This invention relates generally to door latching assemblies, and more particularly, to door latching assemblies that use a motorized lock mechanism to lock a door handle and prevent it from rotating.
There are many factors and constraints that influence designs of lock and trim assemblies, including the number of lock functions supported, the strength of the lock, the ability of the lock to thwart an attack, and the cost of manufacture. Each design constraint compounds the complexity of such a design, because attempting to accommodate a given design constraint may restrict one's ability to accommodate a different design constraint. Because not all designs are equally effective or practical, and because changing circumstances continually give rise to new design constraints, there is always a need for innovation.
For example, lock and trim assemblies that utilize a door lever commonly engage the spindle directly to the door handle, relying on a stop mechanism to prevent the lever and spindle from rotating. In many such assemblies, it is possible to defeat the stop mechanism by applying a crowbar or long wrench to the lever, shearing off components of the stop mechanism. Therefore, it is advantageous for a lock and trim assembly to be designed in a manner that thwarts such an attack.
As another example, many lock mechanisms require a door handle to be in a neutral, non-latch-retracting position in order to lock the handle. It is therefore advantageous for the trim assembly to incorporate a return spring to bias the handle back to the neutral position and an escapement spring to engage the lock when the handle returns to the neutral position.
Moreover, when choosing a replacement trim assembly for a door, it is important to find a trim assembly that is compatible with the spindle and possibly other elements of the interior latching assembly, that matches the door function (e.g., is it an interior door or an exit door), that is compatible with the handedness of the door, that matches the physical dimensions and relative placement of the mortise and/or bore cylinder, and that matches the physical arrangement of trim mounting holes.
Most trim assemblies, however, are only suitable for a specific type or make of lock. It would be advantageous to have a universal trim assembly that, with minimal substitution or rearrangement of parts, accommodates a wide variety of types and makes of locks, as well as a wide variety of lock functions. However, the design of such an assembly is complicated by the typically tight spacing of trim assembly components. For example, a rearrangement of the trim mounting posts may require a rearrangement of other trim assembly components.
The present invention described below can be characterized in many different ways, not all of which are limited by its capacity to address the above-mentioned issues, needs or design constraints.
The present invention is directed to a lock trim assembly that incorporates an electric motor and an escapement assembly to operate a lock. The door trim assembly comprises a driver assembly operated by the motor, an escapement assembly, comprising a control member and an escapement spring, operated by the driver assembly, and a coupling assembly for coupling a door handle to a latch-retracting spindle. The escapement assembly is movable between a locking position that blocks rotation of the spindle and an unlocking position that does not block rotation of the spindle. The coupling assembly alternates between a default orientation and a blocking orientation, wherein the default orientation allows the escapement assembly to move into the locking position and the blocking orientation blocks the escapement assembly from moving into the locking position. When the coupling assembly is in the default orientation, the motor is operable to move the escapement assembly between the unlocking position and the locking position. When the coupling assembly is in the blocking orientation, operation of the motor to drive the blocked escapement assembly into the locking position causes the escapement assembly to store energy in the escapement spring for forcing the escapement assembly into the locking position once the coupling assembly is reoriented back to the default orientation.
The lock trim assembly also preferably incorporates a handle-to-spindle coupling assembly designed to thwart a torque attack on a door lever. Furthermore, the motor and escapement assembly are preferably arranged in a trim assembly that is adaptable to a variety of different doors, latching assemblies, and trim preparations.
These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
These and other aspects and advantages of the embodiments disclosed herein will become apparent in connection with the drawings and detailed disclosure that follows.
The trim assembly 10 comprises a coupling assembly 25—for example, a handle coupler 20 and spindle driver 30—that transfers load from a door handle 18 to a spindle 36. The trim assembly 10 also comprises a return spring 19 and a stopper or locking dog 50 operative to selectively lock the coupling assembly 25, preventing it from rotating to retract the door latch (not shown). The trim assembly 10 also comprises a motor 11, a transmission or driver assembly 60, and an escapement assembly 70 that together operate the stopper 50. The spindle 36 extends into a door cavity that houses a latch assembly (not shown), for example, a cylindrical assembly or a mortise assembly. Rotation of the spindle 36 is operative to retract the latch (not shown).
