Patent Description:
Items of extremely sensitive nature or very high proprietary value often must be stored securely in a safe or other containment device, with access to the items restricted to selected individuals given a predetermined combination code necessary to enable authorized unlocking thereof. It is essential to ensure against unauthorized unlocking of such safe containers by persons employing conventional safe-cracking techniques or sophisticated equipment for applying electrical or magnetic fields, high mechanical forces, or accelerations intended to manipulate elements of the locking mechanism to thereby open it.

Numerous locking mechanisms are known which employ various combinations of mechanical, electrical and magnetic elements both to ensure against unauthorized operation and to effect cooperative movements among the elements for authorized locking and unlocking operations.

<CIT> discloses a self-powered lock and method according to the preamble of claims <NUM> and <NUM> where a charge on a capacitor is supplied by a manual generator. The capacitor retains a reduced level charge after completion of the operation of the lock controls that may serve as a capacitor precharge.

The invention is defined by the independent claims <NUM> and <NUM>. Preferred embodiments are presented in the dependent claims.

Various additional objectives, advantages, and features of the invention will be appreciated from a review of the following detailed description of the illustrative embodiments taken in conjunction with the accompanying drawings.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.

As best seen in <FIG>, a device <NUM> for preventing unwanted opening of a locked enclosure according to a preferred embodiment of this invention has an external user-accessible hub <NUM> conveniently provided with a display <NUM> and a manually rotatable combination input knob or dial <NUM>. Hub <NUM> is attached to the casing <NUM> in any known manner. Alternatively, there may be an access apparatus such as a door disposed between the hub <NUM> and a casing <NUM>.

<FIG> is an exploded view of the device <NUM> for preventing unwanted opening of a locked enclosure according to a preferred embodiment of this invention, as viewed in looking toward the inside surface <NUM> of casing <NUM>. Persons of ordinary skill in the art can be expected to appreciate that the device <NUM> can be mounted on a variety of access apparatuses, such as doors, on a variety of enclosures, such as safes, rooms, structures, and any other enclosure where it is desired to protect the contents from unintended access by locking the enclosure. Moreover, it is not critical to the utility of the present invention that device <NUM> be mounted to a door since, without difficulty, the device <NUM> can be easily mounted to a wall of an enclosure in such a manner that a lock bolt <NUM> projects in its locking position into the door, rather than the enclosure, to lock it to the body of the enclosure.

An aperture <NUM> extends through the entire thickness of casing <NUM> to closely accommodate therein shaft <NUM> extending from combination-input knob <NUM> (see <FIG>) into a space <NUM> defined inside casing <NUM>. In casing <NUM>, there is provided an annular journal bearing <NUM> to closely receive and rotatably support shaft <NUM> via rotary element <NUM> projecting therethrough and into space <NUM>.

A sliding member <NUM> is provided which has a cam notch <NUM> at a superior portion, and a flat cam portion <NUM> at the bottom end. The sliding member <NUM> includes an elongate aperture <NUM>. The elongate aperture <NUM> provides clearance for a case stud <NUM> which is affixed to the casing <NUM> and coupled to an extension spring <NUM>. The spring <NUM> couples to a lever arm <NUM> at a lever stud <NUM> by case stud <NUM>. The spring <NUM> couples to the lever arm <NUM> at aperture <NUM> by case stud <NUM>. As discussed below in more detail, lever arm <NUM> includes a lateral pin <NUM> (see <FIG>) that travels within cam notch <NUM> of sliding member <NUM>. The lever arm <NUM> includes a circular aperture <NUM> at one end and a hook <NUM> at the other end. The hook <NUM> has contiguous portions 47a, 47b and 47c. The lock bolt <NUM> has a pin (not shown) which receives the end of the lever arm <NUM> having the circular aperture <NUM> whereat the lever arm <NUM> is pivotably fixed such that the circular aperture <NUM> is situated concentrically relative to a pivot mounting aperture <NUM> of the lock bolt <NUM>. The lever arm <NUM> is pivotable to engage with a mechanical detent or recess <NUM> (see <FIG>) of the rotary element <NUM>, as explained below in further detail.

As seen in <FIG>, a shaft <NUM>, rotatable by knob <NUM> (see <FIG>), extends into casing <NUM>. The lock bolt <NUM> is slidably supported by casing <NUM> to be projected outwardly into a locking position, or to be retracted substantially within casing <NUM> to an unlocking position, upon appropriate manual operation of combination-input knob <NUM> (see <FIG>) by a user. Casing <NUM> is provided with a detachable back wall <NUM>, fixed to the remaining portion of casing <NUM> by fasteners <NUM>, which also serve to provide support to various components of the device <NUM> according to this invention.

A motor <NUM> and a worm gear <NUM> are provided. The worm gear <NUM> is meshable with and rotates a face gear <NUM>. A blocker member <NUM> is operatively coupled to the face gear <NUM> by a torsion spring <NUM>, the interaction of which is explained in more detail below with respect to <FIG>. As further shown in <FIG>, shroud <NUM> envelops the motor <NUM>, worm gear <NUM> and face gear <NUM> (see <FIG>). Fastener <NUM> engages with aperture <NUM> in a shaft <NUM> in order to fix the shroud <NUM> relative to the shaft <NUM> and thereby the casing <NUM>. Shroud <NUM> assists in maintaining the position of motor <NUM> and also provides protection against access to the motor <NUM> and worm gear <NUM> through the back wall <NUM>.

