Abstract:
A proximity sensing toolbox lock is disclosed. A special motor powered autolock assembly is disclosed that attaches to convention tool boxes by pass through a standard “Double-D” profile keyhole to engage and move a 90 degree lock mechanism in response to an electrical or manual signal, A manual override is provided to disable the automatic operation if desired so that the lock can be operated by a key. Likewise, an override is provided to bypass the key lock and instead manipulate the lock using the assembly and not the manual (key) lock. The exemplary lock and autolock assembly can be adapted to a wide variety of containers and storage cabinets.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/555,534, filed Nov. 4, 2011, which is incorporated by reference herein as if set forth at length. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    This invention relates to storage containers and to locking mechanisms for such containers. Suggested classification is 70/158. 
         [0004]    2. Prior Art 
         [0005]    Theft of took from open toolboxes is a common occurrence, particularly in factories or auto repair facilities where toolboxes are left open during shift work and other workers or the public have access. Workers may have manually or remotely operated locks, but frequent locking and unlocking of the toolbox results in loss work time, and inadvertence or diversion of attention may result in the toolbox being left open unintentionally even by attentive workers. A better solution is needed 
         [0006]    Advantages 
         [0007]    A small motorized locking assembly allows limited angular movement movement in response to either manual or automatic control. 
       SUMMARY 
       [0008]    An exemplary autolock assembly has a 90 degree lock/unlock movement, a manual key lock, a motorized lock, and a manual control for switching between key and motor locking to power said movement. A proximity sensing activation system is provided in a preferred embodiment to automatically activate said motorized lock to unlock said assembly when an activating device is near said assembly and to automatically lock said assembly when said device is not near said assembly. An exemplary autolock assembly is shown and described that is configured to be retrofitted onto a standard “Double-D” keylock hole of a toolbox lock so that an auto-locking toolbox is provided to assist in the prevention of tool theft, The autolock assembly is adaptable to a wide variety of storage containers, cabinets, lockers, drawers, closets, chests, and the like since it can fit through a standard “Double-D” profile keyhole to activate a standard 90 degree movement locking bar often found in such devices. The assembly could be modified easily to fit other keyhole profiles. 
     
    
     
       DRAWINGS 
         [0009]    The invention will be better understood by reference to the drawing and detailed description of an exemplary embodiment of the invention, recognizing that these figures are exemplary in order to satisfy best mode, enablement and written description requirements, In this exemplary drawing: 
           [0010]      FIG. 1  is a top plan view showing two parts of a first exemplary autolock assembly  100 ; 
           [0011]      FIG. 2  is an enlarged view in partial cross section of knob  118  of  FIG. 1 ; 
           [0012]      FIG. 3  is a top view of an upper portion  300  of gear wheel  143  of  FIG. 1 ; 
           [0013]      FIG. 4  is a side view of portion  300 ; 
           [0014]      FIG. 5  is a top view of a locking positive stop carrier disc  133  of  FIG. 1 ; 
           [0015]      FIG. 6  is a side view of disc  133 ; 
           [0016]      FIG. 7  is a top view of a cam wheel of  FIG. 1 ; 
           [0017]      FIG. 8  is a side view of the cam wheel of  FIG. 7 ; 
           [0018]      FIG. 9  is a side view of a bottom busing of  FIG. 1 ; 
           [0019]      FIG. 10  is a bottom view of the bottom bushing of  FIG. 9 ; 
           [0020]      FIG. 11  is a side view of a bottom bolt of  FIG. 1 ; 
           [0021]      FIG. 12  is a cross sectional view taken along line  12 - 12  of  FIG. 11  to show passage of electrical wires through bolt  138 ; 
           [0022]      FIG. 13  is an inside view (i.e., from the bottom looking up in  FIG. 1 ) of clutched selector disc  131  of  FIG. 1 ; 
           [0023]      FIG. 14  is a top vertical cross-sectional view (i.e. from the front looking toward the rear in  FIG. 1 ) of selector disc  131  taken along lines  1444  of  FIG. 13 ; and 
           [0024]      FIG. 15  is a schematic diagram of a proximity sensing system for controlling the assembly of  FIG. 1 . 
