Abstract:
A lock trim assembly incorporates an escapement assembly comprising a control member and an escapement spring. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. A coupling assembly that couples the handle to the spindle rotates between a default orientation and a blocking orientation. The default orientation allows the escapement assembly to move into the locking position. The blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent App. Nos. 62/145,455 and 62/145,460, both filed Apr. 9, 2015, which are herein incorporated by reference for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates generally to door latching assemblies, and more particularly, to door latching assemblies that use a motorized lock mechanism to lock a door handle and prevent it from rotating. 
       BACKGROUND 
       [0003]    There are many factors and constraints that influence designs of lock and trim assemblies, including the number of lock functions supported, the strength of the lock, the ability of the lock to thwart an attack, and the cost of manufacture. Each design constraint compounds the complexity of such a design, because attempting to accommodate a given design constraint may restrict one&#39;s ability to accommodate a different design constraint. Because not all designs are equally effective or practical, and because changing circumstances continually give rise to new design constraints, there is always a need for innovation. 
         [0004]    For example, lock and trim assemblies that utilize a door lever commonly engage the spindle directly to the door handle, relying on a stop mechanism to prevent the lever and spindle from rotating. In many such assemblies, it is possible to defeat the stop mechanism by applying a crowbar or long wrench to the lever, shearing off components of the stop mechanism. Therefore, it is advantageous for a lock and trim assembly to be designed in a manner that thwarts such an attack. 
         [0005]    As another example, many lock mechanisms require a door handle to be in a neutral, non-latch-retracting position in order to lock the handle. It is therefore advantageous for the trim assembly to incorporate a return spring to bias the handle back to the neutral position and an escapement spring to engage the lock when the handle returns to the neutral position. 
         [0006]    Moreover, when choosing a replacement trim assembly for a door, it is important to find a trim assembly that is compatible with the spindle and possibly other elements of the interior latching assembly, that matches the door function (e.g., is it an interior door or an exit door), that is compatible with the handedness of the door, that matches the physical dimensions and relative placement of the mortise and/or bore cylinder, and that matches the physical arrangement of trim mounting holes. 
         [0007]    Most trim assemblies, however, are only suitable for a specific type or make of lock. It would be advantageous to have a universal trim assembly that, with minimal substitution or rearrangement of parts, accommodates a wide variety of types and makes of locks, as well as a wide variety of lock functions. However, the design of such an assembly is complicated by the typically tight spacing of trim assembly components. For example, a rearrangement of the trim mounting posts may require a rearrangement of other trim assembly components. 
         [0008]    The present invention described below can be characterized in many different ways, not all of which are limited by its capacity to address the above-mentioned issues, needs or design constraints. 
       SUMMARY 
       [0009]    The present invention is directed to a lock trim assembly that incorporates an electric motor and an escapement assembly to operate a lock. The door trim assembly comprises a driver assembly operated by the motor, an escapement assembly, comprising a control member and an escapement spring, operated by the driver assembly, and a coupling assembly for coupling a door handle to a latch-retracting spindle. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. The coupling assembly alternates between a default orientation and a blocking orientation, wherein the default orientation allows the escapement assembly to move into the locking position and the blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the default orientation, the motor is operable to move the escapement assembly between the unlocking position and the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation. 
         [0010]    The lock trim assembly also preferably incorporates a handle-to-spindle coupling assembly designed to thwart a torque attack on a door lever. Furthermore, the motor and escapement assembly are preferably arranged in a trim assembly that is adaptable to a variety of different doors, latching assemblies, and trim preparations. 
         [0011]    These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an exploded view diagram of one embodiment of a trim assembly according to the present invention. 
           [0013]      FIG. 2A  is a perspective view of the trim assembly of  FIG. 1 , in assembled form. 
           [0014]      FIG. 2B  is a perspective view of an alternative embodiment of an assembled trim assembly. 
           [0015]      FIG. 2C  is a perspective view of another alternative embodiment of an assembled trim assembly. 
           [0016]      FIG. 2D  is a perspective view of yet another alternative embodiment of an assembled trim assembly. 
           [0017]      FIG. 3  is an exploded view diagram of the motorized lock and escapement mechanism of  FIG. 1 . 
