GB2582625A

GB2582625A - Door lock or latch assembly and method of and kit for fitting such an assembly

Info

Publication number: GB2582625A
Application number: GB1904321.5A
Authority: GB
Inventors: Francis Guy Neely Matthew
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-03-28
Filing date: 2019-03-28
Publication date: 2020-09-30
Also published as: GB201904321D0; GB201908486D0

Abstract

A door latch or lock assembly 40 includes a lock body 44 having a body perimeter and lock bolt 42; at least one, preferably two door side fixation panels 46, 48 extend beyond the perimeter to overlap a side of the door to fix the assembly within a cutout pocket in the edge of a door. The door fixation panels preferably extend beyond all sides of the perimeter except for a door edge profile side. The latch body may be recessed back from the door edge to accommodate a surface mounted striker/keeper. The assembly may be included in a kit form with a template (10, fig.1) prefably of U-shape form with two sides located around a door edge marking the area to be cutout. Also claimed is a lock assembly (figure 11) with at least one lock bolt 42 and first and second inter-engaging cam wedge elements (118, 120) driven together, e.g. by motor driven gears or solenoid to drive/extend the lock bolt.

Description

DOOR LOCK OR LATCH ASSEMBLY AND METHOD OF AND KIT FOR FITTING SUCH AN ASSEMBLY

Technical Field

The present invention relates to a door lock or latch assembly and to a method of and kit for fitting such an assembly to a door. The preferred embodiments described below focus on a front door but the teachings herein are applicable to any door, cover, lid or other element intended to be latched and/or locked to another component.

Background of the Invention

The art of door locks and latches is well developed, including in the field of electronic locking and latching systems.

There are generally two types of locks and latches, the first being embedded into the door structure, the second being surface mounted. The advantage of an embedded lock or latch is a more aesthetic appearance and better enclosing of the lock or latch components to assist in tamper-proofing.

However, embedding a lock or latch assembly into a door is a time consuming and skilled task, involving cutting or drilling accurately recesses and bores into the door structure, and often also in the door frame.

The advantage a surface mounted lock or latch is that the bulk of the lock or latch, or its face plate, does not need to be embedded into the door structure.

However, a surface mounted lock or latch is less secure. Furthermore, it remains necessary to drill accurately at least one hole through the door structure for accommodating the portion of the lock cylinder accessible from the other side of the door.

While some electronic locks do away with a physical key, their structure remains similar to that of existing mechanical door locks and latches, although they can be made physically smaller.

Summary of the Invention

The present invention seeks to provide an improved door lock and latch assembly and an improved method of and kit for fitting such an assembly to a door.

According to an aspect of the present invention, there is provided a door lock or latch assembly including a lock or latch body having a body perimeter, a portion of the perimeter being a door edge profile; and at least one door side fixation panel fixed or fixable in direct contact with the lock or latch body to a side of the door edge profile; the or each door side fixation panel extending beyond the perimeter of the lock or latch body in at least one direction away from the door edge profile; whereby in use the lock or latch assembly is fitted to a door having an edge, first and second door sides extending from the edge and having a door thickness; wherein the lock or latch body is received in a door cut-out extending through the thickness of the door with the lock or latch body door edge profile substantially aligned with a door edge, and with the or each fixation panel extending over a respective door side and attached directly both to the lock or latch body and the door.

The assembly preferably comprises first and second fixation panels each fixed or fixable to the lock or latch body on opposing sides thereof, such that in use each fixation panel extends over and either side of a door.

The or each door fixation panel may extend at least in a direction away from the door edge profile and/or at least in one direction orthogonal to a plane of the door edge profile.

Advantageously, the door edge profile of the lock or latch body is aligned with or extends beyond the at least one door fixation profile in a plane of the door edge profile.

In the preferred embodiment, the at least one door fixation panel extends beyond the lock or latch body in all directions save for the door edge profile.

It is preferred that the at least one fixation panel, or at least one of the fixation panels, and the lock or latch body are formed as an integral unit and such that the at least one door fixation panel is not detachable from the lock or latch body. In some embodiments, the at least one fixation panel and lock or latch body are formed as a unitary piece.

The or each door fixation panel preferably comprises at least one hole for receiving a fixation bolt or screw. Where two fixation panels are provided, they preferably have mutually aligned holes.

