Patent ID: 12215529

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Although the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

References in the specification to “one embodiment,” “an embodiment,” “an illustrative embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. It should further be appreciated that although reference to a “preferred” component or feature may indicate the desirability of a particular component or feature with respect to an embodiment, the disclosure is not so limiting with respect to other embodiments, which may omit such a component or feature. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to implement such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

Additionally, it should be appreciated that items included in a list in the form of “at least one of A, B, and C” can mean (A); (B); (C); (A and B); (B and C); (A and C); or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A); (B); (C); (A and B); (B and C); (A and C); or (A, B, and C). Items listed in the form of “A, B, and/or C” can also mean (A); (B); (C); (A and B); (B and C); (A and C); or (A, B, and C). Further, with respect to the claims, the use of words and phrases such as “a,” “an,” “at least one,” and/or “at least one portion” should not be interpreted so as to be limiting to only one such element unless specifically stated to the contrary, and the use of phrases such as “at least a portion” and/or “a portion” should be interpreted as encompassing both embodiments including only a portion of such element and embodiments including the entirety of such element unless specifically stated to the contrary.

In the drawings, some structural or method features may be shown in certain specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not necessarily be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures unless indicated to the contrary. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, may be omitted or may be combined with other features.

With reference toFIG.1, illustrated therein is a schematic representation of a lockset100according to certain embodiments. The lockset100is mounted to a door90, and generally includes an outside trim110mounted to non-egress side91of the door90, an inside trim120mounted to an egress side92of the door90, and at least one bolt130mounted for extension from a latch edge93of the door90.

The outside trim110is configured for mounting to the non-egress side91of the door90, and in the illustrated form includes an outside escutcheon112, an outside handle114rotatably mounted to the escutcheon112, a lock cylinder116mounted to the escutcheon112, and a credential reader118mounted to the escutcheon112, and may further include a cover119covering at least a portion of the escutcheon112. The outside handle114is operably connected with a latchbolt134such that the handle114is at least selectively operable to retract the latchbolt134. For example, the handle114may be operable to retract the latchbolt134when the lockset100is in an unlocked state, and inoperable to retract the latchbolt134when the lockset100is in a locked state. The lock cylinder116is operably connected with a deadbolt136such that the lock cylinder116is operable to extend and retract the deadbolt136when actuated by a proper key. The credential reader118is operable to receive user input comprising credential information. In various forms, the credential reader118may include one or more of a keypad, a biometric scanner (e.g., a fingerprint scanner, a facial scanner, an iris scanner, and/or a retinal scanner), a card reader (e.g., a smart card reader and/or a proximity card reader), a near field communication (NFC) reader, and/or another form of credential reader.

The inside trim120is configured for mounting to the egress side92of the door90, and in the illustrated form includes an inside escutcheon122, an inside handle124rotatably mounted to the escutcheon122, a lock actuator126operable to alter a locked/unlocked state of the lockset100, and a controller128configured to control operation of the lock actuator126, and may further include a cover129covering at least a portion of the escutcheon122. The inside handle124is operably connected with the latchbolt134such that the handle124is at least selectively operable to retract the latchbolt134. In certain embodiments, the lock actuator126is operable to extend and/or retract the deadbolt136under control of the controller128. Additionally or alternatively, the lock actuator126may be configured to selectively prevent the outside handle114from actuating the latchbolt134. The controller128is in communication with the credential reader118, and is configured to control operation of the lock actuator126, for example based upon information received from the credential reader118. By way of illustration, the controller128may transmit to the lock actuator126an unlock signal in response to receipt of an authorized credential via the credential reader118, and the lock actuator126may unlock the lockset100(e.g., by retracting the deadbolt136and/or permitting retraction of the deadbolt136and/or the latchbolt134) in response to the unlock signal.

As noted above, the lockset100includes at least one bolt130, and in the illustrated form includes both a latchbolt134and a deadbolt136. It is also contemplated that the lockset100may include only one of a latchbolt134or a deadbolt136, or may include plural latchbolts134and/or plural deadbolts136. In the illustrated form, the latchbolt134is at least selectively operable to be retracted by each of the handles114,124, and the deadbolt136is operable to be retracted by each of the lock cylinder116and the lock actuator126.

In the illustrated form, at least one of the outside trim110or the inside trim120includes a corresponding and respective cover119/129. As described herein, the cover119/129covers at least a portion of the corresponding escutcheon112/122, and may further aid in providing a seal to protect internal components of the lockset100from the elements.

With additional reference toFIGS.2-4, illustrated therein is a door hardware apparatus in the form of a trim200according to certain embodiments. The trim200generally includes an escutcheon210, a lock cylinder220mounted in the escutcheon210, a printed circuit board assembly (PCBA)230mounted in the escutcheon210, and a cover300according to certain embodiments. The trim200may, for example, be utilized as the outside trim of a lockset along the lines of the above-described lockset100. While the illustrated trim200is provided in the form of an outside trim including a credential reader202in the form of a keypad assembly203, it is also contemplated that the concepts described in association with the trim200may be utilized in connection with an inside trim, such as the inside trim assembly120.

