Patent Application
20240218704
The present disclosure relates generally to aspects of door locks including deadbolt locks.
Deadbolt locks are one type of lock used to secure doors against entry by unauthorized individuals. The deadbolt lock controls the motion of the deadbolt assembly, allowing the bolt to retract only after a user has provided proper credentials and activated the lock. Many deadbolt locks provide a thumb turn which may be manipulated by a user to lock or unlock the deadbolt.
According to one aspect, a door lock assembly comprises a knob configured to allow a user to lock or unlock a door, and a tailpiece configured to rotate about a longitudinal axis. Rotation of the tailpiece is configured to retract or extend a latch. The door lock assembly further comprises an actuator configured to move in a linear direction parallel to the longitudinal axis, and a mechanical interlocking clutch configured to selectively couple the knob to the tailpiece. The mechanical interlocking clutch is configured to slide in the longitudinal direction in response to a movement of the actuator. In an unlocked configuration the clutch couples the knob to rotate with the tailpiece, and in a locked configuration the clutch uncouples rotation of the knob from the rotation of the tailpiece.
According to another aspect, a door comprises a door including a first face and a second face. With the door closed, the first face is exposed to an unsecured space and the second face is exposed to a secured space. The door additionally includes a bore hole extending between the first face and the second face; and a door lock disposed at least partially within the bore hole. The door lock further comprises a latch configured to prevent the door from opening when the latch is extended, a knob disposed on the first side of the door and configured to extend and retract the latch, a mechanical interlocking clutch configured to selectively couple the knob to the lock; and an actuator configured to move the mechanical interlocking clutch between a coupled position and an uncoupled position. The mechanical interlocking clutch and the actuator are disposed within the bore hole.
According to another aspect, a clutch for a lock assembly comprises a driving plate configured to rotate upon rotation of a knob, a driven plate configured to translate along a longitudinal axis about which the clutch rotates and to engage with the driving plate when translated to abut the driving plate. Each of the driving plate and the driven plate further include a plurality of dogs disposed on the driving plate to face the driven plate and disposed on the driven plate to face the driving plate. The dogs are spaced in a pattern about an axis of rotation of each of the driving plate and the driven plate such that when brought together the dogs on the driving plate enter spaces between dogs on the driven plate and the dogs on the driven plate enter spaces between the dogs on the driving plate. The clutch for a lock assembly additionally comprises an actuator configured to move along an axis parallel to the axis of rotation of the clutch and configured to move the driven plate in and out of engagement with the driving plate. The lock is in an unlocked position when the dogs are brought together and the lock is in a locked position when the dogs are separated.
It should be appreciated that the foregoing concepts, and additional concepts discussed below, may be arranged in any suitable combination, as the present disclosure is not limited in this respect. Further, other advantages and novel features of the present disclosure will become apparent from the following detailed description of various non-limiting embodiments when considered in conjunction with the accompanying figures.
The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. In the drawings:
Aspects described herein relate to improvements to door locks (also referred to as locks) that employ deadbolts. Door locks typically include and exterior portion accessible to persons both authorized and unauthorized to enter the locked space; an interior portion accessible only to users within the locked space; and a deadbolt assembly contained within the door. Within the deadbolt assembly, a sliding member (the bolt) can traverse within the deadbolt assembly and extend therefrom so that it may partially enter the door jamb to prevent the door from opening. The exterior portion of the lock assembly may contain key openings, touchpads, or other interface for a user to present a key, passcode, or other credentials to open the door. The interior portion of the lock assembly resides within the locked space when the door is closed and therefore has no guards to prevent unlocking by those already within that space. Thumb turns may be provided on the unsecured interior side for ease of mechanical operation. Thumb turns may also be employed on the secured exterior side, but if this is done, the lock must be constructed to immobilize or disconnect the thumb turn in the locked condition to prevent unauthorized individuals from accessing the space without first requiring the user to unlock the lock. Furthermore, the lock and thumb turn may be designed to avoid the possibility of an intruder overpowering the thumb turn lock to gain entry to the secured space (such as by grasping and turning the thumb turn with a wrench). For instance, in embodiments described herein, a thumb turn may be decoupled from the lock assembly in the locked state such that the thumb turn free-spins (freewheels), when a user attempts to turn the thumb turn. In this manner, the thumb turn is effectively disconnected from the lock.