           [0018]      FIG. 4  is a perspective view of the trim assembly of  FIG. 2A , with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration. 
           [0019]      FIG. 5  is like  FIG. 4 , showing the trim assembly in an unlocked position. 
           [0020]      FIG. 6  is a plan view of the trim assembly showing the trim assembly in a locked position. 
           [0021]      FIG. 7  is a cross-section view of the trim assembly cut along line A-A of  FIG. 6 , with the trim assembly in a locked position. 
           [0022]      FIG. 8  is another cross-section view of the trim assembly cut along line A-A of  FIG. 6 , with the trim assembly in an unlocked position. 
           [0023]      FIG. 9  is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position. 
           [0024]      FIG. 10  is a perspective view, from a right side, spindle aspect viewpoint, of the inner workings of the trim assembly when in a locked position. 
           [0025]      FIG. 11  is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in a locked position. 
           [0026]      FIG. 12  is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position. 
           [0027]      FIG. 13  is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position. 
           [0028]      FIG. 14  is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an unlocked position. 
           [0029]      FIG. 15  is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition. 
           [0030]      FIG. 16  is a perspective view, from a left side, spindle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition. 
           [0031]      FIG. 17  is a perspective view, from a left side, handle aspect viewpoint, of the inner workings of the trim assembly when in an escapement condition. 
           [0032]      FIG. 18  is a perspective view of the trim assembly when in an escapement condition, with the control member marked in dashed lines to reveal the spread-apart legs of the escapement spring. 
           [0033]      FIG. 19  is a plan view of an alternative embodiment of the trim assembly, with portions of the back plate assembly removed to reveal the inner workings of the trim assembly when in a locked configuration. 
           [0034]      FIG. 20  is another plan view of the alternative embodiment of  FIG. 19 , showing the trim assembly in an unlocked configuration. 
           [0035]      FIG. 21  is another plan view of the alternative embodiment of  FIG. 19 , showing the trim assembly in an escapement condition. 
       
    
    
       [0036]    These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows. 
       DETAILED DESCRIPTION 
       [0037]      FIGS. 1-21  illustrate various embodiments of a trim assembly  10 . In describing preferred and alternate embodiments of the technology described herein, as illustrated in  FIGS. 1-21 , specific terminology is employed for the sake of clarity. The invention is not intended to be limited to the specific terminology so selected, but rather to be construed liberally in the context of this specification. The invention described herein, moreover, should be understood to incorporate all technical equivalents that operate in a similar manner to accomplish similar functions. 
         [0038]    The trim assembly  10  comprises a coupling assembly  25 —for example, a handle coupler  20  and spindle driver  30 —that transfers load from a door handle  18  to a spindle  36 . The trim assembly  10  also comprises a return spring  19  and a stopper or locking dog  50  operative to selectively lock the coupling assembly  25 , preventing it from rotating to retract the door latch (not shown). The trim assembly  10  also comprises a motor  11 , a transmission or driver assembly  60 , and an escapement assembly  70  that together operate the stopper  50 . The spindle  36  extends into a door cavity that houses a latch assembly (not shown), for example, a cylindrical trim assembly or a mortise trim assembly. Rotation of the spindle  36  is operative to retract the latch (not shown). 
         [0039]    The trim assembly  10  also comprises an escutcheon  14  and a back plate assembly  15  that is mounted to the face of the door. The motor  11 , driver assembly  60 , escapement assembly  70 , handle coupler  20 , and most of the spindle driver  30  are contained between the escutcheon  14  and the back plate assembly  15 . The handle coupler  20  is configured to be coupled to and rotated with a door handle/lever  18 . A return spring  19  biases the handle  18  toward a neutral, non-latch retracting orientation. In one embodiment, the handle  18  can be operated in either direction from the neutral, non-latch retracting orientation to retract the latch. The trim assembly  10  may also provide collars or flanged parts  94  and  95  to adapt the trim assembly  10  to particular door widths. 