The escutcheon210provides structural support for the trim200, and generally includes a front face212and a plurality of walls214that extend from the front face212to a rear face216of the escutcheon. The front face212includes a plurality of openings213sized and shaped to receive keys314of the cover300. Each wall214terminates at a corresponding and respective rear surface215that partially defines the rear face216. In the illustrated form, the rear face216is generally open to a chamber218defined by the escutcheon, and a lock cylinder mounting location219is formed within the chamber218. Additionally, the front face212further includes an opening217through which the plug224of the lock cylinder220is accessible. In certain embodiments, such as those in which the cover300covers the entire escutcheon210, the escutcheon210may be raw (i.e., unfinished).

In the illustrated form, the lock cylinder220is mounted to the lock cylinder mounting location219and is positioned at least partially in the chamber218. As is typical of lock cylinders, the lock cylinder220generally includes a shell222, a plug224rotatably mounted in the shell222, a tailpiece226operable to be rotated by the plug224, and a tumbler system228(FIG.5) configured to selectively prevent rotation of the plug224relative to the shell222. The shell222is rotationally coupled with the escutcheon210, and provides support for the plug224, which is rotatably mounted therein. The tailpiece226extends distally from the plug224and is operable to engage a lock mechanism such that rotation of the tailpiece226actuates the lock mechanism. In certain embodiments, the lock mechanism engaged by the tailpiece226may be a deadbolt that extends and retracts in response to rotation of the tailpiece226in opposite directions. In certain embodiments, the lock mechanism may be operable to selectively prevent rotation of a handle that is operably connected with a latchbolt.

The PCBA230is mounted in the chamber218, and in the illustrated form includes a printed circuit board (PCB)232and a plurality of buttons234mounted to the PCB232. Each of the buttons234is aligned with a corresponding opening213such that each button234may be actuated by depression of a corresponding key314. In certain embodiments, the PCB232may include one or more apertures236that facilitate assembly of the trim200as described herein. The PCBA230includes or is configured for connection (e.g., via a port238) with a controller (e.g. the controller128) such that the controller is operable to receive credential information via the PCBA230. As will be appreciated, the credential reader202of the illustrated trim200is provided in the form of a keypad assembly203, the buttons234of which transmit signals when depressed such that the signals generated by the depression of a particular sequence of buttons234can be interpreted by the controller as an access code or credential information. When the credential information matches an authorized credential, the controller128may transmit an unlock signal that causes the lockset100to transition to its unlocked state (e.g., by retracting the deadbolt136and/or permitting retraction of the latchbolt134and/or the deadbolt136).

With additional reference toFIGS.5and6, the cover300conforms to at least a portion of the escutcheon210, and generally includes a monolithic substrate or monolithic structure302that is integrally formed as a single-piece structure, and further includes an outer layer304that coats the monolithic structure302. The monolithic structure302is formed of a non-metallic material such as a plastic material, and the outer layer304may be formed of a metallic material. In certain forms, the monolithic structure302is formed of a thermoplastic material, such as thermoplastic polyurethane. The monolithic structure302may, for example, be formed via a molding process, and may subsequently be coated with the metallic outer layer304via a suitable process (e.g., cladding). The non-metallic monolithic structure302provides the cover300with a certain amount of rigidity while remaining slightly flexible, while the metallic outer layer304provides the cover300with a metallic finish that many users are accustomed to expecting from a door hardware apparatus. As described herein, the cover300includes a front side310, a rear side320, and at least one wall330extending between the front side310and the rear side320such that a chamber308is formed within the cover300.

The front side310of the cover300generally includes a stationary portion312and one or more keys314movably connected with the stationary portion312via flexible regions316, each of which circumferentially surrounds the corresponding key314. The stationary portion312remains stationary relative to the escutcheon210, and the keys314extend through the openings213to a location adjacent a corresponding button234such that depression of a key314actuates the corresponding button234. The flexible regions316may, for example, be provided with a lesser thickness than the stationary portion312to facilitate movement of each key314between a depressed position and a projected position while biasing the key314toward its projected position. In the illustrated form, the front side310further includes an opening317through which the plug224of the lock cylinder220is accessible.

The rear side320of the cover300generally includes a lip322that circumferentially surrounds an opening324through which the chambers218,308are accessible from the rear side of the trim200. The lip322projects inward from the one or more outer walls330, and is positioned behind the rear side216of the escutcheon210such that the escutcheon210is closely captured between the front side310and the rear lip322. Moreover, due to the somewhat flexible nature of the material forming the cover300, the rear side320may be operable to form a seal with the door90when placed against the door90.