Casing <NUM> is conveniently formed, e.g., by machining, molding or in an otherwise known manner, to provide a pair of guide slots <NUM> which are shaped, sized and disposed to closely accommodate lock bolt <NUM> in a sliding motion between its locked and unlocked positions. While it is important to provide its locking function in a highly compact manner, the casing <NUM>, lock bolt <NUM> and guide slots <NUM> are also be shaped and sized to provide the necessary strength to resist any foreseeable brute-force to open the locked enclosure. For example, although the locked enclosure may be made of highly tempered steel or alloy, the lock bolt <NUM> and other elements of the lock may be made of a softer metal, such as brass, or an alloy, such as "ZAMAK. " However, it will be appreciated by persons of ordinary skill in the art that other known materials may be suitable for forming one or more elements of the lock.

Lock bolt <NUM> is provided with the pivot mounting aperture <NUM> into which is mounted a pivot <NUM>, to pivotably connect the lever arm <NUM> to lock bolt <NUM>. Thereby, the pivot <NUM> and lever arm <NUM> communicate a manual force for moving the lock bolt <NUM> along the guide slots <NUM> between locked and unlocked positions.

Lever arm <NUM> is provided with the lateral pin <NUM> (see <FIG>) disposed to be engaged by cam notch <NUM> (see <FIG>) of sliding member <NUM> so as to be forcibly moved in conjunction with sliding member <NUM> caused to be slidingly moved as guided by the blocker member <NUM>. The distal portion of lever arm <NUM> extending beyond the location of lateral pin <NUM> is formed as the hook <NUM>, the shape of which is provided with an outside edge having the plurality of contiguous portions 47a, 47b, 47c. The contiguous portion 47a, 47b, 47c coact with a downwardly depending fixed cam portion <NUM> formed at an inside surface of casing <NUM>. This coaction, at different stages in the course of moving lock bolt <NUM> between its locked and unlocked positions, is best understood with successive reference to <FIG> and is described more fully hereinbelow.

As shown in <FIG>, an end portion of shaft <NUM> which extends into casing <NUM>, preferably has a square cross-section, to which is mounted the rotary element <NUM> via the matchingly shaped and sized central fitting aperture <NUM> (see <FIG>). Accordingly, when the user of the safe manually applies a torque to the combination-input knob <NUM> (see <FIG>), torque transmits to shaft <NUM> to thereby forcibly rotate rotary element <NUM>. Fastener <NUM> fixes the rotary element <NUM> relative to the shaft <NUM>. A split ring (not shown), for example, may be utilized to retain the rotary element <NUM> to shaft <NUM> in a known manner. Other known techniques or structures for retaining the rotary element <NUM> may be used. By this arrangement there is readily available, through rotary element <NUM>, a manually provided torque at a point inside space <NUM> of casing <NUM>, i.e., within the secure containment space <NUM> inside a locked enclosure.

<FIG> shows the configuration of the device <NUM> when the face gear <NUM> is in the first position and the interaction between the rotary element <NUM>, sliding member <NUM>, lever arm <NUM>, motor <NUM>, worm gear <NUM>, face gear <NUM>, and blocker member <NUM>. As described herein, the electricity is provided to the motor <NUM>, whereby the motor <NUM> drives the worm gear <NUM> in a first direction to rotate the face gear <NUM> in a counterclockwise direction (as viewed from a front view as shown in <FIG>) from the first position, i.e., <FIG>, <FIG>, <FIG>, to the second position, i.e., <FIG>, <FIG>. The blocker member <NUM> is disposed rearwardly relative to the face gear <NUM> and operatively coupled to the face gear <NUM> via the biasing member <NUM>. The interaction between the face gear <NUM>, blocker member <NUM> and biasing member <NUM> is described fully hereinbelow. The sliding member <NUM> is operatively coupled to the lever arm <NUM> such that when the lever arm <NUM> moves upwardly and downwardly, the sliding member <NUM> also moves upwardly and downwardly. The position of the sliding member <NUM> is dependent upon the rotation of the rotary element <NUM> and the position of blocker member <NUM>. At a certain point of rotation, the lever arm <NUM> may engage with the recess or mechanical detent <NUM> (see <FIG>) of the rotary element <NUM> in order to move downwardly. The downward movement of the lever arm <NUM> urges the sliding member <NUM> downwardly. The downward movement of the sliding member <NUM> is limited by the rotational position of the blocker member <NUM>. The interaction between the rotary element <NUM>, sliding member <NUM>, lever arm <NUM> and the blocker member <NUM> is described in more detail below.

As shown in <FIG>, the lever arm <NUM> is in the disengaged position, unable to move downwardly to thereby engage with the mechanical detent <NUM> provided on rotary element <NUM>. When the blocker member <NUM> is in the second position, the sliding member <NUM> has the freedom to move further down. In addition, because of the manner of coupling with lever arm <NUM>, the hook <NUM> of lever arm <NUM> is allowed to move under the load from extension spring <NUM> into the engageable position with recess <NUM> of rotary element <NUM>. As the rotary element <NUM> is rotated clockwise (as viewed from a back view as shown in <FIG>) when the lever arm <NUM> is in the disengaged position as shown in <FIG>, the hook <NUM> of the lever arm <NUM>, under loading from extension spring <NUM>, interacts with a cam surface <NUM> of rotary element <NUM>. In turn, the lever arm <NUM> raises and the sliding member <NUM> moves in an upwards direction as indicated by arrow <NUM>. This allows the blocker member <NUM> to rotate to an unlocking position. When the lever arm <NUM> moves to the engageable position (see <FIG>), the hook <NUM> of the lever arm <NUM> interacts with cammed surface <NUM> of the rotary element <NUM> in a cammed relationship until the user rotates the rotary element <NUM> to the point where the hook <NUM> may engage the mechanical detent <NUM> of the rotary element <NUM>, as shown in <FIG>. The movement of the lever arm <NUM> into the engageable position depends on the position of the sliding member <NUM> relative to the blocker member <NUM>.