           [0025]      FIG. 16  is perspective view from inside a toolbox showing a second exemplary embodiment; 
           [0026]      FIG. 17  is an inside view of the cylinder plate of  FIG. 16 ; 
           [0027]      FIG. 18  is an inside view of the cylinder plate of  FIG. 16 ; and 
           [0028]      FIG. 19  is an inside view similar to  FIG. 18  except showing a third exemplary embodiment using a stepper motor to rotate the cylinder plate. 
       
    
    
     DETAILED DESCRIPTION 
       [0029]    First Exemplary Embodiment 
         [0030]      FIG. 1  is a top plan view showing an exemplary autolock assembly  100  contained within an inner housing  101  and an outer housing  102 . Inner housing hold a clutch unit  103 , a motor unit  104  and a manual pivotally mounted override bar  105  having an indexing rod  158  at one end and a pivot  159  at the other end. Inner housing  101  and outer housing  102  are of machined corrosion resistant metal such as stainless steel or aluminum. Inner housing  101  has a motor cavity  107  configured to snugly hold a small electric motor  106  and a dutch cavity  108  configured to hold unit  103 . Outer housing  102  has motor cavity  109 , a dutch cavity  110 , a keylock cavity  112 , a first passageway  114 , and a second passageway  115 . Motor cavity  109  snugly fits a top  116  of motor  106 , a dutch cavity  110  and first passageway  114  configured to surround and contain a top portion  111  of unit  103 , and a keylock cavity  112  configured to contain a keylock  113 . Clutch cavity  110  has a side recess  117  to contain a left side of bar  105 . An manual override knob  118  is held in passageway  114  by a snap ring  119 . Knob  118  has a slot  120  conforming to and adapted to receive a lug  121  of a force piston  122  atop dutch unit  103 , so that when housing  102  and housing  101  are fastened together and knob  118  is rotated, piston  122  is rotated. Keylock  113  is held tightly within passageway  115  by a snap ring  123 , so that when key  124  is rotated a tab  125  of keylock  113  is rotated so as to engage and move the right end  126  of bar  105  for purposes described below. 
         [0031]      FIG. 1  also shows dutch unit  103 , which comprises a pivotally mounted override bar  105 , a drive shaft  127 , crossrod  128 , piston  122 , two washers  129  and  130 , a selector disc  131  with opposed downwardly projecting stops  160  and  161 , an outer dutch plate  132 , two spacer washers  152  and  153 , a positive stop carrier disc  133 , three washers  134 ,  135  and  136 , a gear wheel  143 , an inner bushing  137 , a double-D conductor adapter bolt  138 , a nut  139 , and an inner snap ring  140 . Shaft  127  is a chrome steel cylinder with a reduced diameter outer end  141 . Crossrod  128  passes through a passageway  145  in shaft  127  and a passageway  146  in dutch plate  132  is affixed at its left side  147  and right side  148  to gear wheel  143  so that when gear wheel  143  rotates so does dutch plate  132  and shaft  127 . Likewise the lower end of dutch plate  132 . Bushing  137  is specially configured to an existing “Double-D” lock hole  151  of the container. Also the adapter bushing that the wires run through should make reference to being especially for a Double-D profile. A square adapter  162  is attached by a set screw  163  or other fastener to shaft  127 , so that any suitable adapter can he substituted to conform to whatever existing locking mechanism is present 
         [0032]      FIG. 1  further shows motor unit  104 , which comprises motor  106 , drive shaft  142 , and electrical power wires  149  and  150 , with drive shaft  142  having a pinion gear end  144  engaged with gear wheel  143 . When power is provided through wires  149  and  150  to motor  106 , shaft  142  is rotated to turn gear wheel  143 . Motor  106  is reversible, so that wheel  143  can be selectively rotated either clockwise or counterclockwise and desired for locking and unlocking. 