The lock or latch body is preferably sized to the thickness of the door. In some embodiments, one or both of the fixation panels includes an internally disposed extension portion sized to the lock or latch body or to the cut-out and residing in the cut-out, wherein the lock or latch body and the extension portion or portions together have a thickness sized to the thickness of the door.

The assembly preferably comprises a surface mounted door frame strike plate. In practice, the assembly is sized and arranged so that no cutting or recessing of the door frame is necessary, with space required for the strike plate being accommodated by the lock or latch assembly and door cut-out.

In some embodiments, there may be a plurality of lock or latch bodies fixed or fixable to the at least one fixation panel.

According to another aspect of the present invention, there is provided a kit comprising a door lock or latch assembly as specified and disclosed herein and a template shaped and sized to the lock or latch body and having first and second substantially parallel side flanges coupled together in spaced relationship, the template denoting a section of a door structure to be cut out through a thickness of the door for receiving the door lock or latch assembly.

Advantageously, the template first and second side flanges are coupled together by an end flange.

The template may in some embodiments have at least a depth slightly larger than a depth of the lock or latch body. The template may also or in the alternative have a length greater than a length of the latch or lock body.

The template may be made of a plastics, cardboard or other material. In some embodiments, the template may be made of a strength sufficient to act as a cutting guide for a jigsaw or other saw or cutting element. When used as a cutting guide, the template will typically be sized slightly smaller than the desired cut-out to take into account the cutting margin of the cutting implement.

In some embodiments, there may be provided a plurality of templates, which are advantageously connected together in a longitudinally spaced relationship, for use in demarking door cut-out zones for a lock or latch assembly comprising a plurality of lock or latch bodies.

According to another aspect of the present invention, there is provided a method of fitting a lock or latch assembly to a door, the door having an edge, first and second door sides extending from the edge and a door thickness, the method including the steps of: forming at least one cut-out in the edge of the door through the thickness of the door; fitting to the door a lock or latch assembly comprising a lock or latch body having a body perimeter, a portion of the perimeter being a door edge profile; and at least one door side fixation panel fixed or fixable directly to the lock or latch body; the or each door side fixation panel extending beyond the perimeter of the lock or latch body in at least one direction away from the door edge profile; said fitting comprising locating the lock or latch body in the cut-out with the lock or latch body door edge profile disposed along said door edge, whereby the at least one door side fixation panel is positioned over a respective side the door and extending beyond the cut-out, and fixing the or each door fixation panel to the door.

Advantageously, the fixing step includes bolting, screwing or bonding the at least one fixation plate to the door.

In the preferred embodiments, the step of forming the at least one cut-out is by use of a template sized and shaped to the lock or latch body.

According to another aspect of the present invention, there is provided a lock assembly comprising a lock or latch mechanism provided with at least one lock bolt, a support to which the at least one lock bolt is fitted, a lock housing, first and second inter-engaging wedge elements, wherein the first wedge element cooperates with the at least one lock bolt and the second wedge element cooperates with the lock housing, wherein relative movement between the first and second wedge elements causes movement of the lock bolt support and at least one lock bolt between unlocked and locked positions.

The assembly advantageously includes an actuator mechanism configured to move the lock bolt support at least in the locked position. Preferably, the actuator mechanism is configured to move the lock bolt support both the locked and unlocked positions, although in other embodiments there may be provided instead or in addition a biasing element, such as a spring, for biasing the lock bolt support into the unlocked condition.

Preferably, the actuator mechanism acts on the lock bolt.

The actuator is preferably motorised. In some embodiments, the actuator may be magnetic, in an example in the form of a solenoid.

The first and second wedges are aligned with the plane of the door, such that pressure applied to the door causes movement of the first and second wedges towards the locked condition, thereby strengthening the locking condition.

Advantageously, there are provided pluralities of at least one of the first and second wedges, arranged in inter-digitating manner.

All aspects of the present invention may be combined together in order to achieve all of the advantages taught herein.

Other aspects and advantages of the present invention will become apparent to the skilled person from the specific description that follows.

