Patent ID: 12258788

DETAILED DESCRIPTION

A prior art rim lock is shown inFIG.1, which is modified from 4 313 320 A. While U.S. Pat. No. 4,313,320 A is specifically directed to the implementation of what they describe as a “classroom” function, the general working principles of a rim lock are the same. While some of the improvements discussed in relation to the present invention are specific for rim locks100, it is also appreciated that any improvement can also be applied to other types of locks, such as mortice locks, as appropriate.

The rim lock100comprises a rim look body10and a keep20. The rim lock body10is mounted onto a closure such as a door30. The rim lock body10may also be generally referred to as a housing10for the rim lock100. The door30may be a door for ingress into a room, or may be a door for a cupboard, safe or any other suitable closure. The rim lock body10is be attached to the door30, for example via attachment means such as screws passing through a back plate12. It is possible to attach the rim lock body10directly to the door30. However, the best practice is to use such a back plate12. The rim lock body10may then snap-fit or attach to the back plate12via any known mechanism.

On the opposite side of the door30, there is provided a key plate14with a keyhole for receiving a key to operate the rim lock100. A key cylinder16extends from this key plate14. The key cylinder16is a typical barrel cylinder which operates according to the known principles to rotate when the correct key is inserted into the keyhole and turned. A tail piece18extends from the key cylinder14. The tail piece18turns when a key inserted into the key cylinder16is turned. The key cylinder16extends into a bore formed in the door12and the tail piece18extends therefrom to pass through the back plate12into the rest of the rim lock body10.

The keep20is attached to a frame40of the door30. Alternatively, the keep20may be formed within the frame40of the door. The frame40may be a specifically designed door frame, or may merely be the surrounding surface adjacent the door30. The keep20includes a cavity22which is arranged to receive a bolt11. When the keep20receives the bolt11, the rim lock100inhibits and prevents the door30from opening.

The bolt11is operated between a locked (or closed) position and an unlocked (or open) position by a lock mechanism50within the rim lock body10. This lock mechanism50can be actuated either by a key inserted into the keyhole, or via rotation of a handle17, known in the art as a thumb turn17.

The rear of the bolt11is formed with a transverse slot which receives the front end of a draw plate53to which the head is attached, for example by a pair of pins. However, this is a particular of the specific design and many other variations exist. For example, the draw plate53may be integrally formed with the bolt11.

A crank arm57is mounted for rotation with the thumb turn17. A crank pin56extends through the plane of the bolt draw plate53. Rotation of the thumb turn17thus moves the draw plate53to retract the bolt11.

Likewise, the tail piece18is attached to a T-shaped cam54which is rotatably mounted in the rim lock body10. This cam54includes cam arms55which engage the crank pin56and rotates with the key so as to move the draw plate53to retract the bolt11. The cam arms55form the wings of the T-shape extending from the central portion.

In this sense, the lock mechanism50can be actuated either by the thumb turn17or the key cylinder14.

A rim lock100according to the present invention is shown in perspective inFIG.2. As can be seen from this Figure, the rim lock100generally comprises a rim body, or housing,10and keep20as in the prior art rim lock100. Unless expressly specified otherwise, common features of the smart rim lock100are as described in relation to the prior art rim lock100ofFIG.1. The key difference that makes the rim lock “smart” is that it includes an actuator and a receiver configured to wirelessly receive a signal to control operation of the actuator. This allows the smart rim lock100to be connected to, for example, the Internet of Things. Thus the smart rim lock100can be controlled remotely via a user on a remote device, as well as manually locally via the handle17or a key. For example, the user may be able to actuate the smart rim lock100with be an application (app) on a user's smart phone.

FIGS.3and4show cross-sectional views of the rim lock100ofFIG.2. The rim lock100comprises a latch bolt11(referred to for simplicity as bolt11) which is connected to a throw arm52. The throw arm52may be integral with the bolt11or may be formed as a separate component attached thereto. The throw arm52is formed as a central body with two throw arms52A extending from opposite sides therefrom into the rim body10away from the bolt11. The bolt11and the throw arms52form a lock mechanism. It is possible for the lock mechanism to have one or more throw arms52.