         [0033]      FIG. 2  is an enlarged view of knob  118 . Knob  118  has a knurled outer portion  201 , a smooth flange  202 , and a cylindrical inner portion  203 . Portion  203  has an annular recess  204  near an inner end  205 . Recess  204  receives snap ring  119  to hold knob tightly onto outer housing  102 . Portion  203  has slot  120  and a axial right cylindrical recess  206  designed to receive, respectively the top of selector disc  131  and lug  121 . Selector disc  131  is able to rotate within recess  206  and lug  121  is keyed in slot  120  to force co-rotation of piston  122  with knob  118 . 
         [0034]      FIG. 3  is a top view of an upper portion  300  of gear wheel  143 . Portion  300  is an annular metal body with a central bore  309  and semi-cylindrical channels  307  and  308  which are adapted to receive left side  147  and right side  148  of crossrod  128 . Portion  300  is placed atop a gear wheel  143  sides  147  and  148  in channels  307  and  308  and is then attached to wheel  143  by fasteners  303 , 304 , 305 , 306  to capture rod  128 . Portion  300  provides a first stop  301  and a second stop  302  that are lugs configured to limit angular movement of wheel  143  in both directions to 90 degrees, as that is the customary movement for locking and unlocking of a toolbox lock. 
         [0035]      FIG. 4  is a side view of portion  300  taken along lines  4 - 4  and showing stop  301 , channel  307 , bore  309 , and passageways  400  and  401  for fasteners  303 , 304 , 305 , and  306 . 
         [0036]      FIG. 5  is a bottom view of positive stop carrier disc  133 , showing stops  500  and  501  which engage with stops  301  and  302  to limit shaft  127  to 90 degrees of rotation, as noted above with reference to  FIG. 3 . Disc  133  has a flat right side  502  that is flattened between corner  507  and corner  508  to provide room for pinion gear  144 , Disc  133  has a recess  503  to receive a pin  504  (see  FIG. 1 ) to hold disc  133  in steady position within inner housing  101  so that disc  133  does not rotate with shaft  127 . Disc  133  has a slightly recessed annular portion  505  surrounding a central bore  506 . Portion  505  is recessed in order to better retain washers  134 ,  135  and  136   
         [0037]      FIG. 6  is a side view of disc  133  taken along lines  6 - 6  of  FIG. 5  showing central bore  506  (in phantom), recess  503 , corners  507  and  508  (in phantom) of side  502  and stop  500 . 
         [0038]      FIG. 7  is a top view of outer clutch plate  132 , which has upwardly extending stops  700  and  701 , and upwardly facing recess  706  and a downwardly extending tubular cylindrical sleeve  702  with a central bore  705  adapted to receive shaft  127 , Sleeve  702  has radial passageways  703  and  704  which are adapted to receive and engage left side  147  and right side  148  so that plate  132  rotates with shaft  127 . Recess  706  is configured to receive washers  152  and  153  to set the spacing between selector disc  131  and plate  132  and to serve as a clutch to allow selector disc  131  to move relative to plate  132  or vice versa if either is restrained and the other has rotary force applied thereto. 
         [0039]      FIG. 8  is a side view of plate  132 , showing stops  700  and  701  projecting upward and sleeve  702  downward, with radial passageway  704 , 
         [0040]      FIG. 9  is a side view of a bottom bushing  137 , which is an inner part of a double-D conduction adapter, so called because it fits a conventional lock passageway for a Double-D lock shaft. 
