GB2516950A

GB2516950A - Door lock

Info

Publication number: GB2516950A
Application number: GB1314199.9A
Authority: GB
Inventors: Andrew M Taylor
Original assignee: SECUREFAST PLC
Current assignee: SECUREFAST PLC
Priority date: 2013-08-08
Filing date: 2013-08-08
Publication date: 2015-02-11
Anticipated expiration: 2033-08-08
Also published as: GB2516950B; GB201314199D0

Abstract

The invention relates to a door lock 2 comprising a latch bolt 20, a deadbolt 30 parallel to the latch bolt 20 and an electric actuator 10. The latch bolt and the dead bolt both operate on respective parallel axes. The electric actuator is arranged on a chassis 4 in between the latch bolt and the dead bolt in substantially the same plane. The actuator is operable to actuate the deadbolt 30 along an actuator axis which crosses the deadbolt axis. Preferably the actuator is a linear motor 10. The door lock may comprise a controller on a printed circuit board with a transmitter arranged between the latch bolt and dead bolt axes.

Description

DOOR LOCK

The present invention relates to a door lock and particularly but not exclusively, to the provision of a door lock incorporating a linear motor.

Door locks comprising deadbolt assemblies and latch bolt assemblies are known for use in a door leaf these assemblies are frequently combined in a common unit, the deadbolt being operated by a key, and the latch bolt by a door handle. These common units tend to be a standard size to facilitate universal fitting and easy replacement.

Electrically operated door locks have been proposed, however those using geared motor drives arc relatively complex. Furthermore, given that any door lock must be able to reliably withstand repeated use, any componentry used therein must be of high quality, increasing the overall cost of the door lock.

Fitting an electrically operated door lock into a door leaf is a challenge because of the limited available space envelope. Rotary electric motors have been proposed for electrically operated door locks. In one proposed version a rotary electric motor is used to drive a rack and pinion to deploy the deadbolt of the door lock. However, this arrangement may not easily be incorporated into the limited space within a door lock of standard size.

Furthermore, the rotary electric motor must be controlled to provide a measured amount of travel of the deadbolt. This may be through the use of sensors, limiters or timed rotation; preferably however, to this end ancillary equipment must also be arranged within the door lock, which exacerbates the packaging difficulty.

The invention aims to provide a door lock of compact arrangement, that is effective, reliable and which may be produced at relatively low cost.

According to the first aspect of the present invention there is provided a door lock comprising a chassis having a latch bolt operable on a latch bolt axis; a deadbolt operable on a deadbolt axis; and an electric actuator operable on an actuator axis for actuating the deadbolt, wherein the latch bolt, deadbolt and actuator are arranged on said chassis in substantially the same plane, the latch bolt axis and deadbolt axis being parallel, wherein the actuator is arranged between the latch bolt axis and deadbolt axis, and the actuator axis crosses the deadbolt axis.

The term axis is used to identify an unlimited, imaginary line about which the body to which it applics, rotatcs or rcciprocates.

The invention provides a compact arrangement as the latch bolt, deadbolt and actuator are arranged in the same plane; preferably the actuator is sited between the latch bolt and deadbo lt.

The actuator preferably comprises a linear electric motor. A linear electric motor is an electric motor that produces a linear output, in contrast to the rotary output of a rotary electric motor. The linear motor permits a uni-planar door lock. It is thcrcfore not necessary for the door lock to react side forces associated with rotary electric motors, which require out-of plane componentry to ensure that the motion of the actuator is converted to the reciprocating motion of a deadbolt. Furthermore a linear motor has the capability of providing a powered actuation and retraction stroke, in contrast to the spring return generally provided for a single acting electromagnetic actuator. The provision of the linear motor therefore supports a compact arrangement, and reduces the number of components in the door lock.

The actuation axis may cross the deadbolt axis at an angle of between 600 and 1200 with respect to the deadbolt axis. Preferably the angle may be between 70° and 800. Alternatively the angle may be between 1000 and 1100. Preferable still the angle may be between 72° and 74°. Alternatively, the angle may be between 116° and 118°. By careful definition of the rclative angle of thc actuation axis, requisite travel can be providcd by thc actuator to cnsurc full deployment and retraction of the deadbolt.