         [0040]    As best illustrated in  FIG. 3 , the handle coupler  20  comprises a disk or flange  22  mounted for coaxial rotation with the handle  18 , a slot  24  for receiving a stopper  50 , and fins  28  on either side of the slot  24 . The handle coupler  20  further comprises bent-up tabs  26  that fit into corresponding notches  38  of the spindle driver  30  to detachably couple the handle coupler  20  to the spindle driver  30 . The handle coupler  20  also comprises a bridge  23  that fits into the broach  17  of the handle  18 . The spindle  36  does not go into the broach  17 . Therefore, subjecting the handle  18  to an overtorquing attack shears the bridge  23  without turning the spindle  36 . 
         [0041]    The handle coupler  20  also comprises a spring leg bracket  21  for mounting opposite legs of a return spring  19 . Rotation of the handle coupler  20  pulls and/or pushes the legs of the return spring  19  apart, biasing the handle  18  back toward a neutral, non-latch-retracting position. 
         [0042]    Like the handle coupler  20 , the spindle driver  30  also has a slot  34  for receiving a stopper  50 , although in alternative embodiments, only one of the handle coupler  20  and spindle driver  30  have a slot  24  or  34  for receiving a stopper  50 . 
         [0043]    Advantageously, the use of the spindle driver  30  in conjunction with the handle coupler  20  not only thwarts overtorquing attacks, but also enables the trim assembly  10  to be adapted to a variety of different spindles with minimal substitution of parts. The spindle driver  30 &#39;s eight-pronged opening  39  accommodates both spindles  36  that are square and spindles  36  that are diagonally oriented (as shown, for example, by the Corbin spindle in  FIG. 2C ) when in the neutral, non-latch-retracting position. If the internal latching assembly has a larger or smaller spindle diameter, the trim assembly  10  can be adapted to the spindle  36  simply by swapping out the spindle driver  36  for one with an appropriate-sized spindle aperture. 
         [0044]    The motor  11  is mounted to the escutcheon  14  and includes an upper face or bracket  12  and a shaft  13 . The shaft  13  is oriented perpendicular to the spindle  36 . The driver assembly  60  is mounted on the motor  11  and operative to rotate an eccentrically-positioned offset pin  79  (or, alternatively, a cam) between an engage-lock position and a disengage-lock position. 
         [0045]    The driver assembly  60  comprises a slip clutch  62  mounted on the motor  11  and a carousel  76  mounted on the slip clutch  62  for rotational movement with the shaft  13 . The carousel  76  rotates the eccentrically-located offset pin  79 . 
         [0046]    The escapement assembly  70  comprises a control member  85  and an escapement spring  72 . In  FIGS. 1-18 , the control member  85  is a pivot arm mounted to the escutcheon  14  to pivot about an axis  86  parallel to a spindle axis between locking and unlocking positions. In  FIGS. 19-21 , the control member  85  is a slider that slides vertically between locking and unlocking positions. (Note that for clarity, structure constraining the slider&#39;s movement is not shown in  FIGS. 19-21 ). 
         [0047]    The control member  85  either has a pivot member or post  84  ( FIGS. 19-21 ) upon which the coiled core  75  of the escapement spring  72  is mounted, or an aperture  91  ( FIGS. 1-18 ) for receiving a spring pivot (not shown). The coiled core  75  of the escapement spring  72  is mounted to the control member  85  via the post  84  or inserted spring pivot. The control member  85  also has a spring leg anchor or abutment  87 . The legs  73 ,  74  of the escapement spring  72  straddle the spring leg anchor  87 . In  FIGS. 1-18 , the spring anchor  87  is configured as a wedge  87  that has a lower face  88  and a ramped upper face  89  with a wedge angle that matches the angle between the first and second spring legs  73 ,  74  ( FIG. 17 ). In  FIGS. 19-21 , the spring anchor  87  is configured as a post. In both embodiments, the first and second spring legs  73 ,  74  straddle and grasp a wedge-shaped abutment  87  of the control member  85 . And in  FIGS. 1-18 , the spring leg anchor  87  also provides an abutment that acts as a stop to constrain rotation of the offset pin  79  between two rotational limits. 
         [0048]    The escapement spring  72  is a helical torsion spring with a coiled core  75 , an axis  86  parallel to the spindle&#39;s axis, and two legs  73 ,  74 . Each leg has an elongated radially extending portion  73   a,    74   a  and an axially extending portion  73   b,    74   b  ( FIG. 3 ). In  FIGS. 1-18 , the spring  72  is mounted to the control member  85  by forcing the legs  73 ,  74  to intersect each other and straddle the spring leg anchor  87 . In  FIGS. 19-21 , the legs of the escapement spring  72  do not intersect. 