Specifically, cam notch <NUM> at the upper distal end of sliding member <NUM> engages with lateral pin <NUM> of lever arm <NUM>. As shown in <FIG> extension spring <NUM> keeps a biasing force on the lever arm <NUM> in the downward direction. The coupling described above between lever arm <NUM> and sliding member <NUM> ensures that sliding member <NUM> follows the vertical movement of lever arm <NUM> but, due to the interaction between sliding member <NUM> and blocker member <NUM>, that range of motion is restricted when the blocker member <NUM> is in the locking position. Because of the limited range of motion of lever arm <NUM> when the blocker member <NUM> is in the locking position, the hook <NUM> of lever arm <NUM> will only make contact with a portion of the cam surface <NUM> of rotary element <NUM>. This is done in order to raise the sliding member <NUM> and release pressure off the blocker member <NUM>, thereby allowing the blocker member <NUM> to move under any biasing load caused by the torsion spring <NUM> and the particular orientation of the face gear <NUM>. Once the blocker member <NUM> is in the unlocking position, the hook <NUM> of lever arm <NUM> is free to follow all portions of cam surface <NUM>. When the hook <NUM> reaches the recess <NUM>, from external input rotation of the rotary element <NUM>, it will positively engage with the recess <NUM> as shown in <FIG>.

More specifically, force transmitting through the sliding member <NUM>, the fixed cam portion <NUM>, the outside edge portions 47a, 47b, 47c of lever arm <NUM>, and the hook <NUM> with mechanical detent <NUM> leads to a manually-provided force being transmitted to forcibly draw lock bolt <NUM> into casing <NUM> in the direction of arrows <NUM> as shown in <FIG>. Ultimately, lock bolt <NUM> becomes substantially drawn into casing <NUM> to its unlocked position. As shown in <FIG>, when the user desires to move the lock bolt <NUM> back to the locked position from the unlocked position, the user may rotate the lock dial <NUM> (see <FIG>) to rotate the rotary element <NUM> in the counterclockwise direction. The counterclockwise rotation causes the lever arm <NUM> to move in the direction as indicated by arrows <NUM> and to eventually disengage from the recess <NUM> of the rotary element <NUM>. This movement of the lever arm <NUM> moves the lock bolt <NUM> back to the locked position, wherein the lock bolt <NUM> is extending at least partially out of the casing <NUM>. Depending on the rotational position of the rotary element <NUM> relative to the hook <NUM>, after the user rotates the lock dial <NUM> (see <FIG>) in the counterclockwise direction to move the lock bolt <NUM> to the locked position, the lever arm <NUM> and sliding member <NUM> will essentially be configured as shown in <FIG>.

<FIG> show the functionality of the device <NUM> from a front side view. Descriptions of directions such as clockwise and counterclockwise with respect to these <FIG> should be understood to be relative from this front view. As shown in <FIG>, the lever arm <NUM> is in the disengaged position and unable to engage with the mechanical detent or recess <NUM> (shown in hidden lines) of the rotary element <NUM>. In this configuration, the lock bolt <NUM> is in the locked position and is extending at least partially out of the casing <NUM>. The face gear <NUM> is in the first position and the blocker member <NUM> (shown in phantom lines) is in a locking position. With reference to <FIG> the face gear <NUM> has been rotated to the second position by the worm gear <NUM>. The rotation of the rotary element <NUM> by the user causes the end of the hook <NUM> of the lever arm <NUM> to interact with the cam surface <NUM> (shown in hidden lines) of rotary element <NUM>. The interaction between the hook <NUM> and the cam surface <NUM> of rotary element <NUM> urges the lever arm <NUM> upwards. Due to the cam notch <NUM> at the upper distal end of sliding member <NUM> engaging with lateral pin <NUM> of lever arm <NUM>, the upward movement of the lever arm <NUM> causes an upward movement of the sliding member <NUM>, as shown by arrows <NUM>.

Referring to <FIG>, the face gear <NUM> remains in the second position. As rotary element <NUM> has been even further rotated in the counterclockwise direction, hook <NUM> of lever arm <NUM> engages with the recess <NUM> of the rotary element <NUM>. This engagement is caused by the biasing load of extension spring <NUM>, and the downward movement of both the lever arm <NUM> and the sliding member <NUM> is allowed because the blocker member <NUM> is in the second position as described above with respect to <FIG>. However, the downward movement of the sliding member <NUM> is limited by the position of the blocker member <NUM>, as described below with respect to <FIG>.

As shown in <FIG>, when the user desires to move the lock bolt <NUM> back to the locked position from the unlocked position, the user may rotate the lock dial <NUM> (see <FIG>) and, in turn, rotate the rotary element <NUM> in the clockwise direction. The clockwise rotation causes the lever arm <NUM> to move in the direction as indicated by the arrows <NUM> and to eventually disengage from the recess <NUM> of the rotary element <NUM>. This movement of the lever arm <NUM> moves the lock bolt <NUM> back to the locked position, wherein the lock bolt <NUM> is extending at least partially out of the casing <NUM>. Depending on the rotational position of the rotary element <NUM> relative to the hook <NUM>, after the user rotates the lock dial <NUM> (see <FIG>) in the clockwise direction to move the lock bolt <NUM> to the locked position, the lever arm <NUM> and sliding member <NUM> will essentially be configured as shown in <FIG>.

<FIG> show a front view of the detailed functionality of the face gear <NUM>, blocker member <NUM> and torsion spring <NUM>. Descriptions of directions such as clockwise and counterclockwise with respect to <FIG> should be understood with respect from this front view. <FIG> shows the face gear <NUM> in a first position and the blocker member <NUM> in a locking position. The blocker member <NUM> is operatively coupled to the face gear <NUM> by a biasing member, preferably the torsion spring <NUM>, such that the blocker member <NUM> rotates with the face gear <NUM> as described in more detail below. The face gear <NUM> has a first arm <NUM> protruding transversely from a rear side thereof (see <FIG>). The blocker member <NUM> has a second arm <NUM> protruding transversely from a front side thereof and in a direction opposite of the first arm <NUM>. The torsion spring <NUM> has first and second legs <NUM>, <NUM>. The spring <NUM> is installed such that the first arm <NUM> engages the first leg <NUM> and the second arm <NUM> engages the second leg <NUM> when the face gear <NUM> is in the first position and the blocker member <NUM> is in the locking position.