In an cmbodimcnt the chassis includcs a lever pivoted thercon to link thc deadbolt and thc actuator.

In a preferred embodiment the lever is arranged to pivot about a pivot post of the chassis. In an alternate embodiment the lever includes an axle which pivots about a location on the chassis such as a round hole.

In an embodiment first and second levers are provided having respective arms coupled to the deadbolt and the actuator, the levers having parallel axes orthogonal to said plane, and additional arms for contact with each other. This arrangement allows a different length of travel of the deadbolt relative to the length of travel of the actuator, and furthermore permits variation of the overall lever ratio by substitution of levers of different effective ratio. Levers are less expensive than gears, and require less precision in manufacture.

In one embodiment, arcuate movement of the fir st lever in the range of 40° to 500 translates to an arcuate movement in the range of 1000 to 125° of the second lever.

In an embodiment the deadbolt includes a deadbolt gating having a latch to lock the deadbolt in thc thrown state.

In an embodiment the door lock includes a battery arranged on and preferably with the chassis, for powering the actuator. This precludes the need to route a power supply through the door leaf The latch bolt may be biased to support the load of the door leaf when in the closed condition. This rcduccs thc loading when deploying the dcadbolt using thc actuator.

Furthermore this arrangement prevents potential overload of the motor, which may otherwise occur when a door leaf is mismatched with a door frame such that the deadbolt may not move freely into and out of a recess within the door frame.

In an cmbodiment thc latch bolt is located abovc the dcadbolt.

In an embodiment the door lock fUrther comprises a key barrel for operating the deadbolt.

The key barrel may be rotatably mounted to the chassis below the deadbolt axis. In an embodiment the key barrel includes a radially protruding cylinder cam for engagement with a lever linking the deadbolt and the actuator.

In an embodiment, the chassis comprises a substantially rectangular baseplate and cover. This arrangement provides a self contained unit, adapted to be fitted into a standard recess of a door leaf In an embodiment, the door lock includes a pivotable ever for operating the atch bolt, and includes the usual substantially square hole for the shaft of a door handle. This pivotable lever is preferably between the latch bolt axis and the deadbolt axis, and to one side of the actuator. On the opposite side to the actuator may be arranged an electronic controller for said actuator.

In an embodiment, the pivotable lever for operating the latch bolt and a lever linking the deadbolt and the actuator are engageable to actuate the deadbolt and latch bolt simultaneously. Provision of a mechanical linkage between the pivotablc lever for operating the latch bolt and the lever for operating the deadboh ensures that operation of the inside handle, (and hence the pivotable lever) results in withdrawal of both the latch bolt and the deadbo It, providing emergency egress.

In an embodiment the electronic controller is provided on a printed circuit board extending between the latch bolt and the chassis adjacent the linear motor and connected to a transmitter on the printed circuit board above the latch bolt axis. The connection is preferably via conductive wheels on the printed circuit board. The actuator is preferably connected to terminals on the printed circuit board below the latch boh axis, adjacent the actuator. The provision of the printed circuit board between the electric door lock control features which need to communicate with one another eliminates the need for loose wires which may otherwise snag on the latch bolt or other moving componcntry of the lock assembly According to the second aspect of the present invention there is provided a door with a door lock according to the first aspect of the present invention. The enclosed nature of the door lock means that it is suitable for both factory fitting and retro fitting into door leafs.

An embodiment of the invention will now be described, by way of example only, with reference to the accompanying figures, in which: FIGURE 1A is an exploded general assembly of a door lock according to the invention; FIGURE lB is a partial cut-away profile view of a door lock corresponding to Fig. IA, installed in a door leaf; in the locked condition; FIGURE IC is a partial cut-away profile view of the door lock of Fig. IA in the unlocked condition; FIGURE 2A is a partial cut-away profile view of the door lock of Fig. lÀ with a latch bolt assembly and a deadbolt assembly in the locked condition; FIGURE 2B is a partial cut-away profile view of the door lock of Fig. 2A with the latch bolt assembly and the dcadbolt assembly in the unlocked condition.

