The present invention relates to deadbolt locking systems, and more particularly, but not exclusively, to deadbolt locking systems in which friction and/or misalignment may hinder the extension of the bolt into a locking position.
In deadbolt locking systems, the bolt and a bolt-accepting passage (such as a strike plate opening) may become misaligned, for example due to improper installation or warping. In such a case, friction between the bolt and the strike plate may oppose movement of the bolt, increasing the amount of force required to move the bolt between extended and retracted positions. Furthermore, if the misalignment is severe, the bolt face may contact the flat surface of the strike plate such that no amount of force would be sufficient to throw the bolt through the bolt passage without damaging a portion of the system. In either case, a user may need to manually align the bolt and the bolt passage—for example by pushing or pulling on a portion of the lock system—before the bolt can extend or retract.
In recent years, electronic deadbolt systems have gained popularity. When misalignment occurs in such systems, the throwing mechanism may be unable to produce the force required to overcome frictional forces and throw the bolt through the bolt passage. In such cases, a user may need to manually align the system. Furthermore, when the electronic locking mechanism is battery-powered, there is a significant trade-off between battery life and the force required to throw the bolt. Certain electronic locking mechanisms include remote locking features, whereby a user can lock the system from a remote location. In such a case, the user is not available to manually align the system, and remote locking may become impracticable.
Misalignment is of particular concern when a close fit between the bolt and the strike plate is desired. In such a case, the strike plate opening may be only slightly larger than the bolt, and even a slight misalignment may give rise to the issues described above. With the problems presented by the competing concerns for a close fit and misalignment tolerance, a need exists for further contributions to this area of technology.
An exemplary deadbolt includes a pair of rollers positioned on opposing sides of an axial centerline of the deadbolt. The deadbolt may include chamfers or tapered surfaces extending from side surfaces of the deadbolt toward a face of the deadbolt. The rollers may extend beyond the face, one of the side surfaces, and/or one of the tapered surfaces. As the bolt moves from a retracted position to an extended position, one of the rollers may engage an edge of an opening in a strike plate, for example when the deadbolt is misaligned with the strike plate opening. As the rollers engage the edge, the deadbolt may be urged to a more aligned position. Further embodiments, forms, features, aspects, benefits, and advantages of the present application shall become apparent from the description and figures provided herewith.
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated embodiments, and that such further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated and protected.
With reference to
The housing assembly 110 is positioned at least partially in the cross-bore 103, and includes a housing 112, a casing 114 in which the housing 112 is seated, and a faceplate 116. The faceplate 116 is fastened to the door 102, retaining the housing 112 and the casing 114 within the cross-bore 103. When assembled, the bolt 200 is positioned at least partially in the housing assembly 110, and is operable to extend and retract through openings in the housing 112 and the faceplate 116.
The throwing system 120 is coupled to the bolt 200, and is operable in a retracted state wherein the bolt 200 is in a retracted, unlocking position (
In the illustrated form, the throwing system 120 is an electronic throwing system operable to electrically extend and retract the bolt 200. The exemplary throwing mechanism 122 comprises an electromechanical actuator such as a motor 126, and the throwing system 120 receives power from an energy storage device such as a battery 127. It is also contemplated that the throwing system 120 may be powered by line power and/or another form of energy storage device such as a super-capacitor. The user interface 121 may comprise an input 140 configured to receive a user command 150 issued by or on behalf of a user 160, and a controller 128 configured to actuate the motor 126 in response to the user command 150.
During operation of the illustrated throwing system 120, actuation of the motor 126 provides a torque to the rotor 123; the torque rotates the swing arm 124, which exerts a substantially linear force on the rigid member 125. This linear force is transmitted through the rigid member 125 to the bolt 200, causing the bolt 200 to extend or retract. It is also contemplated that the throwing system 120 may extend and retract the bolt 200 by another method. For example, the throwing system 120 may include a linear actuator (not illustrated) such as a solenoid, which may be directly coupled to the rigid member 125, such that the linear actuator is operable to extend and retract the bolt 200 without rotational or pivotal movement. In other forms, the swing arm 124 may be pivotally mounted, with one end coupled to the rigid member 125, and an opposing end may be coupled to a linear actuator, such that the linear actuator extends or retracts the bolt 200 by pivoting the swing arm 124 about its pivot point.
The user command 150 may, for example, be issued vocally, manually, or via a wireless signal such as an electromagnetic wave. In certain forms, the input 140 may include a credential reader 142 configured to receive and authenticate a wireless user command 152 comprising a credential, which may be issued from a token or wireless communication device 162 such as a keycard, fob, or smart phone. In other forms, the input 140 may include a manually operable input 144 such as a button or keypad configured to receive a manual user command 154 such as the entry of a code, for example with the user's hand 164. In further embodiments, the input 140 may include a microphone 146 configured to receive an audible user command 156, which may be a vocal command issued with the user's voice 166. In still further forms, the input 140 may include a motion sensor 148 configured to sense a motion-based user command 158 such as a gesture or the user 160 approaching the door; the user 160 may, for example, issue the motion-based user command 158 using their body or appendages 168.