The trim assembly 10 also comprises an escutcheon 14 and a back plate assembly 15 that is mounted to the face of the door. The motor 11, driver assembly 60, escapement assembly 70, handle coupler 20, and most of the spindle driver 30 are contained between the escutcheon 14 and the back plate assembly 15. The handle coupler 20 is configured to be coupled to and rotated with a door handle/lever 18. A return spring 19 biases the handle 18 toward a neutral, non-latch retracting orientation. In one embodiment, the handle 18 can be operated in either direction from the neutral, non-latch retracting orientation to retract the latch. The trim assembly 10 may also provide collars or flanged parts 94 and 95 to adapt the trim assembly 10 to particular door widths.
As best illustrated in
The handle coupler 20 also comprises a spring leg bracket 21 for mounting opposite legs of a return spring 19. Rotation of the handle coupler 20 pulls and/or pushes the legs of the return spring 19 apart, biasing the handle 18 back toward a neutral, non-latch-retracting position.
Like the handle coupler 20, the spindle driver 30 also has a slot 34 for receiving a stopper 50, although in alternative embodiments, only one of the handle coupler 20 and spindle driver 30 have a slot 24 or 34 for receiving a stopper 50.
Advantageously, the use of the spindle driver 30 in conjunction with the handle coupler 20 not only thwarts overtorquing attacks, but also enables the trim assembly 10 to be adapted to a variety of different spindles with minimal substitution of parts. The spindle driver 30's eight-pronged opening 39 accommodates both spindles 36 that are square and spindles 36 that are diagonally oriented (as shown, for example, by the Corbin spindle in
The motor 11 is mounted to the escutcheon 14 and includes an upper face or bracket 12 and a shaft 13. The shaft 13 is oriented perpendicular to the spindle 36. The driver assembly 60 is mounted on the motor 11 and operative to rotate an eccentrically-positioned offset pin 79 (or, alternatively, a cam) between an engage-lock position and a disengage-lock position.
The driver assembly 60 comprises a slip clutch 62 mounted on the motor 11 and a carousel 76 mounted on the slip clutch 62 for rotational movement with the shaft 13. The carousel 76 rotates the eccentrically-located offset pin 79.
The escapement assembly 70 comprises a control member 85 and an escapement spring 72. In
The control member 85 either has a pivot member or post 84 (
The escapement spring 72 is a helical torsion spring with a coiled core 75, an axis 86 parallel to the spindle's axis, and two legs 73, 74. Each leg has an elongated radially extending portion 73a, 74a and an axially extending portion 73b, 74b (
The axially extending portions 73b, 74b of the first and second spring legs 73, 74 extend beyond the spring leg anchor 87 into positions above and below the offset pin 79. If non-alignment of the spindle driver slot 34 and/or handle coupler slot 24 blocks the stopper 50 from engaging the spindle driver slot 34 and/or handle coupler slot 24, rotation of the offset pin 79 into an engage-lock position forces the lower spring leg 73 downward and away from the lower face or edge 88 of the spring leg anchor 87, as illustrated in
In
The offset pin 76, control member 85, and escapement spring 72 are respectively arranged so that rotation of the offset pin 79 between its rotational limits biases the control member 85 to travel between its locking position (
The escapement assembly 70 is operative under a non-escapement condition and at least a first escapement condition. The first escapement condition is characterized by an attempt to lock the door when the stopper 50 is not aligned with the spindle driver slot 34 and/or handle coupler slot 24. Until alignment is restored, the stopper 50 is blocked from extending into the slot 24 and/or 34.