FIGURE 3A and 3B are partial cut-away profile views of the door lock of Figs. IA and lB including a cylinder cam; FIGURE 4A and 4B are partial cut-away profile views of the door lock of Figs. IA and lB including an emergency escape action; FIGURE 5 is a partial cut-away profile view of the electromagnetic door lock of Fig. 2A including a lock control system.

With reference to the drawings, a lock assembly 2 has a substantially rectangular case or chassis 4 bounded on one side by a side plate 6, the case 4 defining the housing for a door lock. In use the case 4 is installed in a door leaf 3, with side plate 6 flush with the outer edge of the lock stile as illustrated. The case 4 has a peripheral upstanding sidewall, and is closed by cover S also having an upstanding sidewall. A linear motor 10 is positioned centrally, with a connecting rod 14 arranged to provide an actuation stroke to a pivoting link 16. mounted about a pivot post 8 of the case 4. The link 16 comprises a first radial arm 18 (Fig. IB) coupled to the connecting rod 14, and defines two additional arcuate arms which between the ends thereof hold an operating pin 46 in a two point grip. The axis of the pin 46 is parallel to the pivot axis of the post 8, and moves in an arc above the pivot post 8 as viewed, at the side of the actuator 10 away from the side plate 6.The actuation stroke of the linear motor 10 is an axial movement of the connecting rod 14 along actuation axis 12.

The lock assembly 2 further includes a latch bolt 20 (Fig. 2A), having a latch bolt axis of operation 22 and a deadbolt 30, having a deadbolt axis of operation 32. The latch bolt 20 and deadbolt 30 are arranged either side of the linear motor 10, with their respective axes 22, 32 substantially parallel to one another and perpendicular to the end plate 6. The latch bolt 20 and dead bolt 30 arc adapted to reciprocate through the side plate 6 in a conventional manner.

The latch bolt 20 is above the dead bolt 30, as is conventional.

The lock assembly 2 further includes a key barrel 7, substantially directly below the pivot post 8 of the link 16. A cylinder cam 9 protrudes radially from the key barrel 7 (Fig. 3) and is arranged for rotation with the key barrel 7 upon pivoting of a key (not shown) within the key barrel 7. The cam 9 abuts a radial foot of the link 16, as will be described below.

With reference to Fig. IA the latch bolt 20 has a wedge shaped latch 21, connected to a telescopic cylindrical shaft 23, the centre of the cylindrical shaft is aligned with the latch bolt axis 22. Distal from the wedge shaped latch 21, the cylindrical shaft has a circular flange 24 and a square flange 26 defining a space therebetween. The square flange 26 is mounted on the inner telescoping part, and the circular flange 24 is mounted on the outer telescoping part.

The latch bolt 20 is biased to support the load of the door leaf 3 when in the closed condition.

The deadbolt 30 is defined by a substantially rectangular steel plate 31 reinforced the striker plate end by a U' shaped steel attachment 33. The portion of the plate 31 not reinforced includes a punched hole defining a deadbolt gating 34. Deadbolt gating 34 is substantially oblong-shaped with its long axis orthogonal to deadbolt axis 32. The deadboh gating 34 includes a notch at its upper end on the lock stile side.

A bolt thrower assembly 40 is arranged about the deadbolt 30, and comprises two plate sections 47, 48 mounted on either side of the deadboh 30, on a boh thrower pivot post 42 and attached to one another by a bolt thrower gating pin 44 and by an operating pin 46, arranged substantially on a straight line passing through the pivot post 42. Bolt thrower gating pin 44 passes through the deadbolt gating 34 and bears upon the inner surface of the aperture formed by the deadbolt gating 34 (Fig. 3A).

The pivoting link 16 holds the operating pin 46 of the bolt thrower assembly 40, as described above. The arm 18 extends towards the sidc plate 8 and is connected with the end of the connecting rod 14 by pin joint 15. A foot 19 extends radially from the pivoting link 16 towards the key barrel 7, substantially opposite the operating pin 46, for contact with the cylinder cam 9.