Brief Description of the Drawings

Embodiments of the present invention are described below, by way of example only, with reference to the accompanying drawings, in which: Figures 1 and 2 are schematic perspective views of a template and door with an edge cut-out in accordance with the teachings herein; Figure 3 is a schematic perspective view of an embodiment of lock assembly; Figure 4 is a schematic perspective view of an embodiment of strike plate; Figure 5 is a schematic front elevational view of the embodiment of assembly of Figure 3; Figure 6 is a schematic side elevational view of the embodiment of assembly of Figure 8; Figure 7 is a schematic plan view of the embodiment of assembly of Figures 5 and 6, shown partially in cross-section; Figure 8 is a schematic perspective cross-sectional view of a part of an embodiment of lock or latch assembly showing an arrangement of lock wedges in accordance with the teachings herein; Figure 9 is a schematic perspective view of another part of the assembly of Figure 8; Figure 10 is a view similar to Figure 9, showing further components of the lock assembly of Figure 8; Figure 11 is a schematic cross-sectional plan view of the embodiment of assembly of Figures 8 to 10, fitted to a door; Figure 12 is a schematic cross-sectional perspective view of the embodiment of assembly of Figure 11, fitted to a door; Figure 13 is a schematic view showing the locking of the bolts of the lock assembly of Figures 5 to 12 into the strike plate; Figure 14 is a schematic side elevational view of the lock assembly of Figures 5 to 12; Figure 15 is a schematic front elevational view of the lock assembly of Figure 14; Figure 16 is a schematic view of another embodiment of lock assembly in accordance with the teachings herein, provided with two lock mechanisms, fitted to a door having a traditional surface mounted lock; Figure 17 is a schematic perspective view of another embodiment of lock assembly in accordance with the teachings herein; and Figure 18 is a cross-sectional view of the embodiment of lock assembly of Figure 17 fitted to a door.

Description of the Preferred Embodiments

Described below are various embodiments of lock assembly, kit for fitting a lock assembly to a door and a method of fitting a lock assembly to a door. While different embodiments are described, it is to be understood that the features of the various embodiments can be combined with one another and indeed this is shown in at least some of the drawings. The principal embodiments relate to a lock assembly. It is to be understood, however, that the teachings herein are equally applicable to a latch and as a result any references to a lock are to be construed as applying equally to a latch, and vice versa.

Referring first to Figures 1 and 2, these show respectively a template 10 and a section of a door 12 in accordance with the teachings herein. The door 12 in this example is of a building door, for example an external door, but could be any other door having a latch or lock mechanism. It is common in the art either to have surface mounted locks or locks the main components of which are embedded within recesses formed in the door structure. While surface mounted locks are relatively easy to fit, they can be less secure than other types of lock. Lock systems that are embedded within recesses in the structure of the door require careful making of recesses or chambers within the door structure, which requires skill and time. Furthermore, the door is generally weakened at the location of the lock.

The teachings herein propose a new method of fitting a lock or latch to a door and new assembly therefor, in which a cut-out 14 is made through the entire thickness of the door 12 at an edge 16, as a location at which the door lock or latch is to be fitted. The cut-out 14 can be made by means of a template 10, which includes first and second substantially parallel side flanges 20, 22, in the preferred embodiment of equivalent shapes and dimensions. The side flanges 20, 22 are coupled together in spaced relationship, preferably by means of an end flange 24 as shown in Figure 1. The width of the end flange 24 and the spacing between the side flanges 20, 22 is preferably the same or at least the same as the thickness of the door 12, such that the template 10 can be positioned on an edge 16 of a door 12 with the end flange 24 abutting the edge 16 and the side flanges 20, 22 extending over respective sides 26 of the door 12 and lying in abutment with respective sides of the door 12 or in close proximity thereto. As doors tend to come in a variety of standard thicknesses, the templates 10 can equally be made in a series of standard sizes, specifically widths of the end flange 24 (or spacing between the side flanges 20, 22). In any event, any arrangement can be provided as long as the side flanges 20, 22 can be positioned either side of a door so as to lie an abutment against the door surface or sufficiently close thereto so as to provide an effective cutting marker. In some embodiments at least, the template could be compressible against the door sides.

It is envisaged that in most cases the template 10 would be used only to delineate a cutting line rather than being used as a cutting guide, in which case the template 10 can be formed of any material that provides a suitable marker guide. It may be made, for example, of a plastics material or cardboard, thick paper or other card, or the like. In some embodiments the template is made sufficiently strong to be able to act as a router template, that is as a guide for a jigsaw or other saw or cutting device. When used as a router template, the template will typically be sized slightly smaller than the desired cut-out to take into account the cutting margin or thickness of the cutting implement.