The bolt11is moveable between a first position, also known as a locked position, shown inFIG.3in which the bolt11extends into the cavity22of the keep20to prevent the door30from being opened and a second position, also known as an unlocked position, where the bolt11is retracted from the keep20such that the door30can be opened. The bolt11is biased towards the locked position by one or more biasing means, which may be a resilient member such as one or more springs15, but could also be any element which provides a biasing force such as a magnet.

The bolt11may have a bolt throw of 14 millimetres to 20 millimetres, or of at least 20 millimetres. Other sizes of bolt throw are also possible, but generally result in a less secure lock, which should not be used as a single lock on a door. The bolt throw is the distance the bolt11travels under the action of the key to retract it from the keep20. That is, the amount the bolt11extends from the body10into the keep20. A bolt throw in this range allows the rim lock100to be compliant with the highest security levels of current standards as a longer bolt throw generally corresponds to a more secure lock. For example, this may be British Standard BS3621, or BS8621, or TS621 which is specifically a standard for smart locks. If the rim lock100is complaint with the highest level of the relevant standard it may be used as the sole lock on the door30. Otherwise, a secondary lock may be necessary, such as an additional five lever mortice lock. In particular, many insurers require a lock compliant with BS3621 to be provided on the door30in order for home and contents insurance to be valid.

The total bolt throw needs to be able to be received in the rim lock body10when the bolt11is retracted. In conventional rim locks (such asFIG.1) this is not a particular issue as there are large amounts of empty space within the rim lock body10. However, the smart rim lock100of the present invention also needs to house the actuator60(in the particular embodiment, the actuator60is a motor60, but any other suitable actuator60may be used), battery61, and the associated circuitry and mechanisms.

As such, in the present invention the bolt11is cored out to form a recess11A. when the bolt11is retracted in the unlocked position, the recess11A receives the motor60. In other words, the bolt11is formed of head which is full-sized according to prior art locks, with a thin body portion11B extending therefrom. The thin body portion11B may have a thickness of less than 10 millimetres, preferably less than 5 millimetres.

In use, the various cams engage with the throw arms52A to retract the bolt11. The lock mechanism50is individually actuatable by each of an actuator cam64(also known as a motor cam64), a handle cam74(also known as a thumb turn cam74) and a key cam84. Each of these cams are rotatably mounted within the rim lock body10about generally coincident axes of rotation. This axis of rotation is generally transverse, or perpendicular, to the direction of movement of the latch11. The cams64,74,84are each independently rotatable within the rim lock100. The key cam84is nearest the door30, and the handle cam74is further the door30. The motor cam64is between the key cam84and the handle cam74.

The smart rim lock100may further comprise a controller, memory, processors, a receiver for wireless communication, a transmitter for wireless communication, etc. The controller may control actuation of the motor60to move the bolt11between the unlocked and locked positions. The receiver is able to wirelessly receive a user command to move the bolt11between the unlocked and the locked position. The wireless communication may be via any suitable protocol, for example Bluetooth, Wi-Fi, Li-Fi, or any combination of these. The user command may be transmitted directly from a user's remote device such as a smart mobile phone, preferably via a companion application. Alternatively, or additionally, the smart rim lock100may communicate with a smart hub which itself is in communication with the user's remote device.

In order to improve connectivity of the receiver, the back plate12of the smart rim lock100may be formed of material which is relatively conductive of the communication protocol. For example, the back plate12may be formed of as plastic such as glass filled polycarbonate.

FIGS.5A and5B,6A and6B, and7A and7Bshow the opening movements for each of the thumb turn opening, motor opening, and key opening respectively. In each of these Figures, the biasing members15have been hidden to allow the respective mechanisms to be more easily viewed. The actuator or motor60has been omitted from each Figure except forFIG.6A, for the same reason. The motor60may be positioned between any of the cams64,74,84.

FIG.5Ashows a partial cross-section of the rim lock100to illustrate opening via the thumb turn17(also known as a handle). The thumb turn cam74is rotatably mounted within the rim lock body10as described above. The thumb turn cam74comprises one or more radially extending protrusions76. The radially extending protrusions76are arranged to engage with the throw arms52A as the thumb turn cam74is rotated. In use, the thumb turn17is rotated by a user. This causes the thumb turn cam74to likewise rotate. As the thumb turn cam74rotates the protrusion76engages with the throw arm52A to actuate the lock mechanism and retract the bolt11as shown inFIG.5B. The thumb turn cam74, and the components operatively connecting the thumb turn17and the thumb turn cam74form the thumb turn mechanism or handle mechanism.