A follower assembly 50 links the bolt thrower assembly 40 to the latch bolt assembly 70.

Again, with reference to Fig. IA, the follower assembly 50 comprises substantially identical first and second latch bolt engaging plates 52, 54, a follower plate 56 and four identical bearing discs 58. The first and second latch bolt engaging plates 52, 54 sandwich between them the follower plate 56. The four identical bearing discs 58 are arranged between the first latch bolt engaging plate 52 and the lock case cover 5, the first latch bolt engaging plate 52 and the follower plate 56, the follower plate 56 and the second latch bolt engaging plate 54, and the second latch bolt engaging plate 54 and the lock assembly case 4.

The first and second latch bolt engaging plates 52, 54 are substantially identical and accordingly only the first latch bolt engaging plate 52 will be described in detail. The latch bolt engaging plate 52 has a radial arm 53 which sits in the space between the circular flange 24 and the square flange 26 of the latch boh 20.

The follower plate 56 is shaped substantially like an equilateral triangle, with one corner including a trunk-like projection 57 for contact with the operating pin 46 of the bolt thrower assembly 40 ftig. 4A). Three locating pins are provided through the followers plate 56.

All seven components (the first and second latch bolt engaging plates 52, 54, the follower plate 56 and the four bearing discs 58) include a square bore having a central axis 60, and the seven components are stacked with the axis 60 of the square bore aligned, for engagement with a square door handle shaft (not shown), pivotable in the lock chassis.

The extreme top and bottom bearing discs 58 cngagc holcs in the lock asscmbly casc 4 and lock case cover 5 respectively. The inner pair of bearing discs fit between the three pins arranged in a equilateral triangle through the follower plate 56, to locate the follower plate.

The lock assembly 2 includes a hairpin follower spring 62 which engages with the first and second latch bolt engaging plates 52, 54 to bias the follower plate 56 (via the square shaft) such that the latch bolt is held in a withdrawn condition by action of the arm 53.

Actuation of the connecting rod 14 by the linear motor 10 along the actuation axis 12 causes pivoling link l6toturn aboutpivotpost 8, duetothepinjoint 15. As the link l6pivots,the operating pin 46 of the bolt thrower assembly 40 moves arcuately (Figs. lB and 1C).

Thc platc sections 47,48, of thc bolt thrower assembly 40 arc pivotcd by thc pivoting motion of the link 16 because the operating pin 46 is mounted between the plate sections 47, 48.

However, as the plate sections 47,48 of the bolt thrower assembly 40 are mounted on the bolt thrower pivot pin 42, which is off-set from the pivot post 8, the angular displacement of the plate sections 47, 48 is increased. A 40° pivot of the link 16, on fill extension of the connecting rod 14, causes a 1000 pivot of the bolt thrower assembly 40.

The pivoting of the plate sections 47, 48 has the effect of displacing the bolt thrower gating pin 44, flDm the notch of the deadbolt gating 34, such that the bolt thrower gating pin 44 bears upon the side of the deadbolt gating further flx,m the lock stile, to actuate the deadbolt to withdraw flx,m a deadbolt thrown condition, (Fig. 2k -linear motor in the withdrawn condition), to a deadbolt withdrawn condition, (Fig. 2B. -linear motor extended) along the dcadbolt axis 32. Thc notch of thc dcadbolt gating 34 providcs an ovcr-ccntrc lock whcn thc bolt thrower gating pin is located therein.

The bolt thrower assembly 40 may also be actuated by motion of a key in the key barrel 7. As cylinder cam 9 turns, it bears upon the foot 19 of the link 16. In the same way that actuation of the connecting rod 14 of the linear motor 10 causes pivoting of the link 16 and therefore deployment or withdrawal of the deadbolt 30 via pivoting of the bolt thrower 40, the action of the cylinder cam 9 on the foot 19 of the link 16 causes pivoting of the link, according to the rotation of the key. Anti-clockwise motion of key (arrow A) (Fig. 3A) and therefore cylinder cam 9 causes actuation of dcadbolt 30 into the thrown condition. Clockwise motion of key (arrow B) (Fig. 3B) and therefore cylinder cam causes actuation of the deadbolt 30 into the withdrawn condition. In an unpowered condition the connecting rod 14 does not resist the consequential movement, or may be arranged to provide power assistance.