         [0041]      FIG. 10  is a bottom view of double-D conduction adapter bolt  138 , and for better understanding also showing wire  149 , wire  150 , shaft  127  (in cross-section) and a bottom  1000  of bushing  137 . Wire  149  passes through a side channel  1001  and wire  150  passes through a side channel  1002 . Bolt  138  has a polygonal flange  1003  and a short round tubular portion  1004  extending downwardly from flange  1003 . Bolt  138  also has a double-D configuration threaded 
         [0042]      FIG. 11  is a side view of a double-d conduction adapter bolt  138  and bushing  137  assembled about shaft  127  to show how and outer portion  1101  of wire  150  extends through a side channel  1002  and inner portion  1102  extends radially through a radial channel  1002  to allow power to be supplied from within the toolbox or cabinet being protected through bolt  138  to motor  106  in the interior of housing  101  without being accessible from outside housing  101 ; and 
         [0043]      FIG. 12  is a cross sectional view taken along line  12 - 12  of  FIG. 11  to show passage of outer portion  1101  and inner portion  1102  through bolt  138 , omitting the inner bushing  137 ; 
         [0044]      FIG. 13  is a top view of clutched selector disc  131  and selector bar  105 . Bar  105  appears to be a single bar, but is actually two thin flat bars with an appearance similar to a pair of parallel spaced metal collar stays with pin  158  and pin  1309  maintaining the spaced position. In  FIG. 13  only the upper bar  1310  is seen in FIG.  13 . A solid selector bar could be used, but the spaced configuration lets bar  105  pass over the periphery  1304  of selector disc  131  so that pin  158  can fully engage slots  1301 ,  1302 , and  1303 . Slot  1301  is at the left side  1400  and slot  1303  at the right side  1401  disposed 180 degrees apart with slot  1302  midway between. A selected one of slots  1301 , 1302 , 1303  is engaged by pin  158  of bar  105  under the resilient force of tension spring  1305 . Spring  1305  has a first end  1306  looped around a post  1307  attached to housing  101  (not shown) and a second opposite end  1308  looped around a pin  1309  of bar  105 . Spring  1305  pulls selector arm  105  into resilient engagement with selector disc  131  so that when disc  131  is rotated, pin  158  will fall into and remain in one of slots  1301 ,  1302 ,  1303  set whether the autolock assembly is in autolock mode, manual (key mode) or locked. Selector disc  131  has a first slot  1301 , a second slot  1302  and a third slot  1303  on an outer circumference surface  1304 . Slot  1301  and slot  1303  are 180 degrees apart along surface  1304  and slot  1302  is midway between slot  1301  and slot  1303 , that is ninety degrees along surface  1304  from slot  1301  and ninety degrees from slot  1303 . Slots  1301 ,  1302  and  1303  serve to index unit in cooperation with indexing rod  158 . 
         [0045]      FIG. 14  is a side vertical cross-sectional view of indexing bar  105  and exemplary selector disc  131  taken along lines  14 - 14  of FIG.  13 ., to show operation of bar  105  and selector disc  131 . Three wavy spring washers  1402 , 1403   1404  are disposed in tubular portion  1407 . Portion  1407  has an annular snap ring recess  1405  to allow selector disc  131  to be held in position 
         [0046]      FIG. 15  is top plan view of a tool box  1522  with its lid  1523  partially cutaway to reveal a proximity sensing system  1500  within toolbox  1522  for controlling autolock assembly  100  mounted in housing  101  and housing  102  on a front wall  1501  of an industrial toolbox (not shown). System  1500  comprises a K-9 Sombra PHD proximity sensor  1502 , a small 12V DC backup battery  1503 , a 110V AC to 12V DC float charger  1504 , a 110V AC plug  1505 , a siren  1506 , an LED status indicator light  1507 , an override button  1508 , and an RHD transmitting device  1509  such as a badge or card containing an appropriate signal generator  1510 . Wires  149  and  150  connect assembly  100  to sensor  1502  of sensing system  1500 . Wires  1511  and  1512  connect sensor  1502  to light  1507 , Wires  1513  and  1514  connect sensor  1502  to siren  1506 , Wires  1515  and  1516  connect sensor  1502  in parallel to battery  1503 . Wires  1517  and  1518  connect battery  1503  and charger  1504 . Wires  1519  and  1520  connect charger  1504  to plug  1505  and plug  1505  would be plugged into a standard 110V AC wall socket  1521  to receive electrical power. While system  1500  is shown in  FIG. 15  placed in the lid of toolbox  1522 , it will be understood that the parts can be placed wherever is most convenient and compact for a given toolbox design to keep them out of the way, generally inaccessible and even, if desired, in a locked compartment within the toolbox so system  1500  cannot be tampered with even when toolbox  1522  is unlocked and open, This provides a quantum jump in the level of security for toolboxes. 