The side walls330extend rearward from the front side310to the rear side320, and generally conform to the side walls214of the escutcheon210. In the illustrated form, the cover300has a generally rectangular cross-section, and includes four side walls330. It is also contemplated that other geometries may be utilized, and that the cover300may include more or fewer sidewalls.

In certain embodiments, the cover300may further include one or more posts340that extend rearward from the front side310into the chamber308. Such posts340may extend through the apertures236in the PCB232to prevent relative lateral shifting of the PCBA230and the cover300. In the illustrated form, each post340includes a corresponding and respective head342that engages a rear side of the PCB232to prevent relative longitudinal shifting of the PCBA230and the cover300. In certain embodiments, the head342may be a flexible head that flares outward once passed through the apertures236. It is also contemplated that the head342may be formed by upsetting or otherwise deforming the distal end portion of the post342after it has passed through the aperture236. It is also contemplated that the post340may be secured to the PCB232via one or more fasteners, such as screws.

As noted above, certain embodiments of the subject application involve a monolithic substrate302. While other materials are contemplated, in certain embodiments, the monolithic substrate302is formed of thermoplastic polyurethane (TPU) or a TPU hybrid. Such materials may provide one or more advantages that may not necessarily be provided by other materials. As one example, forming the substrate302of a material comprising TPU may enable the substrate302to be non-opaque (e.g., transparent or translucent). In such forms, the outer layer304may be selectively deposited on the substrate302(or selectively removed from the substrate302) to form indicia315(e.g. numbers, letters, symbols, etc.) that may be illuminated by a light source238(e.g., a light emitting diode) positioned within the escutcheon210(e.g., on the PCBA230). In certain forms, the indicia315may be opaque (e.g. formed of the outer layer304) and the surrounding area may be non-opaque. It is also contemplated that the indicia315may be non-opaque, and the area surrounding the indicia315may be opaque (e.g., formed of the outer layer304). In either form, the outer layer304may be said to comprise the indicia315.

Materials such as TPU may additionally or alternatively provide enhanced resistance to ultraviolet radiation. By contrast, may materials typically used to form flexible keys (e.g., silicone) are often susceptible to ultraviolet radiation and/or require inhibitors and/or coatings to protect the keypad material from ultraviolet radiation.

While one example of a trim200has been thus far described and illustrated, it should be appreciated that a trim according to other embodiments may include additional or alternative features. As one example, the trim may include a handle (e.g., lever or knob) rotatably mounted to the escutcheon210. In these forms and others, the keypad303may be omitted. Moreover, while the illustrated trim200is an outside trim configured for mounting to the non-egress side91of a door90, it is also contemplated that a cover along the lines of the cover300may be utilized in connection with an inside trim configured for mounting to the egress side92of a door90.

With additional reference toFIG.7, illustrated therein is a trim400according to certain embodiments. The trim400generally includes an escutcheon410, a handle420rotatably mounted to the escutcheon410, and a cover430according to certain embodiments. In certain forms, the trim400further includes a wireless communication device440mounted behind the cover430such that the cover430covers the wireless communication device440.

The escutcheon410defines a cover mounting location412sized and shaped to receive the cover430. The outer perimeter of the cover mounting location412generally conforms to the rear side of the cover430. The escutcheon410is formed of metal, and may be provided with a surface finish415.

The handle420is rotatably mounted to the escutcheon410, and may be connected with a latch mechanism (e.g., the latch mechanism134) such that rotation of the handle420actuates the latch mechanism. In the illustrated form, a lock cylinder422is mounted in the handle420. It is also contemplated that the lock cylinder422may be mounted elsewhere or omitted entirely.

With additional reference toFIG.8, the cover430is formed along similar lines as described above with reference to the cover300, and generally includes a non-metallic substrate or monolithic structure432, and further includes a metallic outer coating434. The monolithic structure432may have a greater thickness (e.g., on the order of one millimeter to one centimeter or thicker), and the outer coating434may have a lesser thickness (e.g., on the order of a few angstroms to one micron or thicker). In certain embodiments, the thickness of the monolithic structure432may be on the order of at least one hundred times greater than the thickness of the coating434, or at least one thousand times greater than the thickness of the coating434.

As noted above, the escutcheon410may be provided with a particular surface finish415. In embodiments in which the outer layer434is formed of a metal, the outer layer434may be provided with a matching surface finish435that generally matches the surface finish415of the escutcheon410. In such forms, the cover430may increase the aesthetic appeal of the trim400by providing a consistent surface finish throughout the trim400. Moreover, because the metallic coating434is relatively thin, the metallic coating434may not necessarily interfere appreciably with the wireless communications between the wireless communication device440and an external device. In addition or as an alternative, the coating434may protect the substrate of the monolithic structure432, thereby reducing visible wear.