The Inventors have found that marketplace may find thinner/low profile door locks more desirable than thicker door locks. That is, thinner deadbolt locks have a smaller envelope such that they protrude less far away from and therefore remain closer to the surface of a door than thicker deadbolt locks. Customers may find these thinner locks to be more aesthetically pleasing and may additionally find thinner locks to be less obtrusive to the use of the door.
The Inventors have recognized and appreciated improvements in door locks employing deadbolt assemblies to keep the door lock as low profile as possible while also providing a lock clutch that facilitates decoupling of a knob, such as a thumb turn, from the lock assembly. According to some embodiments, a lock assembly is provided wherein a thumb turn is connected to a lock tailpiece with a sliding and mechanical interlocking clutch disposed therebetween. A tailpiece of a lock serves as a shaft, often of a square or rectangular cross section, the rotation of which actuates the lock such as by actuation the sliding deadbolt or striker. The mechanical interlocking clutch may be engaged or disengaged by a lead screw and motor operating on an axis parallel to that of the rotation of the clutch and tailpiece such that the clutch and clutch actuation may reside within the bore hole of a door when the lock assembly is mounted thereon. It should be appreciated that embodiments of the lock clutches as disclosed herein may be applied to couple/decouple thumb turns from deadbolt lock assemblies; however, other embodiments are contemplated wherein lock clutches may be applied to other types of door locks, such as for coupling/decoupling a door knob or door handle lever to a knob lock or mortice lock.
According to some embodiments, a knob may be selectively coupled to a lock assembly with a mechanically interlocking clutch. As used herein, the term “knob” is referred to as any type of handle, lever, knob, thumb turn or control of any other shape that may be turned by a user to change the position of a latch and/or to open a door. The term “latch”, which may include any component that slidably protrudes from door to engage with a door opening for the purpose of keeping a door closed, may be in reference to a door latch or a deadbolt or striker or any other similarly functioning component. A door may be said to be in an unlocked configuration when a user causes the door to open by turning one or more knobs, and/or pushing on levers etc. without entering credentials such as a key, passcode, or biometric marker. A door may be said to be in a locked configuration when a user must supply credentials to open the door.
A mechanical interlocking clutch may comprise a clutch driving plate which is turned by an outside force, such as from a motor or the user, and a clutch driven plate, which is turned by the driving plate when the clutch is engaged. When the clutch is not engaged, the clutch driven plate is mechanically independent of the clutch driving plate and motion will not be transmitted therebetween. A mechanical interlocking clutch is also a positively engaging clutch, meaning the clutch is either engaged so that the driving and driven plates move together, or it is fully disengaged. In contrast, a friction clutch, such as an automobile clutch, may “slip”, that is, transmit a torque while still allowing for some relative motion between the driving and driven plates. If a mechanical interlocking clutch selectively couples a thumb turn to a deadbolt lock, for instance, the interlocking clutch may allow the thumb turn to operate the deadbolt lock when the clutch is engaged and it may allow the thumb turn to free-spin when the clutch is disengaged.
