Patent Publication Number: US-8539799-B2

Title: Combination lock

Description:
BACKGROUND 
     Combination locks are used in commercial, residential, and institutional environments to provide lockable access to personal items and/or enclosures. The combination lock may be a separate device, such as a combination padlock, which may be shackled to a door, bracket, cable, or other item to restrict access. Alternatively, the combination lock may be integral to an enclosure, such as a safe or a storage locker. Combination locks include single-dial and multiple-dial designs. 
     While the use of a combination lock, as compared to a key based lock, may eliminate the risk of lost, stolen, or copied keys, an authorized combination may be forgotten, preventing access to the locked item by the authorized user. Further, in a situation where an administrator or other such individual needs access to the locked item or items, it may be difficult or impossible to keep track of the authorized combinations, particularly where the combination code is changeable by the user. 
     SUMMARY OF THE DISCLOSURE 
     In accordance with an inventive aspect of the present application, a multiple-dial combination lock may be provided with a mechanism or arrangement for identifying the authorized combination code corresponding to an unlocking orientation of the dials. The code identifying mechanism may be movable between a code concealing condition and a code identifying condition, for example, through use of a key-operated mechanism and a proper key, to prevent unauthorized users from learning the combination code. When the code identifying mechanism is in the code identifying condition, rotation of each dial to its unlocking orientation provides a perceptible indication that the unlocking orientation has been reached. 
     Accordingly, in one exemplary embodiment, a combination lock includes a locking mechanism, a code identifying member, and a plurality of user rotatable dials, with a recess disposed on an outer periphery of each dial. The locking mechanism includes a plurality of dial engaging members configured to hold the locking mechanism in a locking position. Under normal operating conditions, when the code is known by the user, each of the dials is rotated to a known unlocking orientation by the user. The recesses then align with the dial engaging members, allowing the locking mechanism to move from the locking position to an unlocking position. When the code identifying member is moved to a code identifying condition by an authorized user who does not know or has forgotten the code, the dial engaging members are in biased engagement with the dials, such that random rotation of any one of the dials to the unknown or forgotten unlocking orientation causes the corresponding dial engaging member to engage the corresponding recess to provide a perceptible indication that the dial is in the unlocking orientation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features and advantages of the invention will become apparent from the following detailed description made with reference to the accompanying drawings, wherein: 
         FIG. 1  is a perspective view of a combination lock; 
         FIG. 2  is an exploded perspective view of the combination lock of  FIG. 1 ; 
         FIG. 3  is a front cross sectional view of the combination lock of  FIG. 1 ; 
         FIG. 4  is a perspective view of the internal lock components of the combination lock of  FIG. 1 ; 
         FIG. 5A  is a front perspective view of the locking arrangement of the combination lock of  FIG. 1 , shown in a code identifying condition; 
         FIG. 5B  is an exploded view of the locking arrangement of  FIG. 5A ; 
         FIG. 6  is a side perspective view of the internal lock components of the combination lock of  FIG. 1 ; and 
         FIG. 7  is a perspective view of the dial assembly and code change mechanism of the combination lock of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present application relates to combination lock arrangements that may be used with many different types of locks, such as, for example, combination padlocks, safe locks, and integral locks for lockers, mailboxes, storage sheds, or other such structures and enclosures. While the embodiments described in the present application refer to a multiple-dial combination padlock, the inventive aspects described herein may be applied to any type of lock incorporating any number of combination dials. This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as recited in the claims is broader than and unlimited by the described embodiments, and the terms used have their full ordinary meaning. 
     According to one aspect of the present application, a multiple-dial combination lock utilizing a mechanical locking mechanism, such as, for example, a shackle lockably engaged by one or more locking members (for example, ball bearings), may be provided with a code identifying arrangement that allows an authorized user or administrator to ascertain the combination code for the lock. When the code identifying arrangement is operated or moved to a code identifying condition, rotation of each dial to its unlocking orientation provides a perceptible indication that the unlocking orientation has been reached. The code identifying arrangement may be configured to provide many different types of perceptible indications of the unlocking orientation, including, for example, audible indicators (such as a click or beep), visual indicators (such as a light), or tactile indicators (such as a resistance to rotation or impeded rotation in one or both directions). One exemplary embodiment of such a combination lock is described in co-pending U.S. patent application Ser. No. 11/766,462, entitled “Combination Lock” and filed on Jun. 21, 2007, the entire contents of which are incorporated herein by reference, to the extent they are not conflicting with the present application. 
     Referring now to the drawings,  FIGS. 1-7  illustrate an exemplary embodiment of a multiple-dial combination padlock  200  having a key operated code identifying arrangement. As shown in  FIG. 1 , the exemplary padlock  200  includes a lock body  210  configured to retain a shackle  220 , and a series of dials  241 , partially exposed through openings  215  in the lock body  210  to allow user rotation of the dials  241 . The exemplary lock body  210 , as shown in the exploded view of  FIG. 2 , includes housing portions  211   a  and  211   b , top plate  212 , outer casing  213 , and wedge plate  214 , which define cavities within the lock body for accommodating the internal components of the lock  200 . 