In certain embodiments, the user interface 121 may be configured to receive a remote user command 150. The remote user command 150 may be issued by or on behalf of a user 160 that is not within arm's reach—for example, within three feet—of the door 102, and is thus unable to manually align the bolt body 200 with the strike plate opening 137. In certain forms, the user interface 121 may be positioned on or near the door 102, and the remote user command 150 may be issued by or on behalf of a user 160 who is not near the user interface 121. For example, the user 160 may issue the wireless user command 152 via the wireless communication device 162, which may, for example, be a smart phone. As another example, the user 160 may issue the vocal or motion-based user command 156, 158, for example by speaking the vocal command 156 or approaching the motion sensor 148. In other forms, the user interface 121 may be positioned at a remote location with respect to the door 102, and the remote user command 150 may be issued by or on behalf of a user 160 who is near the user interface 121, but remote with respect to the door 102. In such a case, the remote user command 150 may also include the manual user command 154.
While the illustrated throwing system 120 is an electronic throwing system, it is also contemplated that a mechanical form of the throwing system 120 may be utilized. For example, the manual input 144 may include a manually operable thumb turn which, when actuated, rotates the rotor 123 either directly or through the throwing mechanism 122.
The bolt 200 is seated in the housing assembly 110, and comprises a proximal end portion or first end 210, a distal end portion or second end 220, and a roller assembly 230. The first end 210 is connected to the throwing system 120 via the throwing hub 212. When the throwing system 120 is in the retracted state and the bolt 200 is in the unlocking position (
The second end 220 defines a bolt face 222 and side-surfaces 224, and may further include chamfers or tapered surfaces 226. In the illustrated form, the tapered surfaces 226 comprise a substantially rectilinear profile; it is also contemplated that one or more of the tapered surfaces 226 may comprise a curvilinear portion, which may, for example, be convex or concave. It is also contemplated that the tapered surfaces 226 may be omitted, and that the side surfaces 224 may extend to the bolt face 222. The second end 220 also includes a cavity or opening 228 extending axially inward from the bolt face 222. The opening 228 is configured to receive the roller assembly 230, such that the roller assembly 230 may be coupled to the second end 220.
As best seen in
In the illustrated form, the axles 234 enable rotation, but not linear movement, of the rollers 232. That is to say, while the rollers 232 are rotatable, they have a fixed linear position with respect to the bolt 200. In certain forms, the axles 234 may be formed integrally with the rollers 232. For example, an axle 234 may comprise protrusions at the rotational axis of the roller 232, and the protrusions may matingly engage recesses formed in the second end 220. The protrusions and recesses may be configured to enable the rollers 232 to be mounted to the second end 220 via a snap fit connection. It is also contemplated that the protrusions may be formed on the second end 220 and extend into the opening 228, and the recesses may be formed at the rotational axis of the roller 232. In other forms, the axle 234 may be a separate piece. For example, an axle 234 may comprise a rod extending through openings in the second end 220 and the roller 232. Such axles 234 may further be equipped with friction-reducing features, such as bearings.
During operation of the system 100, the bolt 200 may become misaligned with the strike plate opening 137, even when the door 102 is closed. The misalignment may be unintentional, for example due to warping of the door 102, thermal expansion or contraction, or faulty installation of one of the elements of the system 100. In some cases, misalignment may be intentionally provided, for example to ensure a tight fit, or to compress the weather stripping 135 when the door 102 is closed and the bolt 200 is extended (
As can be seen from the foregoing, the rollers 232 reduce friction during extension and retraction of the bolt 200. When the deadbolt assembly 201 is not properly aligned with the strike plate 136, the rollers 232 may also urge the second end 220 into alignment with the strike plate opening 137 as the bolt 200 moves to the extended position. In some applications, misalignment may occur in either direction. For example, warping of the door 102 create a first misalignment in a first direction, and deterioration or improper installation of the frame 130, door stop 134, and/or weather stripping 135 may cause a second misalignment in a second, opposite direction. Thus, the deadbolt assembly 201 may be operable in an aligned position wherein the second end 220 is aligned with the strike plate opening 137, a first misaligned position wherein the second end 220 is misaligned with the strike plate opening 137 in the first direction, and a second misaligned position wherein the second end 220 is misaligned with the strike plate opening 137 in the second direction. In such a case, during extension of the bolt 200, a first of the rollers 232 may engage a first strike plate edge 138 when the door 102 is warped, and the other roller 232 may engage the other strike plate edge 138 when the weather stripping 135 is deteriorated.