In the preferred embodiment, the side flanges 20, 22 are provided with edges 30, 32 respectively, which are advantageously rounded or curved as shown in Figure 1. This facilitates cutting the recess with a saw (for example a jigsaw) in a singular motion. In the particular example shown in Figure 1, the surfaces 30, 32 include first and second side portions 31 that extend substantially perpendicularly to the plane of the end flange 24 (therefore in practice perpendicularly to the door edge 16), a central portion 35 parallel or substantially parallel to the end flange 24, and in practice the door edge 16. Rounded or curved sections 33 lie between the sides 31 and central portion 35. The operative shapes of the side flanges 20 and 22 could be described as rounded rectangular. It is to be appreciated, though, that the side flanges 20, 22 could have any shape or size, in practice dependent upon the shape and size of the lock or latch bolt body, described in further detail below.

In use, the template 10 is located on a door 12 against an edge 16 at which it is desired to locate a door lock or latch and with the end flange 24 abutting the door edge 16. Once positioned at the desired location and height, a mark can be drawn around the edges 30, 32 with any suitable marking implement, for example a pencil or pen. Once the door is marked, the template 10 can be removed and then a cut-out 14 formed by following the marker lines with a suitable saw or other cutting tool. This is an operation that can be carried out very quickly and with significantly less skill than that required to fit a traditional embedded lock or latch mechanism.

Referring now to Figure 3, this shows an embodiment of a door lock or latch assembly 40 designed to be fitted to the door 12 of Figure 2, after having had the cut-out 14 formed as described above. The assembly 40 includes one or more latches or locking bolts 42, in the example shown in Figure 3 there being an array of eight bolts, arranged in four rows with a greater spacing between the two middle rows.

As will become apparent below, the nature of the door lock or latch is not limiting to the teachings herein, and in particular with regard to the assembly shown in Figure 3 and the teachings associated with Figures 1 and 2.

The assembly includes a lock or latch body 44 which incorporates the principal components of the latch or lock, typically the mechanical or electromechanical components thereof, and in this example first and second door fixation panels 46, 48. The fixation panels 46, 48 are, in this embodiment, fixedly attached to the body 44, for example by welding, bonding or by being formed integrally therewith, or by any other suitable mechanism. It is not excluded, however, that the fixation panels 46, 48 could be separate components that are fixed to the lock body during mounting of the assembly 40 to door 12.

Also shown in Figure 3 is an electronics unit 50 for operating the lock or latch electronically, in any manner know in the art. Unit 50 in this embodiment, is disposed exterior of the fixation panel 46 but it would be appreciated that this is an example only. The nature and components of the electronics unit 50 can be standard in the art and operable in any known way, for example by means of a keypad, fob, remotely, including wirelessly.

The body 44 includes a wall 52, which could be described as a body door edge profile and that in practice is aligned or substantially aligned with the edge 16 of door 12. The remainder of the periphery of the body 44 is substantially shaped and sized to the cut-out 14 and in practice to the template 10 shown in Figure 1. It is to be appreciated that in some embodiments the door edge profile 52 of the body 44 may sit slightly proud of the edge 16 of a door, while in other embodiments may be slightly recessed relative to the door edge 16, for instance to accommodate a surface mounted striking plate as described below.

The first and second door fixation panels 46, 48 include straight front edges 54, 56 that are advantageously aligned with the door profile 52 of the body 44, but not necessarily so. In some embodiments, the front edges 54, 56 may stand proud of the door edge profile 52 of the body 44, while in other embodiments they may be disposed in what could be described as behind the surface of the door edge profile 52. The precise disposition of the edges 54, 56 relative to the door edge profile 52 would be dependent upon the particular practical application and also the intended arrangement of the strike plate or plates that may be used with the assembly 40.

In the embodiment shown in Figure 3, the door fixation panels 46, 48 extend beyond the perimeter of the body 44 in every other direction, that is above, below and behind the body 44 as seen from the door edge profile 52. This is the preferred arrangement, although in other embodiments the door fixation panels may extend only one or two of these other directions.