         [0047]    Operation of First Exemplary Embodiment 
         [0048]    Referring first to  FIG. 15 , plug  1505  is plugged into socket  1521  to power up charger  1504  through wires  1519  and  1520 , which provides power through wires  1517 ,  1518 ,  1516  and  1515  to proximity sensor  1502  which then is initialized and begins looking for a specific activation signal from generator  1510 . When device  1509  is thus detected by sensor  1502 , sensor  1502  sends a signal via wires  149  and  150  to autolock assembly  103 . If assembly  103  is in automatic mode, as set by knob  118  and disc  131 , motor  106  moves clutch unit  103  so as to rotate adapter  162  ninety degrees to unlock cabinet  1522 . This would be done at initial installation. After that system  1500  would generally remain powered so that locker, drawer, cabinet or toolbox  1522  would be automatically opened at the start of a worker&#39;s shift when the worker with the proper RFID badge came in proximity to toolbox  1522 . When the worker (not shown) goes to the restroom, break room, lunch, to visit another location in the plant to address a problem or just socialize, sensor  1502  fails to sense the presence of generator  1510  and in similar fashion reverses power and causes motor  106  to reverse and dutch unit  103  to relook toolbox  1522 . When the worker returns, sensor  1502  once again senses generator  1510  and the process repeats itself and continues repeating throughout the workday. As noted this provides a quantum leap in the level of security for workplace toolboxes and thus, if adopted, could virtually eliminate theft of valuable tools from tool lockers, tool cabinets, toolboxes, dispensaries, drug cabinets, pharmaceutical storage units, cash registers, and an almost infinite variety of locked storage places of all types. 
         [0049]    The exemplary embodiment has so many figures because it is no easy or obvious task to design a compact automatic motorized lock driving unit that can fit on the outside of toolbox (to conserve valuable space within the toolbox) and be secure yet able to be powered through a standard Double-D profile locking hole as most convention toolboxes have. This rather complex design achieves that seemingly insurmountable task and does it compactly and effectively with a sleek exterior that is tamper proof. Indeed, since from the outside appearance it is not even clear where the hidden locking hole is located, the toolbox is better protected even against deliberate tampering such as with a drill. It is believed the operation of the system is made abundantly clear from the drawings and the structure description above such that any person of ordinary skill in the art of toolbox and lock design is enabled to replicate the invention. Specific dimension are omitted as those will depend on the particulars of the storage cabinet sought to be locked and unlocked using the system  1500 . 
         [0050]    Second Exemplary Embodiment 
         [0051]      FIG. 16  is perspective view from inside a toolbox showing a second exemplary autolock assembly  1600  mounted inside a toolbox lid  1601  of a toolbox  1602  having, by way of example for purposes of illustration, a locking rod  1603  that rotates to move into and out of engagement with toolbox  1602  to prevent opening lid  1601 . Assembly  1600  includes a locking plate  1605 , a cylinder  1606 , a linear actuator  1607 , an actuator arm  1608 , and a support post  1609 . Plate  1605  is shown in an unlocked vertical first position  1610 . Rod  1603  passes through a vertical slot  1612  in a lid support rail  1604 , Rod  1603  includes a dogleg  1611  so that when plate  1605  rotates, rod  1603  is laterally restrained by slot  1612  and thus forced to rotate by the circular movement of dogleg  1611 . 
         [0052]      FIG. 17  is a magnified inside view of plate  1605  in a second position  1700  showing plate  1605  rotated counter-clockwise into a locked position. Rod  1603 , omitted for clarity, would lie within opening  1701  of plate  1605 . Plate  1605  is fastened to cylinder  1606  by machine bolt  1702  and washer  1703 . 
         [0053]      FIG. 18  is a magnified view of plate  1605  in position  1610  and arm  1608  moved to the right relative to the position in  FIG. 17 . Arm  1608  is provided with a tapered section  1800  to allow support post  1609  to still support end portion  1801  of arm  1608  in this slightly lower vertical position so as to avoid excess pressure on connection  1802  between arm  1608  and plate  1605 . 