According to some embodiments, a clutch connecting a knob, such as a thumb turn, with a door lock assembly may be actuated by a linear drive or linear actuator, the linear actuator being arranged to be parallel with the rotational axis of the clutch and tailpiece, such that the motion of the linear actuator is along a longitudinal axis of the tailpiece. The longitudinal axis of the tailpiece is normal to the outer and inner surfaces of a door. The tailpiece may extend along an axis connecting inside and outside doorknobs, inside and outside thumb turns, or a thumb turn and a key cylinder in some embodiments. A linear actuator may include an electric motor and a lead screw. A linear actuator with an axis parallel to the tailpiece may include an electric motor with the axis of the armature of the motor running parallel to the tailpiece. A leadscrew may be provided to convert rotational motion of the motor to linear motion along the longitudinal axis of the tailpiece and would therefore be parallel with the tailpiece and also parallel with the axis of the motor armature. In some embodiments the leadscrew may be coaxial with the armature of the motor and may be a separate piece or may form a unitary piece with the armature. In other embodiments, the leadscrew may be parallel with the motor armature and geared thereto.
According to some aspects, a door lock assembly may comprise a mechanical interlocking clutch and clutch actuator that are configured to be disposed within a bore hole of a door. Door locks such as deadbolt locks may be mounted to a door by at least partially inserting the door lock into a bore hole within the door. The axis of the bore hole may be normal to the inner and outer surfaces of a door, and run therebetween at a location where it is desired to mount the lock, parallel or potentially concentric with the tailpiece. Portions of the lock that are disposed within the door bore may or may not protrude past the inner and outer surfaces of the door. If a lock may be entirely within the door bore then that lock may be substantially flush with the door surface excluding any knobs, thumb turns, escutcheon plates, etc. that may be provided for a user to control the lock.
Turning to the figures, specific non-limiting embodiments are described in further detail. It should be understood that the various systems, components, features, and methods described relative to these embodiments may be used either individually and/or in any desired combination as the disclosure is not limited to only the specific embodiments described herein.
In the locked position, the stop 243 which comprises an upper portion of the clutch driver unit 204 contacts stop switch 241 to stop the motion of the motor and leadscrew with the clutch decoupled. When the clutch driver unit 204 moves away from the thumb turn to disengage the clutch driven plate 203 from the clutch driving plate 202, the stop 243 moves toward the stop switch 241. The relative locations of the stop 243, stop switch 241 and clutch shifter fork 205 are such that the stop activates the stop switch when the shifter fork has moved the clutch driven plate completely out of engagement with the clutch driving plate, such that the clutch is fully disengaged and further movement of the clutch driver unit 204 in the direction of the tailpiece is not necessary. The stop switch discontinues motion in the clutch disconnecting direction such as by sending a stop signal to a controller, or by directly disconnecting power from the motor 240.
Together, the clutch driving plate and clutch driven plate form a mechanical interlocking clutch. Each of the driving plate and the driven plate include a plurality of dogs protruding from a face of the respective plate and spaced apart by a distance forming a recess between adjacent dogs. Dogs from one plate may enter the recess of the opposing plate when the clutch plates are engaged. Each dog may have at least one thrust face substantially normal to the direction of rotation of the clutch plate and configured to transmit force to a thrust face of an opposing dog on an opposing plate. The clutch plate with dogs and recesses forms a castellated structure. The dogs disposed on the clutch driving plate 252 face the dogs on the clutch driven plate 251. The dogs are spaced in a pattern about the axis of rotation of each of the driving plate and the driven plate to create the recesses, such as recess 253, that a dog from the opposing plate may enter when the plates are brought together. For instance, when brought together, the dogs of the clutch driving plate enter spaces between dogs on the clutch driven plate and the dogs on the clutch driven plate enter spaces between the dogs on the clutch driving plate. When so engaged, forces may be transmitted between the thrust faces of the dogs and the clutch may transmit a rotational torque independent of the friction between the plates or the normal forces pressing those plates together in an axial direction. When the clutch is disengaged, the dogs of one plate are outside of the recesses of the other plate and either plate may spin without imparting motion to the other plate.