The amount by which the door fixation panels 46, 48 extend beyond the perimeter of the lock body 44 is dependent upon the degree of strengthening desired to be provided by the door fixation panels 46, 48, and/or for aesthetic or other functional reasons. They will typically extend in the region of 1 to 15 centimetres from the lock body 44, although it is to be understood that these dimensions are an example only and will typically be dependent upon the design of the door. The door fixation panels may extend beyond the lock body 44 by the same amount in each direction or by different amounts. For example, they may extend above and below the body 44 by a greater amount than that by which they extend rearwardly.

It is preferred that the door fixation panels 46, 48 are the same size and shape for symmetry, although this is not essential and they may differ. In some embodiments, they may be shaped and sized to act as a door push plate.

The door fixation panels 46, 48 could have, save for their front edges 53, 56, any shape desired for aesthetic or other purposes, in the embodiment shown being generally rectangular with rounded rear corners.

In the embodiment of Figure 3, each door fixation panel 46, 48 is formed with two holes 58, aligned between the respective fixation panels 46, 48, for the receipt of a fixation bolt (not shown) in Figure 3 but shown in others of the drawings.

It will be appreciated that in some embodiments there may be provided one or more cover panels to cover the door fixation panels 46, 48 for aesthetic purposes and for preventing direct access to the fixation bolt or bolts.

The door fixation panels may be made of a single layered material, although in other embodiments may be composite structures. They may, as 10 explained, be provided with one or more cover panels and they may in some embodiments include a layer of heatproof material to protect the internal components of the latch or lock assembly from damage by heat.

The lock or latch body 44 has a thickness, providing a spacing between the door fixation panels 46, 48 that is preferably the same as of a close fit to the width of the door 12 to which it is to be mounted. As most doors come in standard sizes, the door lock assembly of Figure 3 can equally be made in standard door widths. AS described below, in some embodiments, one or both of the fixation panels 46, 48 may have an internal extension portion designed to fit within the cut-out, in which case the lock or latch body will have a thickness less than the thickness of the door by at least the thickness of the extension portion(s) of the fixation panel(s).

Referring now to Figure 4, this shows a part cross-sectional view of a door frame 70 having fitted thereto a strike plate 80 suitable for the door lock or latch assembly 40 of Figure 3. The door frame 70 can be a standard construction with suitable decorative mouldings 72, of which many types and designs are known in the art.

In the embodiment shown in Figure 4, the strike plate 80 is surface mounted to the interior of the door surround 74, thereby saving the need to dig a recess in the internal door frame panel 74 in order to accommodate the strike plate 80. This can be achieved, in the preferred embodiment, by recessing the body door edge profile 52 of the assembly 40 relative to the door edge 16, providing space to accommodate the strike plate 80.

In the embodiment shown, the strike plate 80 has at least a height consistent with and no greater than the height of the body door edge profile 52 of the body 44.

The strike plate 80 includes an array of apertures or recesses 82 sized, shaped and arranged to receive each one of the latches or bolts 42.

The strike plate 80 is also provided with a plurality of holes 84 to 90 for receiving fixation screws 84' to 90'. It is preferred that the fixation holes 84-90 are non-aligned in the longitudinal direction of the strike plate 80, which is the typical direction of woodgrain in a door frame. So doing avoids having a plurality of screws 84'-90' along the same line of the wood grain, which can weaken the internal door frame panel.

It will be appreciated that the strike plate 80 may in some embodiments be fitted into a recess in the internal door frame panel 74, if desired.

Referring now to Figures 5 and 6, these show, respectively, front and side elevational views of the assembly 40 shown in Figure 3. The door fixation panels 46, 48 may be formed integrally with the body 44 or at least with one side of the lock body 44 as a unitary component or, as described above, may be fixed thereto during manufacture of the assembly 40.

In the embodiment of Figure 5 the door fixation panels 46, 48 may be provided with extension portions 60, 61 which extend inwardly towards the lock or latch body 44. The extension 60 is in use formed as a unitary pad with to its associated panel 46 and in this example has lateral dimensions (length and depth) which are the same as or similar to those of the lock or latch body 44. The extension 61 is shown as an addition to its associated panel 48 and is typically bonded, welded or otherwise affixed thereto. The extension 61 is in this example larger in terms of height (and optionally depth too) relative to the lock or latch body 44 but in practice is still sized to fit within the door cut-out. It will be appreciated that the features of these examples, may be combined and/or swapped as desired. The extension(s) 60 and/or 61 and the lock or latch body 44 will typically have a combined thickness that is the same as or similar to the thickness of the door structure 12.

