery access hole  24  he might use two picks to try and “walk” the override bracket  25  down in small increments eventually allowing access to the battery lid screw and compromising security. 
         [0050]    The override bracket  25  is normally biased upward towards the top and front of the unit by two compression springs  28 ,  29 . A small protruding feature  30  on the crank cover  31  normally (such as when someone is using key) does not interact with the override bracket  25 . However, when someone necessarily pushes down on the override bracket  25  through the battery lid  23  access hole  24  to “pick” the unit, override bracket  25  moves down slightly until it gets “snagged” by protruding feature  30  on crank cover  31 . See also  FIG. 15 . This prevents to override bracket from being “walked” down to allow access to battery lid  23  screw. 
         [0051]    Accordingly, the apparatus is configured to include a battery compartment lid having a retention fastener, an override bracket blocking access to the fastener from the exterior, and having a position in which such access is unblocked, there being means blocking movement of the bracket to said position in response to unauthorized such access. 
         [0052]    Hall Effect cam position sensing is also provided. See  FIG. 16 . A gear motor  32  drives a cam  33 . The cam  33  has a “high” lobe and a “low” lobe. The high lobe pushes the cam follower assembly  8  down, which couples handle to output. With the cam “low” lobe down, the handle is not coupled to the output. It is therefore important to control the position of the cam  33  such that either the “high” or “low” lobe is down and gear motor  32  does not stop in a position of flux. The cam houses two magnets  34  that interact with a Hall Effect unit  35 . The Hall Effect unit senses the magnetic flux of the magnets and “communicates” with microprocessor  80  such that motor starting and stopping position can be correctly controlled. 
         [0053]    The Hall Effect unit is powered via an I/O port of the microprocessor.