As shown in the example ofFIGS.5A and5Bthe thumb turn protrusions76extend over enough of the circumference of the thumb turn cam74that the thumb turn cam76can be rotated in either direction to retract the bolt11. While the depicted example has two thumb turn protrusions76, the same effect could be achieved with a single thumb turn protrusion76which may extend over the same circumferential extent of the thumb turn cam76.

A clutch arm94is provided, actuated by a snib92. This clutch arm94acts to prevent the smart lock100from being forced open (jimmied). The clutch arm94is biased towards a position as shown inFIG.5Bwhere it is disengaged from the key cam74. In this position the snib92it in its most extended position from the smart lock100. When the door is closed, the snib92engages a face on the keep20, forcing it to retract. This movement of the snib92then moves the clutch arm94to the position shown inFIG.6Awhere it engages with the key cam64. In this position, the clutch arm94prevents the bolt11from moving. A further arrangement of the clutch arm94is shown inFIG.8and described below.

Actuation of the lock mechanism using the motor60is shown inFIGS.6A and6B. Attached to the output shaft of the motor is a bevel gear62. This bevel gear62engages with a corresponding geared surface on the motor cam64. Thus, actuation of the motor60drives rotation of the bevel gear62and hence rotation of the motor cam64. The motor cam64is provided with a motor cam protrusion66. As the motor cam64rotates the motor cam protrusion66engages with the throw arm52to thereby retract the bolt11to the unlocked position. The motor bevel gear62and motor cam64form the motor mechanism. While the motor cam protrusion66could be similar to the thumb turn protrusion76in that it could be shaped so that the motor cam64can rotate in either direction to actuate the lock mechanism, this is not necessary. Instead, additional functionality can be imparted into the smart lock100as discussed below by having the motor cam64have a single direction of operation to actuate the bolt11.

The smart lock100may be retained in the unlocked position shown inFIG.6Bto latch the lock100. This may be used when the user does not want the door20to be locked, for example if they are heading out briefly such as to take out their garbage. Typically, this is achieved with a mechanical button on the face of the rim lock100. This mechanical button can only be operated from within the property. As described above, the springs15are acting to bias the bolt11towards the locked position. Accordingly, the biasing force provided by the springs15needs to be overcome to retain the bolt11in the unlocked position ofFIG.6B. While this could be achieved by providing a constant output from the motor60, this requires additional energy usage and hence a faster rate of drain of the battery61.

Instead, it is preferable if the motor60and biasing member(s)15are selected such that the motor stall torque is greater than the torque transferred to the motor from the force of the biasing member(s)15. Thus, the motor60is able to retain the bolt11in the unlocked position without drawing additional power. For example, the motor stall torque may be in the region of greater than 0.25 Nm, preferably greater than 0.275 Nm, most preferably greater than 0.29 Nm. Of course, the particular value for motor torque must be selected based upon the biasing member(s)14chosen and the particular mechanism. Such values of motor stall torque may be suitable, for example for biasing member(s)14which exert an opposing torque in the region of 2.5 Nm. The gearing connecting the motor60may be selected to gear up to this. This may be biasing member(s)14which provide a force in the region of 10 N to 11 N. The biasing force may be prescribed a minimum value in order to meet security levels of a particular standard, in a similar manner to the bolt throw.

This latching position may be triggered by a user pressing a button19on the rim lock100, or on a remote device such as their mobile phone which is then transmitted to the rim lock100. The button19may be, for example, provided on the thumb turn17as shown inFIG.2. The smart lock100may include a transmitter for communication with a remote device, such as a user's smart phone or a smart hub. This allows the smart lock100to send the user an alert or notification when the latching has been engaged, to reduce the chance that the door20is accidentally left latched.

FIGS.7A and7Bshow operation of the rim lock100when actuated by the key. The key cam84is connected to the tail piece18of the key cylinder16. In particular, there may be a slot arranged to receive the tail piece18of the key cylinder. As the tail piece18rotates when the correct key is inserted into the keyhole and turned, the cam84likewise rotates. The cam84comprises a key cam projection86which engages with the draw arm52A to thereby retract the bolt11in a manner similar to the thumb turn cam74and motor cam64. The connection between the tail piece18and the key cam84, and the key cam84, form the key mechanism.