In the configuration as shown in <FIG>, the first leg <NUM> biases the first arm <NUM> in a counterclockwise direction and the second leg <NUM> biases the second arm <NUM> in a clockwise direction. The counterclockwise bias on the first arm <NUM>, due to the engagement of the first leg <NUM>, biases the face gear <NUM> in the counterclockwise direction. Specifically, in the first position, a first end tooth 57a of face gear <NUM> is biased against the worm gear <NUM> to maintain a mesh therebetween. Because the face gear <NUM> is a sector gear containing a plurality of teeth <NUM> along only a portion of the circumference thereof, the bias in the counterclockwise direction assists in maintaining a mesh between the worm gear <NUM> and the face gear <NUM> when the face gear <NUM> is in the locking position. Specifically, when the worm gear <NUM> threads have run off either end of the first end tooth 57a or a second end tooth 57b of the face gear <NUM>, the mesh has been exited. The bias from torsion spring <NUM> is to promote the maintenance of mesh by a reentry or reengaging of the mesh between worm gear <NUM> and teeth <NUM> of face gear <NUM> when the motor <NUM> rotates the worm gear <NUM> in the appropriate direction. This configuration is particularly advantageous because it allows the motor <NUM> to overrun multiple rotations without a stall condition since, in a preferred embodiment, power is applied to the motor <NUM> during a fixed time interval. The configuration of first and second end teeth 57a, 57b relative to the torsion spring <NUM> is such that the amount of bias on the blocker member <NUM> when the blocker member <NUM> is in the locking and unlocking positions is controlled. The configurations of the sliding member <NUM>, lever arm <NUM> and rotary element <NUM> that correspond with the positions of the worm gear <NUM>, blocker member <NUM> and torsion spring <NUM> as shown in <FIG> are shown in <FIG> and <FIG>.

<FIG> shows the face gear <NUM> rotating counterclockwise from the first position to the second position. As the face gear <NUM> rotates, the first arm <NUM> rotates, thereby causing the first arm <NUM> to engage with the second leg <NUM>. The engagement with the first arm <NUM> and the second leg <NUM> causes the rotation of the torsion spring <NUM> in the counterclockwise direction. Due to the counterclockwise rotation, the first leg <NUM> engages with the second arm <NUM>. As the face gear <NUM> continues to rotate towards the second position, first arm <NUM> rotates therewith and also advances the second leg <NUM>. The first leg <NUM> is prevented from further rotation due to the engagement of the first leg <NUM> with the second arm <NUM>. The second arm <NUM> is prevented from rotation due to the frictional engagement between a flat bottom portion <NUM> of the sliding member <NUM> and a round cam section <NUM> of blocker member <NUM> which prevents the blocker member <NUM> from rotating in the counterclockwise direction. The further counterclockwise rotation of the face gear <NUM>, resulting in the further rotation of the second leg <NUM> relative to the first leg <NUM> creates a bias on the second arm <NUM> and the blocker member <NUM> in the counterclockwise direction. As indicated by arrow <NUM>, sliding member <NUM> selectively disengages from the blocker member <NUM> and moves in an upward direction relative to the blocker member <NUM>. This upward movement of the sliding member <NUM> is due to the interaction of the sliding member <NUM> with the lever arm <NUM> and rotary element <NUM>, as discussed with further detail with respect to <FIG> and <FIG>.

With reference to <FIG>, after the face gear <NUM> has rotated to the second position, due to the engagement of the second leg <NUM> and first arm <NUM>, the second leg <NUM> creates a bias on the first arm <NUM> to rotate the face gear <NUM> in the clockwise direction. The clockwise bias on the face gear <NUM> assists in maintaining a mesh between the face gear <NUM> and worm gear <NUM> when the face gear <NUM> is in the second position. Specifically, in this configuration, second end tooth 57b of face gear <NUM> is biased against the worm gear <NUM> thereby maintaining a bias therebetween. More specifically, the spring bias from torsion spring <NUM> maintains a mesh between the second end tooth 57b and worm gear <NUM> by reengaging the mesh therebetween after a disengagement of mesh.

As shown in <FIG>, due to the counterclockwise bias from the first leg <NUM> on the second arm <NUM> and thus the rotary blocker <NUM>, when the sliding member <NUM> disengages from the blocker member <NUM>, the blocker member <NUM> rotates counterclockwise to reach an unlocking position. The rotation of the blocker member <NUM> to the unlocking position is limited due to the engagement between a protrusion <NUM> on the blocker member <NUM> and a second stop <NUM> of the casing <NUM>. This engagement prevents the blocker member <NUM> from rotating further in the counterclockwise direction. As discussed above, the lever arm <NUM> follows the cammed surface <NUM> of rotary element <NUM> in a cammed relationship, but, before the hook <NUM> engages the mechanical detent or recess <NUM>, the sliding member <NUM> is prevented from moving downward. As such, the sliding member <NUM> is prevented from re-engaging the blocker member <NUM>. After the hook <NUM> of the lever arm <NUM> engages the mechanical detent or recess <NUM> of the rotary element <NUM>, sliding member <NUM> is able to move in a downward direction relative to and towards the blocker member <NUM>. Further rotation of the rotary element <NUM> by rotation of the lock dial <NUM> (see <FIG>) moves the lock bolt <NUM> from the locked to the unlocked position, where the lock bolt <NUM> is retracted into the casing <NUM> in the unlocked position. The sliding member <NUM> includes the bottom portion <NUM> preferably having a shape complementary to a flat cam portion <NUM> of the blocker member <NUM>. The engagement of the bottom portion <NUM> of the sliding member <NUM> and the flat cam portion <NUM> of the blocker member <NUM> causes the blocker member <NUM> to rotate in the clockwise direction a distance, indicated by the letter "D," away from the unlocking position, as shown in <FIG>.