Actuation of the connecting rod 14 by the linear motor 10 along the actuation axis 12 has a secondary effect, (Figs. 4A and 4B). As the link 16 pivots, the operating pin 46 of the bolt thrower assembly 40 is displaced, to move away from the trunk-like projection 57 of the follower plate 56. In consequence the hairpin spring 62 pivots the first and second latch bolt engaging plates 52, 54, and in doing so their respective arms 53, 54 bear upon the square flange 26 of the latch bolt 20, causing the latch bolt 20 to withdraw along its axis 22 (Fig. 4B). A stop pin 72 of the chassis, limits relative clockwise motion of the follower plate 56.

This motion also represents the emergency escape action of the lock assembly 2. Clockwise pivoting of a door handle having a square shaft passing through the square bore of the follower assembly 50 on the inside side of the door leaf results in clockwise pivoting of the follower plate 56. As shown in Figs. 4A and 4B, clockwise pivoting of the follower plate 56 pivots the bolt thrower assembly 40 to mechanically withdraw the deadbolt 30 and simultaneously withdraw the latch bolt 20 via pivoting of the latch bolt engaging plates 52, 54.

A lock controller 80 is incorporated into the door lock (Fig. 5) and comprises a sensor printed circuit board (PCB) and processor 82 fitted with latch bolt sensor 84, door sensor 86, deadbolt withdrawn status sensor 88 and a deadbolt thrown status sensor 90. A communications PCB 94 is provided above the latch bolt and a deadbolt magnet 92 is provided on the dcadbolt for interaction with the sensors 88 and 90.

The controller 80 is trapezoidal, and fits between the latch bolt 20, deadbolt 30, linear motor and side plate 6. The latch bolt sensor 84 is located adjacent the latch bolt 20. The deadbolt thrown and deadbolt withdrawn status sensors 88, 90 are located adjacent the deadbolt 30. The deadbolt magnet 92 is positioned such that in the deadboh thrown condition the deadboh magnet 92 is substantially aligned with the deadboh thrown status sensor 88 and in the deadbolt withdrawn condition the deadbolt magnet 92 is substantially aligned with the deadbolt withdrawn status sensor 90.

A ring magnet 98 is fitted beneath a strike plate 96 of a door frame 97 such that when the door leaf 3 is closed the door sensor 86 substantially aligns with the ring magnet 98 to detect a door closed condition.

The communications PCB 94 includes a transmitter, and is located above the latch bolt 20, and provides information regarding the door leaf 3, latch bolt 20 and deadbolt 30 statuses to a receiver (not shown) typically rcmote from the door lock.

In use the controller 80 provides that the deadbolt 30 cannot be thrown electrically until the door leaf 3 is in the closed condition and the latch boh 20 is extended into the strike plate of the door frame. If the deadbolt 30 is thrown by key action with the door open, the illicit state is dctectcd and the linear motor 10 actuatcd to withdraw thc dcadbolt 30, overriding thc key.

The ratio of the pivot of the lthk to the pivot of the bolt thrower is not limited to 4:10, with other ratios envisaged to ensure full deployment of the deadbolt.

The communications PCB 94 and sensor PCB and processor 82 may be provided as a single board, with a bridging section passing between the latch bolt 20 in its retracted position and the top of the linear motor 10. A portion of this single board may extend between the lock case 4 and the telescopic cylindrical shaft 23 of the latch bolt 20, increasing the region of the board adjacent the linear motor 10. The bridging section may carry tracks to connect the functionality of the sensor, processor and communications. This precludes the need for connecting wires, which could become snagged on the wires below the level of the latch bolt.

Any suitable material may be used for the door lock of the invention, typically conventional materials such as steel and brass.

The skilled addressee will appreciate that varions other configurations are possible within the scope of the appended claims.