Movement of the handle 18 and handle coupler 20 into a neutral, non-latch-retracting position lines the stopper 50 up with the handle coupler slot 24. Once aligned, the stored energy of the escapement spring 72 rotates the control member 85 down, extending the stopper 50 into the slot 24 and/or 34, thus locking the handle 18 in a non-latch-retracting position.
A second escapement condition is characterized by an attempt to unlock the door while the locked lever arm 18 is being pushed on. The asymmetry of the load exerted on the stopper 50 may have a binding effect, preventing the stopper 50 from retracting out of the slot 24 and/or 34. Under this condition, rotation of the offset pin 79 into a disengage-lock position will push the upper leg 74 of the escapement spring 72 upward and away from the ramped upper surface 89 of the spring anchor 87, again winding up and storing energy in the spring 72. Once pressure is released from the lever arm 18, thereby removing the binding effect, the spring 72 forces the control member 85 up, retracting the stopper 50 away from the slot 24 and/or 34.
In the non-escapement condition, by contrast, the spring anchor 87 stays in substantial alignment with the offset pin 79 as the offset pin 79 rotates between engage-lock and disengage-lock positions.
In either escapement condition, the control member 85 is blocked from rotating, thereby impeding movement of one of the legs 73, 74 of the escapement spring 72. Operation of the motor 11 in either escapement condition causes the pin 79 to spread the axially extending portions 73b, 74b of the legs 73, 74 apart, winding up and storing energy in the escapement spring 72. Once the stopper 50 is free to travel between locked and unlocked positions, the stored-up energy of the wound-up escapement spring 72 is released into control member 85, causing the control member 85 to rotate until the spring legs 73 and 74 reach their minimum-energy condition, in which they are once again grasping the spring anchor 87.
The driver assembly 60 optionally comprises a slip clutch 62 mounted to the motor 11. The slip clutch 62—which, in one embodiment, comprises an over-torque clutch—comprises a keyhole for receiving the motor shaft 13, a stationary portion mounted to the motor bracket 12, and a carousel 65 driven within torque limits by the motor shaft 13. Carousel couplers 66 couple the carousel 65 to the pin carrier 76 for synchronized rotation therewith. In another embodiment, the motor 11 is directly connected to the pin carrier 76.
Advantageously, the back plate assembly 15 allows trim mounting posts 99 to be mounted to the trim assembly 10 in a variety of arrangements, to accommodate a variety of existing borehole and trim mounting hole arrangements, without interfering with the motor 11, driver assembly 60, and escapement assembly 70. In the embodiment shown, the back plate assembly 15 comprises an upper plate or deadbolt plate 96, a mid plate 93 positioned over the motor 11, driver assembly 60, and escapement assembly 70, and a bottom plate or spindle plate 97. Posts 99 can be mounted to the plates 93, 96, and 97 wherever necessary to adapt the trim assembly to any of a variety of configurations of trim mounting holes on an existing door. In
Also advantageously, the trim assembly 10 is configured and arranged in a manner that shares much in common with the trim assembly described and depicted in my co-pending U.S. patent application Ser. No. 15/047,521, Feb. 18,2016, and entitled “Door Trim Assembly with Clutch Mechanism,” which application is herein incorporated by reference for all purposes. Many of the components are the same or substantially the same. The back plate assembly 15 and spindle driver 30, for example, are the same. The same handle 14 may be used. The escutcheon 14, for example, is the same except for a few stamped parts. The commonalities between the locks reduce the cost of manufacture and allow for a more uniform set of instructions in assembling either trim assembly to a door.
Several different types of motors 11 are suitable for use with the present invention. In one embodiment, a stepper motor is used. In another embodiment, gear motor is used in conjunction with an over torque clutch 62.
It should be noted that the embodiments illustrated and described in detail herein are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims.
This application claims the benefit of U.S. Provisional Patent App. Nos. 62/145,455 and 62/145,460, both filed Apr. 9, 2015, which are herein incorporated by reference for all purposes.
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