An aesthetic cover plate may be disposed over one or both of the door fixation panels 48 and may or may not be provided with holes for receiving a locking bolt.

The electronic unit 50 can be seen protruding from the door fixation panel 46 and may include a plurality of lamps 62 for indicating the state of operation of the electronic locking system. The unit 50 may include a battery, back up battery and other electronic logic circuitry, as known in the art and described in further detail below.

The latch elements 42 in this embodiment preferably have angled edges 43 for facilitating the receiving of the elements 42 into their respective slots 82 in the striking plate 80. In an embodiment, the elements 42 may have leading edges 43 at a 60° angle, although this may be up to 90° in some embodiments.

Referring now to Figure 7, this shows a top plan cross-sectional view of an embodiment of the assembly 40 substantially similar to that of the other embodiments described and shown above. In this embodiment, the door fixation panels 46, 48 are formed integrally with the latch or lock body 44 as a singular unit, and also as a single unit with the casing of the electrics unit 50. The fixation panel 46 includes a flange portion 102 that extends beyond the door edge profile 52 of the body 40, acting as a stop against a door frame 70 and provides additional security. The lock assembly 40 includes a lock or latch plate 100 to which the lock or latch elements 42 are attached or integral with. The lock or latch plate 100, as described in further detail below, is able to move in and out of the lock of latch body 44 between latched or locked and unlatched or unlocked positions. The movable lock or latch plate 100 has the advantage of enabling the latch or lock elements 42 to move in unison, simplifying the mechanism.

Referring now to Figure 8, this is a perspective view of a part of a preferred embodiment of lock mechanism that can be used in a door lock or latch assembly of the type disclosed herein.

Shown and described in Figures 8 to 12 as a lock arrangement, although the skilled person will readily appreciate that this could be readily converted into a latch operable, for example, by means of a door handle or knob without any locking function.

The assembly 110 is referred to below as a lock assembly with electronic lock components but it is to be understood that this assembly and these components could equally be configured as a handle or knob operated latch.

The assembly 110 includes a lock plate 112, a lock body 114 fitted to components (not shown in the drawings) to fix the assembly 110 to a door which may be the assembly 40 shown in Figures 3, 5 and 6. The movable lock plate 112 and the lock body 114 form a chamber 116 in which there are disposed two arrays of wedge elements 118, 120. In the embodiment shown, the wedge elements 118, 120 are disposed in facing and interdigitating sets, as will be apparent in particular from Figures 6, 11 and 12. The wedges 118, 120 are able to slide relative to one another and within the chamber 116, that is relative to the walls of the chamber 116 provided by the lock plate 112 and the lock body 114, as described in further detail below.

In this embodiment, the lock plate 112 includes a front portion 122, extending laterally therefrom and preferably at 90° to a second portion 124.

Similarly, in the embodiment shown in Figure 8, the body portion 114 includes a back wall and a side wall 124. The locking plate 112, in practice, is able to move forwards and backwards relative to an axis extending transversally of the wedges 118, 120. The front face 122 of the moveable lock plate 112 is provided lock bolts 42, which in this embodiment are equivalent to the lock bolts 42 shown in particular in Figures 3 and 5.

Also attached to the front plate 122 and extending rearwards of the front face are upper and lower stabilisation panels 130 and 190, which have a relatively wider front section and a narrower rear section, the purposes of which are described in further detail below. The panels 130, 190 are in practice disposed above and below the uppermost and lowermost extents of the wedges 118, 120 and can slide relative thereto.

Disposed at opposing ends of the wedges 118, 120 are low friction elements, coatings or membranes 140, which optimise the slidability of the wedges 118, 120 relative to the walls of the movable locking element 112 and the lock body 114. These are described in further detail below.

With reference now to Figure 11, this is a cross-sectional view, in plan, of the embodiment of lock assembly 110 shown in Figures 8 to 10. The movable locking plate 110 can be seen with its front and side panels 122, 124 disposed at right angles to one another (in this embodiment) and with the front panel 122 in practice aligned with the edge 16 of door 12 and with the strike plate 80 fixed to the door frame 70. In this embodiment, it can be seen that the strike plate 80 is disposed in a rebate of the door frame 70.