         [0049]    The axially extending portions  73   b,    74   b  of the first and second spring legs  73 ,  74  extend beyond the spring leg anchor  87  into positions above and below the offset pin  79 . If non-alignment of the spindle driver slot  34  and/or handle coupler slot  24  blocks the stopper  50  from engaging the spindle driver slot  34  and/or handle coupler slot  24 , rotation of the offset pin  79  into an engage-lock position forces the lower spring leg  73  downward and away from the lower face or edge  88  of the spring leg anchor  87 , as illustrated in  FIGS. 15-18 and 21 . This spreads the spring legs  73 ,  74  apart, winding the coiled core of the escapement spring  72  and storing energy. (Note that in the non-intersecting spring leg embodiment of  FIGS. 19-21 , the spring is wound oppositely of the embodiment of  FIGS. 1-18 ). Assuming that the carousel  76  is maintained in the same position, realignment of the spindle driver  30  and handle coupler  20  allows the spring  72  to release the stored energy by driving the upper spring leg  74  and control member  85  in a downward direction, until the stopper  50  is engaged with the spindle driver slot  34 , as illustrated in  FIGS. 9-11 . 
         [0050]    In  FIGS. 1-18 , a hanger  86  projects out from the control member  85 . The hanger is configured to fit in a slot  51  of the stopper  50  in order to carry the stopper  50  between locked and unlocked positions. In  FIGS. 19-21 , the stopper  50  is rigidly coupled to, or simply an extension of, the control member  85 . In both embodiments, the stopper  50  is operative for radial movement between a locked configuration that blocks the spindle driver  30  and/or handle coupler  20  from rotating and an unlocked configuration in which the spindle driver  30  and handle coupler  20  are free to rotate. In a locked configuration, the stopper  50  engages the spindle driver slot  34  and/or handle coupler slot  24 , blocking the spindle driver  30  from rotating. 
         [0051]    The offset pin  76 , control member  85 , and escapement spring  72  are respectively arranged so that rotation of the offset pin  79  between its rotational limits biases the control member  85  to travel between its locking position ( FIGS. 9-11, 19 ) and its unlocking position ( FIGS. 12-14, 20 ). They are also arranged so that the offset pin  79  is in contact with and operative to push the second leg  73  of the escapement spring  72  away from the first leg  74  of the spring  72 , thereby biasing the control member  85  toward the locking position. If the spindle driver slot  34  and/or handle coupler slot  24  are not aligned with the stopper  50 , then one of the fins  28  of the handle coupler  20  blocks the stopper  50  from descending into a locking position. Rotating the offset pin  79  into the engage-lock position results in a first escapement condition, described further below, in which the offset pin  79  pushes the second leg  73  of the escapement spring  72  away from the first leg  73 , as shown in  FIGS. 15-18 and 21 . The stored energy of the spring  72  biases the control member  85  toward the locking position. If the spindle driver  30  rotates from a position in which the slot  24  and/or  34  is/are not aligned with the stopper  50  to a position in which the slot  24  and/or  34  is/are aligned with the stopper  30 , the biasing of the escapement spring  72  pushes the stopper  50  into the slot  24  and/or  34 . 
         [0052]    The escapement assembly  70  is operative under a non-escapement condition and at least a first escapement condition. The first escapement condition is characterized by an attempt to lock the door when the stopper  50  is not aligned with the spindle driver slot  34  and/or handle coupler slot  24 . Until alignment is restored, the stopper  50  is blocked from extending into the slot  24  and/or  34 . 
         [0053]    Movement of the handle  18  and handle coupler  20  into a neutral, non-latch-retracting position lines the stopper  50  up with the handle coupler slot  24 . Once aligned, the stored energy of the escapement spring  72  rotates the control member  85  down, extending the stopper  50  into the slot  24  and/or  34 , thus locking the handle  18  in a non-latch-retracting position. 