For high security rim locks100, it is preferable if the rim lock100can be placed into a state where the bolt11is not moveable from the locked position by one or both of the thumb turn17or the key cylinder16. For example, overnight a user may wish to disable the key cylinder16so that even an intruder with the correct key cannot open the door30. This may be useful, for example, where keys are borrowed by third parties. When a user is leaving their property for a long period of time they may wish to disable the thumb turn17. This prevents an intruder that has accessed the property via another entry point (such as via a window) from being able to exit via the door30. This may make it harder for the intruder to steal high value items which are difficult to transport through the initial entry point, such as a large television.

The smart rim lock100according to the present invention may disengage the key mechanism or the handle mechanism from the lock mechanism in order to prevent either the key cylinder16or thumb turn17from actuating the lock mechanism to move the bolt11to an unlocked position. In particular, this may be achieved via movement of the motor cam64.

In particular, the motor cam64may be rotated in a direction opposite to the direction it rotates in to open the bolt11in order to disengage one or both of the thumb turn cam74and the key cam84from the lock mechanism. For example, the thumb turn cam74or key cam84may be moved in the direction of their axis of rotation. This may then move the cam74,84out of alignment with the throw arms52A. Then, the cams74,84are able to freely rotate within the rim lock100without engaging the throw arms52A. Accordingly, even as the cams74,84rotate they will not engage the throw arms52A and hence will not move the bolt11to the unlocked position.

This may be achieved by the motor cam64having one or more ramped surfaces on its faces. These ramped surfaces can then engage with corresponding surfaces on the thumb turn cam74and/or key cam84so as the move them out of alignment with the throw arms52A. With the thumb turn cam74and/or key cam84out of alignment, they may engage with a protrusion on the housing of the smart lock100that prevents them from further movement or rotation.

Alternatively, or additionally, there may be a hooked surface on the motor cam64. This hooked surface can engage the clutch arm94and therefore retain the thumb turn cam74and/or the key cam84in place. An example of this arrangement is shown inFIG.8and discussed below.

Thus, the thumb turn17and/or the key cylinder16can be effectively de-activated from controlling the lock mechanism.

FIG.8shows a further arrangement of the clutch arm94and motor cam64, which may be applied to any of the arrangements described above. The smart lock100is generally as described above, and the operation of the various cams is as described above.

The motor cam64is provided with a protrusion66engages with the throw arm52to thereby retract the bolt11to the unlocked position. The motor cam64shown inFIG.8will rotate in an opposite direction (counter-clockwise based uponFIG.8) compared to the motor cam64ofFIGS.5A to7B. This does not fundamentally affect operation of the smart lock100.

The motor cam64further comprises a hook68. With the clutch arm94in the position engaging the key cam84(i.e. the door30is closed and the smart lock100is in the locked position), the motor cam64can be rotated such that the hook68engages with the clutch arm94. The hook68engages with the clutch arm94and retains it in this position as shown inFIG.8. Thus, the key cam84cannot rotate to open the smart lock100. The rotation of the motor cam64to engage the hook68may be in the opposite direction to the rotation of the motor cam64to actuate the bolt11.

The clutch arm94may further comprise a shoulder which abuts against at least one of the throw arms52A of the bolt11in the locked position when the clutch arm94engages the key cam84. Thus the clutch arm94may physically prevent the bolt11from moving.

With the bolt11in the latched position (i.e. retained by the motor60after an opening event), a user may wish to instruct the lock to close after the door has been shut. For example, this may be relevant if someone has used the app to move the bolt11to the unlocked position and they now wish to secure the door30. Alternatively, a user approaching a locked door30may send a user input to the smart lock100that they would like to open the door.

In order to achieve this the rim lock100may include a timer which actuates the bolt11from the unlocked position to the locked position, or from the locked position to the unlocked position, after a predetermined time delay which may be triggered by the receipt of a user input. However, this may be unsuitable for many use cases. For example, if the user is not close to the door30when they send the signal to open the rim lock100this predetermined time delay may expire before the user reaches the door30. This could be the case, for example, where a user is transporting an item such as shopping from a car. On the opposite side, if a user is very close to the door30when the send the opening command they may be able to open the door30and pass therethrough and go to shut the door before the predetermined time has expired. This may mean that the door30bounces back out of locked position, so that at the expiry of the predetermined time the bolt11is no longer aligned with the keep20and hence when the bolt11is moved to the locked position it is not retained within the keep20and hence the door30is unsecured.