The movable locking plate 110 is generally free to move, in particular in a direction towards and away from the strike plate 80. The lock body 40, equivalent to the lock body 40 of Figure 2, is in this example formed integrally as a single unit with the door fixation panels 46, 48 and also with the casing 50 of the electronics unit. Disposed within the casing 50 is a controller 150, which may include a microprocessor, inputs/outputs (such as push buttons), a communication module, whether wired or wireless and so on. It will also include at least one battery and potently a backup battery and also, in some instances, a mechanical override which may be key operated. The control unit may include components to enable it to operate by an application on a mobile device, such as a telephone, with a fingerprint, facial or iris recognition, with an alpha numerical code and so on. The power supply could be battery sourced, which may be rechargeable, or could be mains operated, for example. In some embodiments, the unit may be wirelessly chargeable, for example, inductively.

The controller unit 150 is connected to a motor 152 which includes an output shaft (shown in Figurel2) which is attached to a toothed cog 154, which engages with a toothed disk 156 fixed to a pusher plate 160 through an interconnected shaft and also to a threaded element, or screw, 162. The threaded element 162 passes through a threaded bore (not shown in the drawings) in the wall 164 of the electronics housing 50. Operation of the motor 152, by controller 150, causes the cog 154 to rotate, in turn causing rotation of the toothed disk 156, which will move away from or towards the wall 164 under the bias of the screw 162 in dependence upon the direction of rotation of the cog 154 and motor 152.

When the toothed disk 156 moves away from the wall 164 (to the left in the view of Figure 11) this will press upon the lateral wall portion 124 of the locking plate 110 and also against wedges 120, which would be pushed further into the interstices with the wedges 118. This causes the wedges 118, 120 to spread longitudinally (in the plane of the door 12) and as a result to push the wall portion 122 of the lock plate 110 outwards towards the strike plate 80. For this purpose, between the push disk 160 and the side wall 124 there is preferably provided a low friction coupling 140, which may be a PTFE disk, membrane or coating on one or both of the pusher disk 160 and wall 124. A similar element to the low friction membrane or coating 140 is located on the wall of the housing 114 at the other end of the wedges 118, 120. It is preferred also that the wedges 118, 120 are provided at least at their abutting surfaces with a low friction coating or material. In practice all moving or sliding components are preferably provided with low friction coatings or made of low friction materials.

It is preferred that the or each low friction element or coating is made if a polytetrafluoroethylene, such as Teflon(TM) for longevity, although any other suitable low friction material, including wax or grease may be used.

As will be apparent in Figure 11, in this implementation, the lock bolts 42 in their retracted positon are not directly aligned with the recesses 82, for the reason that the movement of the locking plate 110 under control of the motor 152 and the wedges 118, 120, will be in a direction that could be described as diagonal. It is for this reason also that the lock bolts 42 are preferably chamfered as shown, which assists in aligning the lock bolts 42 into their respective apertures 82 of the strike plate 80.

In practice, movement of the pusher disk 160 away from the wall 164, to the left in the view of Figure 11, presses the wedges 118, 120 towards one another and pushes the locking plate 110 outwardly towards the strike plate 80 at the door frame, thereby locking the door 12 to the frame 70.

Movement of the pusher disk 160 in the opposite direction, that is towards wall 164, will allow release of the wedges 118, 120 and release of the locking plate 110 from the strike plate 80, preferably by the aid of sprung elements as described in further detail below.

An advantage of the lock arrangement shown in Figure 11 is that once locked, should someone seek to push the door open (to the right of the view in Figure 11), this will cause further compression of the wedges 118, 120 into one another, increasing the force of the locking plate 110 against the strike plate 80 and of the lock elements 42 into their respective recesses 82, thereby strengthening the locking action by the very action of someone trying to push the door open.

Figures 12 and 13 show different views of the embodiment of lock assembly 110 shown in Figure 11 and it is believed do not require any separate description.