Some embodiments described may utilize an electric motor and a leadscrew as a linear actuator to move the clutch plates in and out of mesh. Embodiments are contemplated where solenoid linear actuators may be used to position a clutch actuator. For instance, the embodiments of
While some embodiments described are applied to deadbolt lock assemblies with thumb turns, the lock clutch may be applied to other types of lock assemblies or to deadbolt lock assemblies not including thumb turns. For instance, a clutch may be applied to the handle or door knob of a knob or striker type lock so as to allow the door handle to free-spin (freewheel). In knob or handle type locks, such as ordinary door knob locks, the striker latch may be biased or spring loaded to the extended position such that it may be necessary for a user to maintain force on a door knob or door handle to hold the striker latch in a retracted position such as while opening the door from the door jamb. Aspects may be used in cartridge locks or mortise locks. Other embodiments may be applied to locks for other applications, such as cabinets or cupboards, safes, lockers, storage boxes, vehicles, or to access equipment such as electrical cabinets. This disclosure is not intended to be so limiting to the type of lock assembly, application, or to the type of handle, knob, or thumb turn to which the clutch may be applied.
While some embodiments disclose include electrically operated linear actuators configured to be disposed within the bore hole of a door, other methods of actuation are contemplated. For instance, a lock clutch may be actuated by the manual movement of a button, slide, or lever, such as may be included on a secured side of a door for a user to set manually, such as to lock or unlock a door from the interior of a room or apartment. As used herein, “manual” or “manual actuation” refers to an operation wherein the actuation force that may produce actuation movement is provided by physical interaction with a user such as by a user's hand pushing, pulling, rotating etc. or other tactile user input. In some embodiments, the slide may take the form of a button passing through the axis of rotation of a door knob or thumb turn, the button being connected to a clutch driven plate by a clutch driver. In other embodiments, a slider may be used to connect and disconnect the clutch. Other embodiments are contemplated where a mechanical actuator may include a key cylinder configured to be located on the secured side of the door to control the longitudinal movement of the clutch plates. In some embodiments, a key cylinder or handle may be attached to a leadscrew, such as any of the leadscrews previously described, allowing a user to manually operate the clutch by rotation of the key cylinder or handle. Manually actuated embodiments may be configured to dispose the clutch actuator within the bore hole of a door as with the electrically actuated embodiments previously described.
Components of the lock clutch may be formed from plastics, polymer matrix composites, copper alloys including brass and bronze, zinc alloys, aluminum alloys, magnesium alloys, ferrous alloys, or other suitable materials according to some embodiments. Components may be molded, such as by injection molding, cast, die cast, stamped, welded, or formed by any appropriate process or combination of processes. Components may be painted, plated, or coated for decoration or function such as to resist corrosion or to reduce friction.
Various aspects of the present disclosure may be used alone, in combination, or in a variety of arrangements not specifically discussed in the embodiments described in the foregoing and is therefore not limited in its application to the details and arrangement of components set forth in the foregoing description or illustrated in the drawings. For example, aspects described in one embodiment may be combined in any manner with aspects described in other embodiments.
Also, the embodiments described herein may be embodied as a method, of which an example has been provided. The acts performed as part of the method may be ordered in any suitable way. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.
Use of ordinal terms such as “first,” “second,” “third,” etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements.
Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing,” “involving,” and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items.
Further, some actions are described as taken by a “user”. It should be appreciated that a “user” need not be a single individual, and that in some embodiments, actions attributable to a “user” may be performed by a team of individuals and/or an individual in combination with computer-assisted tools or other mechanisms.
While the present teachings have been described in conjunction with various embodiments and examples, it is not intended that the present teachings be limited to such embodiments or examples. On the contrary, the present teachings encompass various alternatives, modifications, and equivalents, as will be appreciated by those of skill in the art. Accordingly, the foregoing description and drawings are by way of example only.
This application claims the benefit under 35. U.S.C. § 119(e) to U.S. Provisional Application Ser. No. 63/437,043, titled “CLUTCH FOR A LOCK,” filed Jan. 4, 2023, which is herein incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63437043 | Jan 2023 | US |