When the bolt 200 is in the retracted position and the deadbolt assembly 201 is in the aligned position, the side surfaces 224 are aligned with the strike plate opening 137, such that extension of the bolt 200 causes the second end 220 to enter the strike plate opening 137. When the bolt 200 is in the retracted position and the deadbolt assembly 201 is in the first misaligned position (
While the illustrated rollers 232 comprise substantially similar diameters, it is also contemplated that one of the rollers 232 may comprise a greater diameter than the other roller 232. For example, if it is anticipated that misalignment due to warping of the door 102 will be of greater concern than misalignment due to deterioration of the weather stripping 135, the first roller 232 may comprise a greater diameter than the second roller 232. The fact that the diameter of the first roller 232 is greater than that of the second roller 232 may enable the deadbolt assembly 201 to accommodate greater misalignment in the first direction than in the second direction. In certain forms, one of the rollers 232 may cross the central axial plane 221.
While the illustrated channels 429 are substantially parallel to the longitudinal axis 421, it is also contemplated that one or more of the channels 429 may be angularly offset from the longitudinal axis 421, for example at an oblique angle. For example, one or more of the channels 421 may be parallel, substantially parallel, perpendicular, or substantially perpendicular to the corresponding tapered surface 428. In embodiments which employ such angularly offset channels 429, the springs 436 may bias the rollers 432 to the extended roller position, and the direction of biasing may be at least partially in the direction of bolt 400 extension. Furthermore, one or more of the channels 429 may be curved.
In certain forms, one or more of the rollers 432 may protrude beyond the faceplate 116, even when the bolt 400 is in the retracted position. In such a case, as the door 102 is closed, the strike plate 136 may urge the rollers 432 inward (i.e. further into the opening 428) against the force of the springs 436. When the door 102 reaches the closed position, one of the rollers 432 may form an initial contact point 402 with the strike plate edge 138, for example if the second end 420 is misaligned with the strike plate opening 137. That is to say, when the bolt 400 is in the retracted position and the deadbolt assembly 401 in a misaligned position, the strike plate 136 may urge one of the rollers 432 toward the retracted roller position.
The biasing force provided by the spring 436 may urge the roller 432 outward (i.e. further out of the opening 428), creating an initial force vector 404 prior to linear force being applied to the bolt 400 by the throwing system (not illustrated). In such a case, the strike plate 136 creates an initial opposing force 406 including an initial axial force vector 406a which compresses the spring 436 and an initial radial force vector 406r which urges the roller 432 toward the strike plate opening 137. The initial radial force vector 406r may provide partial alignment of the bolt 400 prior to force being applied by the throwing system. As the bolt 400 moves toward the extended position, the interaction between the roller 432 and the strike plate 136 continues to urge the bolt 400 to the aligned position as described above with reference to the deadbolt assembly 201. Additionally, as the bolt 400 extends, the spring 436 urges the roller 432 in the direction of bolt extension; the energy stored in the compressed spring 436 may supplement the force provided by the throwing system as the spring 432 expands from the compressed state.
With reference to
The illustrative strike plate roller assembly 530 includes a pair of rollers 532 rotatably mounted to the strike plate 510. The rollers 532 are mounted to the strike plate 510 at opposing sides of the through-hole 512, such that the rollers 532 define a strike plate opening 536 therebetween. As best seen in
In certain embodiments, the strike plate rollers 532 are rotatably mounted on a fixed axis 534. In such embodiments, the strike plate rollers 532 are free to rotate, but cannot move linearly with respect to the strike plate 510. A fixed axis may comprise, for example, an axle extending through a bore in the roller 532, or an indentation formed on one of the strike plate 510 and the roller 532 and a mating protrusion formed on the other of the strike plate 510 and the roller 532. In other forms, one or more of the rollers 532 may be linearly movable with respect to the strike plate 510; for example, the axle 534 and a spring may be positioned in a channel formed in the strike plate in a manner similar to the previously described roller assembly 430.
With specific reference to
In certain embodiments of the present invention, a set of rollers may be provided to both the strike plate and the bolt.
As can be seen from the foregoing, the illustrative roller assemblies described herein reduce friction as a bolt moves between its locking and unlocking positions. When utilized with electronic throwing assemblies comprising a motor or another form of electromechanical actuator, the reduced friction enables the motor to extend and retract the bolt using less current than would otherwise be required. Additionally, the roller assemblies may further serve to align the bolt with a strike plate opening as the bolt extends to the locking position. In other words, the roller assemblies may enable the bolt to extend to the locking position while also providing the proper alignment between the bolt and a bolt-accepting cavity. As such, the system can be locked without requiring manual adjustment of the system, which may be unavailable if the user is not present at the door.
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, more preferred or exemplary utilized in the description above indicate that the feature so described may be more desirable or characteristic, 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.
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Number | Date | Country | |
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20150330120 A1 | Nov 2015 | US |