In order to solve this, the rim lock100may comprise one or more sensors which are able to detect movement of the door30or an element attached to the door30. Particularly, the sensors may detect when the door begins to open. While this could be achieved by having corresponding sensors, or elements of sensors on either side of the door30and frame40, this is not a preferable solution as it requires a consistent alignment between these. Further, as this is an additional part it increases the cost and complexity. Many customers do not want to install another thing to their door or frame, and some door frames may be unsuitable for this based upon its thickness or architrave profile.

Instead, according to the present invention the movement of the door30is sensed by components solely, or exclusively, attached to the door30. That is, there is a standalone sensor system which is able to detect movement of the door30without requiring any additional sensors mounted elsewhere. Of course, there may be additional sensors detecting other parameters mounted elsewhere.

After movement of the door30is sensed, the controller may control the motor60to actuate the lock mechanism to move the bolt11to the locked position. As in the present example the bolt11has a latch profile. That is, bolt11has an angled front face which allows the door30to be closed when the bolt11is in the locked position as the angled front face slides against the face of the keep20to retract the bolt11against the biasing member(s)15. Particularly, the face of the bolt11which first contacts the keep20during a closing movement of the door may form an angle of between 20° to 70° with a first point of contact of the keep20. The angle may be between 30° to 60°.

That is, the bolt11may have a generally right trapezoid shape when viewed in cross-section in a direction along its plane of movement. The bolt11may therefore by a right trapezoidal prism. Of course, deviations from the strict mathematical shape are still covered by this. The angled face may be curved rather than at a straight line. The relevant angle can then be defined based upon a tangent of this curve. Once the bolt11is aligned with the cavity22of the keep20the biasing members(s)15then return the bolt11to the locked position and thereby lock the door30. This may be an active movement or it may be from a biasing force. Accordingly, the user can then push the door30closed from this position.

In particular, the lock may comprise an accelerometer to detect closing of the door30. The accelerometer may sense the acceleration of the door30, or of a component within the lock to detect the movement of the door30. The accelerometer may be a part of an inertial measurement unit, such as a six-axis inertial measurement unit. Alternatively, any suitable sensor to detect movement of the door30may be used, such as a compass.

In particular embodiments, the smart rim lock100may also use a predetermined time delay. For example, the signal from the sensor may indicate that the door30has begun opening and a time delay may then begin before the bolt11is actuated to the locked position.

The controller may “learn” what opening of the particular door30looks like on the signal from the sensor by instructing the user to carry out a number of opening repetitions and recording the signal and storing this in some memory. In future opening events the signal received from the sensor may be compared to the stored signal to identify an opening event.

This method of determining when a door30has begun opening in order to actuate a lock mechanism may be applied more generally to any smart lock, whether it is a rim lock or otherwise. For example, this method may be applied to a smart lock for a mortice lock. The smart rim lock100may determine when the door has passed through a threshold opening amount, in order to distinguish over small movements when the door30is still closed. For example, the smart rim lock100may monitor for the door30past a threshold value which corresponds to the door being 5% of its fully open movement, preferably at least 15% of its fully open movement, more preferably at least 25% of its fully open movement.

The motion sensing of the door30may also be used to determine if, for example, the door has been opened by force such as being kicked in. The controller may detect that the door has begun to move, and that the lock mechanism has not been actuated. This may trigger a notification or alert, such as to a user's remote device.

In many situations, the smart rim lock100of the present invention will be used to replace a user's existing standard rim lock. For example, a user may be upgrading their existing rim lock to a smart rim lock100. In such a scenario, the user may not want to change their keys. Therefore, the smart rim lock100according to the present invention can be used to replace an existing rim lock without replacing the key cylinder16.

In order to carry out the replacement of an existing rim lock, the following steps may take place. Firstly, the rim lock body10of the previous rim lock may be detached from the back plate12. The detachment of the rim lock body10will also typically detach all of the mechanisms of the previous rim lock. The back plate12is then detached from the door30.