After a predetermined period of time, electricity is provided to the motor <NUM> to thereby rotate the worm gear <NUM> in the second direction, thereby rotating the face gear <NUM> in the clockwise direction back to the first position as shown in <FIG>. Alternatively, a sensor (not shown) is provided to detect the position of the lock bolt <NUM> and communicate with the motor <NUM> through a controller, such as a microcontroller <NUM> (see <FIG>), to thereby drive the worm gear <NUM> based on the position of the lock bolt <NUM>. By way of example, the sensor may sense whether the user has driven the lock bolt <NUM> into the unlocked position as described above. Upon sensing that the lock bolt <NUM> is in the unlocked position, the sensor may communicate with the controller to thereby supply power to the motor <NUM>, thereby driving the worm gear <NUM> in a second direction, the second direction being opposite to the first direction and thereby rotating the face gear <NUM> from the second to the first position.

As the face gear <NUM> rotates from the second position to the first position, the first arm <NUM> engages with the first leg <NUM>, thereby rotating the first leg <NUM> therewith. The rotation of the first leg <NUM> causes the second leg <NUM> to rotate in the clockwise direction, whereby the second leg <NUM> engages with the second arm <NUM>. Further rotation of the second leg <NUM> is prevented due to the engagement with the second arm <NUM>, which prevents further rotation in the clockwise direction due to the engagement of the bottom portion <NUM> of the sliding member <NUM> with the flat cam portion <NUM> of the blocker member <NUM>. In this configuration, due to the relative movement and position between the first and second legs <NUM>, <NUM> of the torsion spring <NUM>, the first leg <NUM> biases the first arm <NUM> in a counterclockwise direction and the second leg <NUM> biases the second arm <NUM> in a clockwise direction.

As discussed above with respect to <FIG> and <FIG> and as further shown in <FIG>, the user rotates the lock dial <NUM> (see <FIG>) in a clockwise direction to rotate the rotary element <NUM> and the lock bolt <NUM> moves from the unlocked position to the locked position. Accordingly, the hook <NUM> disengages in an upward direction from the mechanical detent or recess <NUM> of the rotary element <NUM>. Further rotation of the rotary element <NUM> causes the hook <NUM> to again interact with the cammed surface <NUM> of the rotary element <NUM> in a cammed relationship. The upward movement of the lever arm <NUM> causes the sliding member <NUM> to move in an upward direction due to the coupled relationship between the lever arm <NUM> and the sliding member <NUM>. The upward motion of the sliding member <NUM> disengages the sliding member <NUM> from the blocker member <NUM>. Due to the bias on the second arm <NUM> by the second leg <NUM> in the clockwise direction, the disengagement of the sliding member <NUM> from the blocker member <NUM> allows the blocker member <NUM> to rotate in the clockwise direction to the locking position. The rotation to the locking position in the clockwise direction is limited by the engagement of the protrusion <NUM> of the rotary blocker <NUM> with the first stop <NUM>. As discussed previously with respect to <FIG>, when the face gear <NUM> is in the first position and the blocker member <NUM> is in the locking position, the first leg <NUM> biases the first arm <NUM> in a counterclockwise direction and the second leg <NUM> biases the second arm <NUM> in a clockwise direction.

Many of the movements of components have been described directionally, for example, to move in a counterclockwise or clockwise direction. Persons skilled in the art will appreciate that the configuration of the components described in a directional manner may be configured in a manner such that the component moves in an opposite direction as described. By way of example, in an alternative embodiment, the worm gear <NUM> and face gear <NUM> may be configured such that the face gear <NUM> rotates in a clockwise direction to rotate from the first to the second positions and in a counterclockwise direction to rotate from the second to the first position.

In an alternative embodiment, rather than utilizing the torsion spring <NUM> as the biasing member, a spring clutch (not shown) is utilized. Specifically, the spring clutch is operatively coupled to the face gear <NUM> and the blocker member <NUM> in order to rotate the blocker member <NUM> in the similar or same manner as the torsion spring <NUM>.

<FIG> shows an exploded diagram of the motor <NUM>, worm gear <NUM>, face gear <NUM>, and blocker member <NUM>. Extending from the rear side of the face gear <NUM> is a shaft <NUM>. The torsion spring <NUM> is situated on the shaft <NUM> and is located between two spring clips 98a and 98b that engage with recesses 100a, 100b on the shaft <NUM>. The torsion spring <NUM> is allowed to freely rotate about the shaft <NUM> with respect to an axis extending along the center of the shaft <NUM>. The blocker member <NUM> is situated on the shaft <NUM>. The blocker member <NUM> is allowed to freely rotate about the shaft <NUM> with respect to the axis extending along the center of the shaft <NUM>. The face gear <NUM> is allowed to freely rotate about the shaft <NUM> with respect to the axis extending along the center of the shaft <NUM>. The shaft <NUM> is fixed to the casing <NUM> during assembly such that all degrees of freedom for shaft <NUM> will be fixed relative to the case <NUM> once assembled.