     The exemplary lock  200  includes a locking mechanism, discussed in greater detail below, that releases the shackle  220  from a locked condition when each of the dials  241  is rotated to an unlocking orientation. While the illustrated dials  241  include number markings to identify the rotational orientation of each wheel, any types of markings may be used (including, for example, letters, pictures, and colors). While many different locking mechanisms may be employed, in the illustrated embodiment, the shackle  220  is secured in a locked condition within the lock body  210  by a blocking member  230 , which forces locking members  235  into engagement with corresponding notches  225  (as shown in  FIG. 3 ) in the shackle  220  when the blocking member  230  is in an extended or locked condition, thereby preventing axial movement of the shackle  220 . 
     A dial assembly  240  is disposed within the lock body  210  of the exemplary lock  200 , and includes a series of wheels  245  and hubs  243  rotatable about a post  242 . Each of the wheels  245  engages a corresponding hub  243  on its inner diameter (for example, using interlocking gear teeth, as shown in  FIG. 6 ), such that each of the wheels  245  engages with one of the hubs  243  to rotate together as a dial  241 . The lock  200  may further include a spring detent plate  247  (see  FIG. 2 ) to hold each of the wheels  245  in place in one of several set positions (for example, the numbered “0” through “9” positions on a conventional lock dial) when the wheels  245  are not being manually rotated by a user. 
     Each of the hubs  243  includes an unlocking feature, such as, for example, a recess  244  (shown in  FIGS. 4 and 7 ), disposed on an outer periphery of the hub  243 . Other types of unlocking features may be utilized, including, for example, notches, ramps, or projections. The blocking member  230  may include (or may be part of a blocker assembly including) dial engaging members  234  configured to engage the recesses  244  to unlock the lock. When the recesses  244  are aligned with the dial engaging members  234 , the exemplary blocking member  230  becomes axially movable from the extended or locked condition to the retracted or unlocked condition, in which the dial engaging members  234  are received in engagement with the recesses  244 . In the unlocked condition, a narrow end portion  237  of the blocking member  230  axially aligns with the locking members  235 , allowing the locking members  235  to disengage from the shackle notches  225 , thereby allowing the shackle  220  to be axially pulled from the lock body  210  to disengage the short leg  222  of the shackle  220  from the lock body  210 . As shown in  FIGS. 2 and 4 , a biasing spring  236  may be disposed between the blocking member  230  and the housing portion  211   a  to bias the blocking member  230  toward the locked position, such that the shackle  220  must be manually pulled by the user to force the locking members  235  inward and the blocking member  230  downward against the force of the spring  236 . While many different configurations may be used to retain the long leg  221  of the shackle  220  in the lock body  210  in this unlocked condition, in the illustrated embodiment, a shackle pin  227  biased by springs  228  engages a groove  224  near the end of the long leg  221  to prevent the long leg  221  from disengaging from the lock body  210 . The upper edge of the groove  224  is tapered to allow the pin  227  to be forced (against springs  228 ) out of the groove  224  when the shackle is returned to the locked condition. A chamfer may also be provided on a bottom surface of the shackle  220  to permit installation of the shackle after the shackle pin  227  has been installed. This may allow for installation of the shackle  220  at the end of the assembly process, which may make it easier and more efficient to provide locks having different size, shape, or material shackles. 
     To identify or ascertain the proper combination code of a multiple dial combination lock, a code identifying or dial engaging mechanism may be included in the lock and movable between a code concealing (or dial disengaged) condition and a code identifying (or dial engaging) condition. In the code identifying condition, the code identifying mechanism provides for independent engagement of each of the dials, such that a perceptible indication is provided when each of the dials is rotated to an unlocking orientation. To provide for independent engagement with each of the dials, the code identifying mechanism may be provided with a series of resilient pins, tabs, or other such components configured to move independent of each other and separate from the blocker assembly. In one such embodiment, portions of the blocker assembly (such as, for example, the dial engaging members) may be configured, when in the code identifying condition, to independently move and engage each of the dials to produce a perceptible indication when each dial is rotated to the unlocking orientation. 
     In the illustrated embodiment, the code identifying mechanism includes a slider or code identifying member  250  having a series of axially extending passages  251  (see  FIG. 5B ) sized to receive the dial engaging members  234  therethrough. A series of cavities  253  are aligned with the passages  251  to retain spring members  254  associated with each of the dial engaging members  234 . Each of the dial engaging members  234  includes a flange portion  238  (or other suitable structure) having an upper surface that engages an end of the spring member  254 , and a lower surface that abuts the bottom of the cavity  253 . When the code identifying member  250  is moved to a code identifying condition (in this embodiment, axially moved downward), each the dial engaging members  234  is moved into engagement with an outer periphery of the corresponding hub  243 , and the spring members  254  are compressed to provide spring loaded engagement between the code identifying member  250  and the dial engaging members  234 . When one of the dials  241  is then rotated to the unlocking orientation, the corresponding spring loaded dial engaging member  234  is forced into engagement with the recess  244  to provide an indication that the unlocking orientation has been reached. While different types of engagement may be used to provide different perceptible indications (such as, for example, a click-type detent or electrical connectivity between the hub and the dial engaging mechanism), in one embodiment, the recess (or other such unlocking feature)  244  and the dial engaging member  234  may be configured to provide stopping engagement or impeded movement of the dial in one or both rotational directions. In the illustrated embodiment, upon engagement of the dial engaging member  234  with the recess  244 , rotation of the dial  241  is impeded. Therefore, to identify the proper combination code, after the code identifying member  250  is moved to the code identifying condition, each dial  241  is rotated until rotation is impeded. 