Claims

Claims 1. A door lock comprising a chassis having: a latch bolt opcrablc on a latch bolt axis; a dcadbolt opcrablc on a dcadbolt axis; and an electric actuator operable on an actuator axis for actuating the deadbolt, wherein the latch bolt, dcadbolt and actuator arc arrangcd on said chassis in substantially thc samc planc, thc latch bolt axis and dcadbolt axis bcing parallcl, whcrcin thc actuator is arranged between the latch bolt axis and deadbolt axis, and the actuator axis crosses the deadbolt axis.
2. A door lock according to claim I wherein the actuator comprises a linear motor.
3. A door lock according to claim 1 or claim 2 wherein the actuator is between the latch bolt and the deadbolt.
4. A door lock according to any of claims 1 to 3 wherein the actuation axis crosses the deadbolt axis at an angle of between 60° and 120° with respect to the deadbolt axis.
5. A door lock according to claim 4 whcrcin thc anglc is bctwccn 70° and 80°.
6. A door lock according to claim 4 wherein the angle is between 100° and 1100.
7. A door lock according to claim 5 wherein the angle is between 72° and 74°.
8. A door lock according to claim 6 wherein the angle is between 116° and 118°.
9. A door lock according to any prcccding claim whcrcin said chassis includcs a lcvcr pivoted thereon to link the deadbolt and the actuator.
10. A door lock according to claim 9 whcrcin thc lcvcr is arrangcd to pivot about a pivot post of thc chassis.
11. A door lock according to claim 9 wherein the lever includes an axle which pivots about a location on the chassis.
12. A door lock according to any preceding claim wherein first and second levers are provided having respective arms coupled to the deadbolt and the actuator, the levers having parallel axes orthogonal to said plane, and additional arms for contact with each other.
13. A door lock according to claim 12 wherein arcuate movement of the first lever in the range of 40° to 50° translates to an arcuate movement in the range of 1000 to 125° of the second lever.
14. A door lock according to any preceding claim wherein the deadbolt includes a deadbolt gating having a latch to lock the deadbolt in the thrown state.
15. A door lock according to any preceding claim including a battery arranged on the chassis for powering the actuator.
16. A door lock according to any preceding claim wherein the latch bolt is biased to support the load of the door leaf when in the closed condition.
17. A door lock according to any preceding claim wherein the latch bolt is located above the deadbolt.
18. A door lock according to any preceding claim further comprising a key barrel for operating the deadbolt.
19. A door lock according to claim 18 wherein the key barrel is rotatably mounted to the chassis below the deadbolt axis.
20. A door lock according to claim 19 wherein the key barrel includes a radially protruding cylinder cam for engagement with a lever linking the deadbolt and the actuator.
21. A door lock according to any prcccding claim wherein the chassis comprises a substantially rectangular base plate and cover.
22. A door lock according to any preceding claim further comprising a pivotable lever for operating the latch bolt, the pivotable lever having a substantially square hole for the shaft of a door handle.
23. A door lock according to claim 22 wherein the pivotablc lever for operating the latch bolt and a lever linking the deadbolt and the actuator are engageable to actuate the deadbolt and latch bolt simultaneously.
24. A door lock according to claim 22 wherein the pivotable lever is between the latch bolt axis and thc dcadbolt axis and to onc side of thc actuator.
25. A door lock according to claim 24 further including an electronic controller, arranged between the latch bolt axis and the deadbolt axis and at the opposite side of the actuator to the pivotable lever.
26. A door lock according to claim 25 wherein the electronic controller is provided on a printed circuit board cxtcnding between thc latch bolt and the chassis and connected to a transmitter on the printed circuit board above the latch bolt axis.
27. A door lock according to claim 26 wherein the connection of the electronic controller and the transmitter is via conductive tracks on the printed circuit board.
28. A door lock according to claim 26 or claim 27 wherein the actuator is connected to terminals on the printed circuit board below the latch bolt axis and adjacent the actuator.
29. A door with a door lock according to any of claims Ito 28.
30. A door lock substantially as described herein with reference to the accompanying drawings.