Referring to <FIG> and <FIG>, the lock further includes a relock mechanism <NUM> which prevents movement of the lock bolt <NUM> from the locked to the unlocked position when the lock is tampered with or compromised in any manner. The relock mechanism <NUM> comprises a first pin <NUM> coupled to the back wall <NUM> of the casing <NUM>. The first pin <NUM> is coupled to a spring-biased second pin <NUM> in a configuration that prevents a movement of the second pin <NUM> in the direction of the spring bias. The second pin <NUM> is situated above an aperture <NUM> in a superior portion of the lock bolt <NUM>. In a preferred embodiment, the second pin <NUM> contains a recess <NUM> for accepting the free end <NUM> of the first pin <NUM>. The free end <NUM> of the first pin <NUM> is preferably shaped according to the shape of the recess <NUM> in order to provide a complimentary fit between the first and second pins <NUM>, <NUM>. Different shapes of the recess <NUM> of the second pin <NUM> and free end <NUM> of the first pin <NUM> are contemplated in order to provide alternative coupling configurations between the first and second pins <NUM>, <NUM>. The first and second pins <NUM>, <NUM>, before the back wall <NUM> of casing <NUM> have been tampered with, are preferably situated essentially perpendicular to one another, whereby the first pin <NUM> prevents a movement of the second pin <NUM> that is perpendicular to the first pin <NUM>.

When the back wall <NUM> is tampered with, such, when the back wall <NUM> is at least partially removed, the first pin <NUM> decouples from the second pin <NUM>. Due to the spring bias on the second pin <NUM> by a spring <NUM>, the second pin <NUM> moves in the direction of the spring bias. Preferably, the second pin <NUM> is biased downwards towards the aperture <NUM> of the lock bolt <NUM> and in a direction perpendicular to the movement of the lock bolt <NUM> and enters the aperture <NUM> of the lock bolt <NUM> after being decoupled from the first pin <NUM>. Alternatively, the second pin <NUM> could be suspended elsewhere within the casing <NUM> with respect to the lock bolt <NUM>. For example, the second pin <NUM> may be suspended on a wall other than the back wall <NUM>. As such, the aperture <NUM> in the lock bolt <NUM> would be situated to thereby allow the second pin <NUM> to enter the aperture <NUM> when the casing <NUM> is tampered with. The second pin <NUM> is manufactured with material properties that would enable it to resist the movement of the lock bolt <NUM> from the locked to the unlocked position.

<FIG> shows the face gear <NUM> in an alternative embodiment. Rather than utilizing solely a spring bias from the torsion spring <NUM> to maintain a mesh between the face gear <NUM> and worm gear <NUM> as shown in <FIG>, a pair of stopper members <NUM> project from the face gear <NUM> as shown in <FIG>. The stopper members <NUM> are so situated to prevent the worm gear <NUM> from rotating further and, in turn, cause the face gear <NUM> to cease meshing with the worm gear <NUM>. Preferably, there are two stopper members <NUM> disposed on a front face of the face gear <NUM> having a shape adapted to interact with the worm gear <NUM> such that the worm gear <NUM> is unable to continue rotation once engaged with one of the stopper members <NUM> when the face gear <NUM> rotates between the locking and unlocking positions. This configuration ensures that mesh is maintained between worm gear <NUM> and face gear <NUM>.

Referring to <FIG>, an alternative embodiment of a device <NUM>' includes the lock dial <NUM> and a display <NUM>'. In this embodiment, the display <NUM>' is front facing. The display <NUM>' is configured to be facing frontwards for ease of use reasons. For example, the front facing display <NUM>' is advantageous in situations such as where the lock is disposed on a safe that is in an elevated position. Some users may not be tall enough to see the upwardly facing display in such a situation. Therefore, it is advantageous to provide the front facing display <NUM>' for such a situation.

<FIG> shows an exemplary generator-motor circuit <NUM> according to an exemplary embodiment of the self-powered lock according to the invention having the lock dial <NUM>, i.e., user input device <NUM>, as described above, the operation of which is described in more detail below. The lock dial <NUM> is operatively coupled to a generator <NUM>. The generator <NUM> is operatively coupled with a rectifier <NUM> for converting AC power into DC pulses for use with the remainder of the circuit <NUM>. The rectifier <NUM> is operatively connected to a primary capacitor bank <NUM>, a generator pulse detector <NUM>, a motor driver circuitry having an electric motor <NUM>, and first, second, and third pass transistors <NUM>, <NUM>, <NUM>, which direct the DC pulses from the rectifier <NUM>. The first pass transistor <NUM> selectively directs DC pulses to an auxiliary capacitor bank <NUM> in order to charge the auxiliary capacitor bank <NUM> in certain situations, as described in more detail below. The second pass transistor <NUM> selectively directs DC pulses to a voltage detector <NUM>, which, in turn, directs the third pass transistor <NUM>. Accordingly, the third pass transistor <NUM> directs DC pulses to a voltage regulator <NUM> for powering a microcontroller <NUM>, or other controller. The circuit <NUM> further includes a voltage sensor <NUM> and a temperature sensor <NUM>, each communicating with the microcontroller <NUM>. The motor drive circuitry having the electric motor <NUM> is driven by the electricity sent to it by the microcontroller <NUM>.

Furthermore, the generator <NUM> is operatively connected to the LCD display <NUM> having an LED backlight. The circuit <NUM> further includes an interface PCB & LED backlight drive circuit <NUM>. The generator <NUM> provides electricity to the LED backlight of the LCD display <NUM> as well as the microcontroller <NUM>, which provides LCD control signals to an LCD driver module <NUM>. As such, the LCD driver module <NUM> provides LCD drive signals to the LCD display <NUM>. However, the LCD drive signals and the LED backlight drive are powered independently from each other via the generator <NUM>.

<FIG> furthermore shows that the microcontroller <NUM> is mounted on a circuit board (not shown) within the device <NUM>. The microcontroller <NUM> is operatively connected to the display <NUM> to control the device <NUM> by a specific set of operating instructions. Exemplary operation of the circuit <NUM> is diagrammed in <FIG> and each should be considered with reference to the circuit <NUM> shown in <FIG>.