The key cylinder12is retained within the door30and not removed. A new back plate12suitable for the present smart rim lock100is then attached to the door30. This may involve the door30having to be chiselled to account for any differences in the overhang of the bolt face between the existing rim lock and the new smart rim lock100. As discussed above, the back plate12for the smart rim lock100may be more conductive of wireless signals than the back plate12of the previous rim lock100.

With the new back plate12attached to the door30, the rim lock body10of the smart rim lock100can then be attached to the back plate12. The rim lock body10will have an opening in the key mechanism for receiving the tail piece18of the previous key cylinder16.

While the keep20of the previous rim lock may not need to be replaced if it aligns with the latch11of the smart rim lock100, it is preferable that it is replaced with the keep20for the smart rim lock100to ensure compatibility.

The smart rim lock100is thus installed on the door30to replace the previous rim lock without the need to replace the key cylinder16. The user thus achieves the smart functionality without having to replace their keys.

This means that the smart rim lock100according to the present invention may be sold as a standalone item without a key cylinder16. Alternatively, or additionally, a kit may be sold of the smart rim lock100with a key cylinder16.

In particular, this method of replacement of an existing rim lock with a smart rim lock100may include the steps of: removing the housing10from the back plate12; and then removing the back plate12from the door30. The key cylinder16of the existing rim lock can then be kept. The smart rim lock back plate12is then installed onto the door30. The smart rim lock100is then attached to the smart rim lock back plate12. This attachment to the smart rim lock back plate12is so that the tail piece18is received by the smart rim lock100in an operable connection such that actuation of the key cylinder12actuates the key mechanism of the smart rim lock100.

As discussed above, the motion sensing of the door30may be applied to other types of smart lock and not just a rim lock. A particular example of this is a mortice sash lock. With such a lock, there is a deadbolt and a latch bolt11which may both be controlled by a single tail piece18. The latch bolt11may be generally similar to the latch bolt11described above, particularly in that it may be biased towards the extended position. The deadbolt does not include such an angled face and is generally a rectangular cuboid. Unlike a rim lock, the latch bolt11and lock mechanism are retained within the door30, as opposed to the housing10of a rim lock. Thus, the latch bolt11protrudes from a side face of the door30to be received in a keep20or strike plate which may be formed into the door frame.

With the mortice sash lock in the fully locked position both the deadbolt and the latch bolt11are extended and locking the door30, this is a second locked position of the lock mechanism50. As the tail piece18rotates, the deadbolt is first retracted, but the latch bolt11is still extended. This is a first locked position of the lock mechanism50. Further rotation of the tail piece18causes the retraction of the latch bolt11such that the lock mechanism50is in the unlocked position. When this is done by a user with a key in a key cylinder16, the user will hold the key in the cylinder16to maintain the latch bolt11in the retracted position against the biasing force.

When the lock mechanism of the mortice sash lock is actuated via the actuator60, the actuator60drives the lock mechanism50so as to first retract the deadbolt and then the latch bolt11. If the actuator60were turned off the biasing force would drive the latch bolt11back to the extended position. If the door30were not yet open, such as if the user triggered the unlocking and was not immediately ready to open the door30, the latch bolt11would then extend back into the keep20and prevent the door30from opening.

Thus, in a similar manner as to the rim lock100, the mortice sash lock may comprise one or more sensors which are able to detect movement of the door30or an element attached to the door30. This generally operates in the same manner as discussed above in relation to the rim lock100.

The user triggers the actuator60to open the mortice sash lock, this causes the actuator60to rotate the tail piece, or lock cylinder, to first retract the deadbolt and then retract the latch bolt11. The motor60stall torque is then used to hold the latch bolt11in the retracted position against the biasing force. After movement of the door30is sensed, the controller may control the motor60to actuate the lock mechanism to move the latch bolt11to the locked position. This may be an active movement or it may be from the biasing force. That is, the motor60may actuate the latch bolt11to a neutral position from which the latch bolt11can be moved to a fully extended position via the biasing force. This then allows the user to push the door30closed, after which the actuator may continue to actuate the deadbolt to fully lock the door.

The sensing mechanism may be as described above and may include any suitable variations and examples included. In this sense, the motion sensing may be applied to other lock types than a rim lock.