     While a dial engaging member (such as a axially movable pin) may be provided in many different orientations and positions within the lock, in the illustrated embodiment, the dial engaging members  234  are positioned between the blocking member  230  and the dial assembly  240 , such that when the dial engaging members  234  are aligned with the recesses  244 , the blocking member  230 , code identifying member  250 , and dial engaging members  234  may all be axially moved to the unlocking position, regardless of whether the code identifying member  250  is in the code identifying condition or the code concealing condition. In other embodiments (not shown), dial contacting portions of the dial engaging members may be provided in some other orientation for engagement with the dials, and may function separately from the locking mechanism. In still other embodiments (not shown), a set of dials may be provided with a first set of unlocking features for engaging the locking mechanism (such as a blocker assembly) and a second set of features (e.g., recesses, projections, etc.) for engaging the dial engaging members, where alignment of the first set of unlocking features with the locking mechanism corresponds with alignment of the second set of features with the dial engaging members, for identification of the combination code when the dial engaging member is in the code identifying condition. 
     Many different mechanisms or configurations may be utilized to allow an authorized user or administrator to move a code identifying mechanism from a code concealing condition to a code identifying condition for identification of the combination code, including, for example, key-operated mechanisms, master code combinations (with wheels configured to move a dial engaging mechanism to a code identifying condition when in a predetermined “master” combination), or electronically operated mechanisms (such as an electronic key card or an infrared or radio frequency transmitter and receiver). In the illustrated embodiment, a key-operated pin tumbler cylinder  260 , as known in the art, extends from a side of the lock body  210 , and is operable (with a proper key) to move the code identifying member  250  into the dial engaging position. The lock  200  may be configured to use a conventional key cylinder, consistent with a door key cylinder, such that an authorized user may use his or her house key to identify the combination code on the combination lock. 
     While many different operative connections may be provided between the key operated cylinder  260  and the code identifying member  250 , in the illustrated embodiment, an inner end of the key cylinder  260  engages a disc-shaped cam driver  270 , which is rotatable to pivot (via pin  273  in slot  283 ) a camming lever  280  assembled with the blocking member  230  and partially disposed between the blocking member  230  and the code identifying member  250 . Pivoting of the camming lever  280  forces the code identifying member  250  axially downward and away from the blocking member  230  into the code identifying condition, as shown in  FIG. 5A . Springs  256  may be provided between a lower portion of the blocking member  230  and an upper portion of the code identifying member (see  FIGS. 3 and 5B ) to return the code identifying member  250  to the axially upper or code concealing condition when the key cylinder  260  is rotated back to the normal code concealing condition. Also, a guiding pin  255  may be affixed to the code identifying member  250  for sliding movement through a corresponding opening  239  in the blocking member  230  (see  FIG. 5B ), to maintain alignment of the code identifying member  250  with respect to the blocking member  230 . 
     The exemplary lock  200  is also configured to allow an authorized user to change the combination code upon unlocking the lock. As best seen in  FIG. 7 , a code change member  290  is disposed in the lock body  210  and accessible through an opening  219  (see  FIG. 1 ) in the bottom of the lock body  210 . The code change member  290  includes a contoured surface  291  that engages the post  242 . When the shackle  220  is locked, the end of the long leg  221  engages a stepped end  292  of the code change member  290  to prevent movement of the code change member (see  FIG. 4 ). When the lock  200  is unlocked and the shackle  220  is lifted, the code change member  290  may be rotated (for example, by a screwdriver inserted in a slot  294  in the exposed end) such that the contoured surface  291  axially pushes the post  242  and hubs  243 , disengaging the hubs  243  from the wheels  245 . Upon disengagement of the hubs  243  from the wheels  245 , the wheels  245  may be rotated to a new authorized combination. Once the new combination has been set, the code change member  290  may be returned to the original position, and a biasing spring  249  returns the post  242  and hubs  243  to reengage the hubs  243  with the wheels  245  in the new orientation. A fastener or pin  205  used to secure the outer casing  213  to the housing  211  may also retain the code change member  290  at the base of the housing  211 . 
     While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative indicators and ranges may be included to assist in understanding the present disclosure; however, such indicators and ranges are not to be construed in a limiting sense and are intended to be critical indicators or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.