<FIG> show flow diagrams of the lock operation. In the operational mode of <FIG>, once a rotation of the lock dial <NUM> is detected, the lock power activates and obtains authentication information or the proper combination values X, Y, Z from memory along with a value P that represents the number of incorrect combination entries attempted since the last unlocking of the lock. Specifically, the display <NUM> is a Liquid Crystal Display configured to indicate the numerical value N input by the user via the lock dial <NUM>, and actions for the user including dialing left (←DL), dialing right (DR→), and open right (OP →). In addition, the display <NUM> will display a lightning bolt symbol when the user has entered an improper combination and a key symbol when a change key (not shown) is inserted into the device <NUM>.

More specifically, according to <FIG> and <FIG>, rotation of the lock dial <NUM> in either the clockwise (CW) or counterclockwise (CCW) direction generates power for storage in the primary capacitor bank <NUM> via the generator <NUM>. For reference, the rotation CW or CCW with respect to <FIG> is in relation to the user viewing the front of the lock dial <NUM>. On initial power up, the primary and auxiliary capacitor banks <NUM>, <NUM> are discharged. As the user turns the lock dial <NUM>, generated AC power is rectified into DC pulses. The DC pulses charge the primary capacitor bank <NUM>. The DC pulses are detected by the generator pulse detector <NUM>, which turns on the second pass transistor <NUM> with each DC pulse. The voltage of the primary capacitor bank <NUM> is communicated to the voltage detector <NUM>. Generally, the initial voltage charge will not exceed a threshold voltage limit of the voltage detector <NUM> until the user turns the lock dial <NUM> to generate sufficient voltage. Once the voltage exceeds the threshold voltage limit, the third pass transistor <NUM> is turned on. Accordingly, the primary capacitor bank <NUM> directs stored charge to the voltage regulator <NUM> and powers on the microcontroller <NUM>. The microcontroller <NUM> then turns on the third pass transistor <NUM> for directing power to the microcontroller <NUM> even if rotation of the lock dial <NUM> ceases for some period of time. As rotation of the lock dial <NUM> continues, the microcontroller <NUM> monitors the voltage of the primary capacitor bank <NUM> in order to display user prompts and continue operation as described below. In addition, the primary capacitor bank <NUM> is electrically connected to the microcontroller <NUM> and the electric motor <NUM>. However, the auxiliary capacitor bank <NUM> is also electrically connected to the electric motor <NUM> via the first pass transistor <NUM> for providing additional power in cold temperature conditions, such as below <NUM>°F, the purpose of which will be described below in more detail.

The lock dial <NUM> is rotated until a minimum voltage is detected by the microcontroller <NUM>. According to the exemplary embodiment, an analog-to-digital converter (not shown) is manufactured into the microcontroller <NUM> to detect, or otherwise sense, voltage. However, it will be appreciated that any device or method of detecting voltage may similarly be used. In any case, once the minimum voltage, such as <NUM> volts, is detected from the primary capacitor bank <NUM>, the display <NUM> indicates for the user to dial left, i.e., CCW. Should the user dial CCW, the user may input a combination as described below. However, should the user dial right, i.e., CW, the display <NUM> indicates an audit count. The user may repeat dialing right to indicate both the firmware level and repeat again for the firmware date on the display <NUM>.

Once the user initiates the CCW rotation of the lock dial <NUM>, the microcontroller <NUM> obtains the value of P from memory. If P has a value of <NUM> or greater, the display <NUM> indicates this value. At this point, the device <NUM> initiates detection of the ambient temperature via a temperature sensor <NUM> operatively connected to the microcontroller <NUM>. The microcontroller <NUM> compares the measured ambient temperature to a predetermined temperature at which the effects of ESR diminish the ability of the primary capacitor bank <NUM> to operate the electric motor <NUM>, otherwise referred to herein as the ESR threshold temperature. Regardless of whether or not the ambient temperature is above the ESR threshold temperature, the generator <NUM> electrically charges the primary capacitor bank <NUM>.

In the event that the measured ambient temperature is below the ESR threshold temperature, the microcontroller <NUM> operates the first pass transistor <NUM> and charges both the primary and auxiliary capacitor banks <NUM>, <NUM>. The microcontroller <NUM> then senses the voltage stored in the available capacitor banks. In other words, depending on the ambient temperature, the generator <NUM> charges the primary capacitor bank <NUM> or both primary and auxiliary capacitor banks <NUM>, <NUM>, in anticipation of operating the device <NUM>. In addition, the microcontroller <NUM> continues to sense the voltage charge in the available capacitor banks throughout the operation of the device <NUM>. Should the detected voltage drop below the predetermined charge value for the ambient temperature, the display <NUM> will indicate for the user to either dial right or dial left, depending on the status of the operation. In this way, the device <NUM> will remain charged throughout the operation of the device <NUM> shown in <FIG>.

Once the microcontroller <NUM> detects the ambient temperature and accommodates for any effect of ESR as directed above, the microcontroller <NUM> initializes a loop timer and obtains X, Y, and Z values from memory. After verifying the detected voltage and detecting that CCW rotation has stopped and CW rotation has begun, then the microcontroller <NUM> stores the entered dial value at the stop as X1. This process is repeated to obtain values for Y1 and Z1. Next, the microcontroller <NUM> verifies if the entered values X1, Y1, Z1 match the proper combination values X, Y, Z. If the values match, the operation will proceed as described below. If the values do not match or the entire combination was entered in less than ten seconds, the display <NUM> will indicate a lightning bolt, P will be increased, and the lock will power off. This may be generally referred to as an entry error. In addition, the device will shutdown, or otherwise timeout, without error if the user's time between inputting the combination values X1, Y1, Z1 exceeds <NUM> seconds. However, if the user's total time to input the combination is greater than <NUM> seconds, the entry will again be treated as an entry error.