         [0054]    A second escapement condition is characterized by an attempt to unlock the door while the locked lever arm  18  is being pushed on. The asymmetry of the load exerted on the stopper  50  may have a binding effect, preventing the stopper  50  from retracting out of the slot  24  and/or  34 . Under this condition, rotation of the offset pin  79  into a disengage-lock position will push the upper leg  74  of the escapement spring  72  upward and away from the ramped upper surface  89  of the spring anchor  87 , again winding up and storing energy in the spring  72 . Once pressure is released from the lever arm  18 , thereby removing the binding effect, the spring  72  forces the control member  85  up, retracting the stopper  50  away from the slot  24  and/or  34 . 
         [0055]    In the non-escapement condition, by contrast, the spring anchor  87  stays in substantial alignment with the offset pin  79  as the offset pin  79  rotates between engage-lock and disengage-lock positions. 
         [0056]    In either escapement condition, the control member  85  is blocked from rotating, thereby impeding movement of one of the legs  73 ,  74  of the escapement spring  72 . Operation of the motor  11  in either escapement condition causes the pin  79  to spread the axially extending portions  73   b,    74   b  of the legs  73 ,  74  apart, winding up and storing energy in the escapement spring  72 . Once the stopper  50  is free to travel between locked and unlocked positions, the stored-up energy of the wound-up escapement spring  72  is released into control member  85 , causing the control member  85  to rotate until the spring legs  73  and  74  reach their minimum-energy condition, in which they are once again grasping the spring anchor  87 . 
         [0057]    The driver assembly  60  optionally comprises a slip clutch  62  mounted to the motor  11 . The slip clutch  62 —which, in one embodiment, comprises an over-torque clutch—comprises a keyhole for receiving the motor shaft  13 , a stationary portion mounted to the motor bracket  12 , and a carousel  65  driven within torque limits by the motor shaft  13 . Carousel couplers  66  couple the carousel  65  to the pin carrier  76  for synchronized rotation therewith. In another embodiment, the motor  11  is directly connected to the pin carrier  76 . 
         [0058]    Advantageously, the back plate assembly  15  allows trim mounting posts  99  to be mounted to the trim assembly  10  in a variety of arrangements, to accommodate a variety of existing borehole and trim mounting hole arrangements, without interfering with the motor  11 , driver assembly  60 , and escapement assembly  70 . In the embodiment shown, the back plate assembly  15  comprises an upper plate or deadbolt plate  96 , a mid plate  93  positioned over the motor  11 , driver assembly  60 , and escapement assembly  70 , and a bottom plate or spindle plate  97 . Posts  99  can be mounted to the plates  93 ,  96 , and  97  wherever necessary to adapt the trim assembly to any of a variety of configurations of trim mounting holes on an existing door. In  FIG. 2A , for example, two posts  99  are positioned at relative 4:30 and 10:30 o&#39;clock positions on the spindle plate  97 . In  FIG. 2B , two posts  99  are positioned at relative 1:30 and 7:30 o&#39;clock positions on the spindle plate  97 . And in  FIG. 2D , which depicts a trim assembly  10  for an exit door, a single post  99  is positioned at the 6:00 o&#39;clock position on the spindle plate  97 . Also, the deadbolt plate  96  provides an elongated aperture  69  for receiving a deadbolt assembly. This accommodates variable spacing that may exist in existing doors between the deadbolt borehole and the spindle  36 . 
         [0059]    Also advantageously, the trim assembly  10  is configured and arranged in a manner that shares much in common with the trim assembly described and depicted in my co-pending U.S. Patent Application No. ______, filed the same day as the instant application, and entitled “Door Trim Assembly with Clutch Mechanism,” which application is herein incorporated by reference for all purposes. Many of the components are the same or substantially the same. The back plate assembly  15  and spindle driver  30 , for example, are the same. The same handle  14  may be used. The escutcheon  14 , for example, is the same except for a few stamped parts. The commonalities between the locks reduce the cost of manufacture and allow for a more uniform set of instructions in assembling either trim assembly to a door. 
         [0060]    Several different types of motors  11  are suitable for use with the present invention. In one embodiment, a stepper motor is used. In another embodiment, gear motor is used in conjunction with an over torque clutch  62 . 
         [0061]    It should be noted that the embodiments illustrated and described in detail herein are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.