With additional reference toFIG.9, illustrated therein is an exemplary process500that may be performed to manufacture a cover such as the cover300. Blocks illustrated for the processes in the present application are understood to be examples only, and blocks may be combined or divided, and added or removed, as well as re-ordered in whole or in part, unless explicitly stated to the contrary. Additionally, while the blocks are illustrated in a relatively serial fashion, it is to be understood that two or more of the blocks may be performed concurrently or in parallel with one another. Moreover, while the process500is described herein with specific reference to the cover300illustrated inFIGS.2-6, it is to be appreciated that the process500may be performed to generate covers having additional and/or alternative features, such as the cover430illustrated inFIGS.7and8.

The process500may begin with block510, which generally involves forming a substrate or monolithic structure of a nonmetallic material. Block510may, for example, involve forming the monolithic substrate302of the cover300. In certain forms, block510may involve forming the monolithic substrate with one or more movable keys. For example, block510may involve forming a stationary portion312in block512, forming a movable key314in block514, and forming a flexible portion316in block516such that the flexible portion316connects the stationary portion312with the movable key314. Block510may, for example, involve molding the monolithic substrate of a material comprising a thermoplastic, such as a material comprising thermoplastic polyurethane. As will be appreciated, at least a portion of the substrate302may conform to a corresponding portion of the body to which the cover will be mounted (e.g., the escutcheon210). In such forms, the stationary portion312may include at least a portion of the portion that conforms to the corresponding portion of the body.

The process500may continue to block520, which generally involves coating the monolithic substrate with a metallic coating. Block520may, for example, involve coating the monolithic structure302with a metallic material (e.g., one comprising steel or copper) to thereby form the outer coating304. In certain forms, block520may, by way of illustration, involve a cladding process, an electroplating process, or another process for depositing a relatively thin layer of metal on a substrate.

In certain forms, the process500may include block530, which generally involves providing the metal outer layer with a surface finish. Block530may, for example, involve painting, brushing, distressing, and/or polishing the metallic outer layer. In certain embodiments, such as those in which the cover is intended to cover only a portion of the body to which it will be mounted, block530may involve providing the metal outer layer with a surface finish that matches the surface finish of the exposed portion of the body. By way of example, when the cover being manufactured is the cover430, block530may involve providing the outer layer434with the surface finish435that matches the surface finish415of the escutcheon410.

With additional reference toFIG.10, illustrated therein is an exemplary process600according to certain embodiments. Blocks illustrated for the processes in the present application are understood to be examples only, and blocks may be combined or divided, and added or removed, as well as re-ordered in whole or in part, unless explicitly stated to the contrary. Additionally, while the blocks are illustrated in a relatively serial fashion, it is to be understood that two or more of the blocks may be performed concurrently or in parallel with one another. Moreover, while the process600is described herein with specific reference to the cover300illustrated inFIGS.2-6, it is to be appreciated that the process600may be performed to generate access control devices including covers having additional or alternative features, such as the cover430illustrated inFIGS.7and8.

The process600generally involves assembling an access control device having a cover, such as a cover manufactured according to the above-described process500. For example, the process600may involve creating an access control device along the lines of the above-described trim200or the above-described trim400.

The process600may include block610, which generally involves mounting the cover to a body such that at least a portion of the cover conforms to at least a portion of the body. As one example, block610may involve mounting the cover300to the escutcheon210such that the cover sidewalls330conform to the escutcheon sidewalls214, the cover front side310is positioned in front of the escutcheon front side212, and the lip322of the cover rear side320is positioned behind the escutcheon rear side216. As another example, block610may involve mounting the cover430to the escutcheon410such that a perimeter of the cover430conforms to the perimeter of the cover mounting location412.

In certain embodiments, the process600may include block620, which generally involves positioning a button within the body such that a movable key of the cover is operable to actuate the button. For example, block620may involve positioning the PCBA230within the chamber218such that each movable key314is operable to actuate a corresponding one of the buttons234.

In certain embodiments, the process600may include block630, which generally involves positioning a wireless communication device behind the cover. As one example, block630may involve positioning the wireless communication device440behind the cover430. As should be appreciated, block630may be performed prior to installing the cover430such that the cover430, when installed to the escutcheon410, covers the wireless communication device440. In embodiments in which the outer coating434is relatively thin, the cover430does not appreciably interfere with the wireless communications between the wireless communication device440and an external device positioned outside the trim400.

The process600may include block640, which generally involves mounting an assembled trim including the cover to a door. In certain embodiments, block640may involve forming a seal between the cover and the door. For example, installation of the trim200to the door90may form a seal between the rear side320of the relatively pliable cover300and the outer surface of the door90such that the internal components (e.g., the PCBA320) are protected from the elements.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected.

It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and/or “a portion” is used the item can include a portion and/or the entire item unless specifically stated to the contrary.