With the entries correct and the device <NUM> charged, the microcontroller <NUM> again senses the ambient temperature to determine whether cold temperature conditions are present. If the ambient temperature is above the ESR threshold temperature, the primary capacitor bank <NUM> is operatively connected to the electric motor <NUM>. The microcontroller <NUM> then verifies the amount of charge in the primary capacitor bank <NUM> before finally discharging the primary capacitor bank <NUM> and activating the electric motor <NUM>. If the ambient temperature is below the ESR threshold temperature, both the primary capacitor bank <NUM> and the auxiliary capacitor bank <NUM> are operatively connected to the electric motor <NUM> via the first pass transistor <NUM>. The microcontroller <NUM> then verifies the amount of charge in the available capacitor banks before finally discharging each of the available capacitor banks and activating the electric motor <NUM>. Finally, the display <NUM> indicates for the user to open to the right so that the lock bolt <NUM> (see <FIG>) may be retracted by the user.

Furthermore, the device <NUM> also conserves power while powered off. Specifically, the microcontroller <NUM> will turn off the third pass transistor <NUM>. This deprives the voltage regulator <NUM> of power, which, consequently, turns off the microcontroller <NUM>. Given that the third pass transistor <NUM> is biased to be turned off, minimal current flows from either of the primary and auxiliary capacitor banks <NUM>, <NUM>. Thus, the primary and auxiliary capacitor banks <NUM>, <NUM> retain charge for longer periods of time. On subsequent power up, energy is more likely to be retained in the primary and auxiliary capacitor banks <NUM>, <NUM> depending on the elapsed time since the previous operation of the device <NUM>. For instance, the device <NUM> may power on in as little as one rotation of the lock dial <NUM>. In any case, this enhances the user experience by conserving energy and requiring less rotation of the lock dial <NUM> to charge the device <NUM> than would otherwise be necessary.

With regard to conserving excess charge produced by the generator <NUM>, a voltage limiting diode (not shown) is traditionally used to ground excess charge within the primary capacitor bank <NUM> when the auxiliary capacitor bank <NUM> is not in use. However, the device <NUM> will effectively precharge the auxiliary capacitor bank <NUM> rather than ground excess charge from the primary capacitor bank <NUM>. More particularly, the device <NUM> retains energy in the auxiliary capacitor bank <NUM> by isolating the excess power with the first pass transistor <NUM>. The excess electricity being generated is sensed by the microcontroller <NUM>. In this way, the user experience is again enhanced by conserving energy and requiring less rotation of the lock dial <NUM> to charge the device <NUM>, especially when activating the electric motor <NUM> with both the primary and auxiliary capacitor banks <NUM>, <NUM>.

For instance, when the ambient temperature is above the ESR threshold temperature, the microcontroller <NUM> will pulse the first pass transistor <NUM> both on and off in order to precharge the auxiliary capacitor bank <NUM>. Specifically, when the first pass transistor <NUM> is off, the generator <NUM> does not charge the auxiliary capacitor bank <NUM>. When the first pass transistor <NUM> is on, the generator <NUM> charges the auxiliary capacitor bank <NUM>. The first pass transistor <NUM> is pulsed on when the primary capacitor bank <NUM> is above a predetermined charge and pulsed off when the primary capacitor bank <NUM> is below the predetermined charge. For example, the predetermined minimum charge may be <NUM> volts. However, when both the primary and auxiliary capacitor banks <NUM>, <NUM> are equal to the predetermined charge, the voltage limiting diode (not shown) grounds the excess charge.

The device <NUM> may also include "LCD over-modulation" as an added security benefit. Specifically, when the display <NUM> is LCD, the display <NUM> communicates with an LCD driver module <NUM> operatively connected to the microcontroller <NUM>. Traditionally, the microcontroller <NUM> directs the LCD driver module <NUM> to operate particular LCD segments shown on the LCD display <NUM>. These LCD segments are "flickered" in rapid succession in order to prevent damage to the LCD display <NUM>. However, the rate of this rapid flicker is traditionally determined by the clock signal of the microcontroller <NUM>, which, according to an exemplary embodiment, may vary between <NUM> and <NUM>. For example, the number N=<NUM> may always display at a clock signal frequency of <NUM> for a traditional display. However, according to an exemplary embodiment of the device <NUM>, the LCD driver module <NUM> is configured to receive the data from the microcontroller <NUM> and convert the clock signal to a unique clock signal representative of the intended number. Going further, the LCD driver module <NUM> randomizes the unique clock signal for any given number. For example, the number "<NUM>" may display once at <NUM> and another time at <NUM>. In this way, any attempts to detect the frequency of the LCD display <NUM> will result in a wide array of detected frequencies; thus, making it more difficult to tie a particular frequency to a particular number.

Claim 1:
A self-powered lock, comprising:
a lock operable by a motor (<NUM>);
a manually operable electricity generator (<NUM>) generating electricity upon manual actuation by a user, the electricity being used to supply power input to a controller (<NUM>); and
an electricity storage device (<NUM>, <NUM>) storing electricity generated by the electricity generator (<NUM>),
wherein at least a portion of the electricity stored by the electricity storage device (<NUM>, <NUM>) is used when the lock is operated,
wherein the electricity storage device (<NUM>, <NUM>) is configured to store an unused portion of electricity after the lock is operated, the unused portion of electricity usable for a subsequent lock operation to supply power input to the controller (<NUM>), characterized in that the electricity storage device comprises primary and auxiliary capacitor banks (<NUM>, <NUM>), at least a portion of the electricity stored in the primary and/or auxiliary capacitor banks (<NUM>, <NUM>) being used when the lock is operated, wherein the auxiliary capacitor bank (<NUM>) is precharged with excess charge from the primary capacitor bank (<NUM>), the excess charge being an unused portion of electricity after the lock is operated, and the excess charge in the auxiliary capacitor bank (<NUM>) is usable for a subsequent lock operation to supply power input to the controller (<NUM>).