         [0054]    Operation of Second Exemplary Embodiment 
         [0055]    Referring first to  FIG. 16 , actuator  1607  has retracted to pull arm  1608  to the right to place plate  1605  in an unlocked vertical first position as shown in FIG.  18 . Upon receipt of a locking signal, actuator extends to push arm  1608  to the left to rotate plate  1605  counter-clockwise to the position shown in  FIG. 17 , Such rotation of plate  1605  in turn rotates rod  1603  to lock lid  1601  to toolbox  1602  in the usual manner such as seen in U.S. Published Patent Application No. 2011/0185779A1 to Crass, et al. and assigned to Snap-On, Incorporated. However, in this embodiment a proximity sensor like that described in  FIG. 15  would be provided to operate actuator  1607 . As noted this provides a quantum leap in the level of security for workplace toolboxes and thus, if adopted, could virtually eliminate theft of valuable took from tool lockers, tool cabinets, toolboxes, dispensaries, drug cabinets, pharmaceutical storage units, cash registers, and an almost infinite variety of locked storage places of all types. 
         [0056]    Third Exemplary Embodiment 
         [0057]      FIG. 19  is an inside view similar to  FIG. 18  except showing a third exemplary autolock assembly  1900  which is similar to assembly  1600  except using a stepper motor  1901  and a toothed locking plate  1905 , Plate  1905  has gear teeth  1902  which are driven by a gear  1903  powered by motor  1901  under control of a control unit  1906 . Assembly  1900  would be mounted inside toolbox lid  1601  similar to the manner of mounting actuator  1607  to rotate plate  1905 . While gear  1903  is shown position midway along teeth  1902 , gear  1903  would be positioned at the upper right end  1904  when plate  1905  was in the unlocked position and at an opposite lower left end  1907  when in the unlocked position. 
         [0058]    Operation of Third Exemplary Embodiment 
         [0059]    Stepper motor  1901  would be configured by programming control unit  1906  to rotate plate  1605  in similar fashion to the push and pull of arm  1608  of assembly  1600 , except that this would be done by rotating gear  1903  engaging teeth  1902  to achieve rotation. Motor  1901  would rotate gear  1903  clockwise to unlock assembly  1900  and counterclockwise to lock assembly  1900 . Whether a linear actuator  1607  or stepper motor  1901  or the external housing system of assembly  100  is chosen is a design choice, as assembly  100 , assembly  1600 , and assembly  1900  are all designed to move plate  1605  between position  1610  and position  1700  repeatedly in response to proximity signals while still achieving a conventional key lock capability and to be retrofit to existing toolboxes  1602 . 
         [0060]    Conclusion, Considerations, and Coverage 
         [0061]    Accordingly the reader will see that, according to the invention, l have provided an auto-locking assembly for locked containers that can be delivered to users in kits to replace existing locking assemblies. It will be understood that the exemplary system  1500  and exemplary autolock assembly  100  are just that, examples of a currently preferred mode of the invention. However, examples would come to mind as alternatives for assembly  103 , such as an internal system within a toolbox as shown in assembly  1600  and assembly  1900 . Any of the systems could work with a multi-position keylock cylinder that would fit within a standard Double-D hole and switch an internal locking unit from manual to automatic. And different sensors, alarms, lights, bells, whistles etc. could be incorporated. With modern computer systems, even wireless, the RHD proximity sensor might be replaced with a wireless local network based signal generation so that a production control supervisor could, for example automatically open and close all locks in a selected portion of a factory remotely from an office using retrofit kits such as that in autolock assembly  100 , assembly  160 o 0 p or assembly  1900  or any variant thereof. 
         [0062]    So, as noted, while the above description contains many specifics, various alternatives are shown so these are not limitations on the scope of the invention, but rather illustrative exemplifications of the various embodiments thereof, Many other embodiments are possible within the teachings of the invention. 
         [0063]    Thus coverage in the claims below should be determined by the claims and their legal equivalents, and limited only by the prior art and not ted to the examples given.