Referring back to Figure 9, this shows a portion of the lock assembly 110 above the wedges 118, 120. Attached to the body wall 140 there is provided a top cover plate 170 having a series of apertures 172 therein. The tops of the wedges 118, 120 are provided with pins 174 which extend through the apertures 172. Connected to the pins 174 is an expansion spring 180, which may include interconnecting bands 182 connecting together the pins of respective ones of the sets 118, 120 of the wedges. The expansion ring 180 acts to pull the pins 174, and equally the wedges 118 and 120, away from one another, that is in an unlocking direction. It will be appreciated that the expansion ring 180 is just one example of spring or biasing mechanism and that other arrangements are equally usable, including for example coil springs, leaf springs and so on.

Attached to the front lock plate wall portion 112 is guide plate 130, similar to the guide plate 190 at the bottom of the wedges shown in Figure 8, and which acts as a guide to the movement of the locking plate 110. Advantageously, the guide plate 130 slides underneath the expansion ring 180 attached to the pins 174. There is also provided a compression spring 192 attached at one end to the front lock plate wall portion 112 and at the other end to the body portion wall 140. The spring 192 is normally in tension, such that it acts to pull the locking plate 110 towards to the body portion wall 140, that is to an unlocking condition. As a result, when the motor 152 is actuated in the reverse direction, moving the push disk 160 towards wall 164 and away from the locking condition, the springs 180 and 192 act to push the wedges 118, 120 away from one another and to disengage the lock bolts 42 from the strike plate recesses 82.

The narrower diameter sections of the guides 130, 190 extend between the two sets of pins 174 and ensures that the lock plate 110 remains properly aligned.

Although not visible in the drawings, in the preferred embodiment, an equivalent arrangement or pins, expansion band and spring 192 is provided at the lower end of the wedges 118, 120, cooperating with the lower guide plate 130. There will also be provided a holding plate similar to holding plate 170 shown in Figures 9 and 10.

It will be appreciated that the apertures 172 and the holding plates need not be square as shown and could be slots instead, typically angled at an angle consistent with the movement of the locking plate 110 and related to the taper angle of the wedges.

A side elevational view of the lock assembly of Figures 3 to 13 is shown in Figure 14, while an end elevational view of the fixation panels and electronics unit is shown in Figure 15.

Referring now to Figure 16, this shows another embodiment of the invention, in which a door 12 and door frame 70 are fitted with a double lock assembly of the type disclosed herein, in which a single pair of door fixation panels supports two lock assemblies 40 spaced from one another longitudinally in relation to the door 12 along the door edge 16. This provides an even more secure lock, spread over a greater extent of the door opening. In this particular example of Figure 16, the door 12 is also fitted with a surface mounted lock 210 of conventional format.

It will be appreciated that the double lock assembly arrangement shown in Figure 16 has two cut-outs 14 in the door 12, which is preferred, although in some embodiments there may be a single longer cut-out.

With reference now to Figures 17 and 18, these show another embodiment of lock assembly 40', which has characteristics very similar to the embodiment of Figure 3 save for the fact that the lock mechanism is a standard double deadbolt lock mechanism having two deadbolts 220, which may be of conventional mechanical form that is key operated (through a key slot not visible in Figures 17 or 18). There may also be a handle or knob and spindle mechanism, as desired.

As the internal components of such a mechanical lock are well known in the art, it is not necessary to describe these in any detail herein. It will be appreciated that these components could equally be motorised or electromagnetic.

It should be appreciated that the door lock or latch assembly disclosed herein can be used with locks of a variety of mechanisms and are not restricted to the specific embodiments described herein.

While the preferred embodiments use two door fixation panels 46, 48 in some embodiments only a single door fixation panel may be provided. It is, however, preferred that two fixation panels are used as these will significantly add strength to the lock and also to the door itself by strengthening the entire area around the lock assembly, which is not something that is prevalent in existing door lock assemblies.

In summary, there is disclosed a new type of lock or latch assembly that can be fitted in a short time, typically in around three minutes, and can be stronger than existing embedded locks. This is especially the case when benefiting from a smaller lock or latch mechanism, which can optimises door strength.

There is also described a new type of locking system, although a more conventional type of lock mechanism could also be employed. The lock may either be conventionally controllable or more likely by the use of an electronic system of known type.

In the embodiment of new lock mechanism disclosed, a torque sensitive motor 152 turns a toothed cog 156 that moves a push disc 160 against the locking plate 140, which in turn squashes the wedges 42 (which are sprung in the opposite direction but with less force than the force of the disc, in order that the wedges return to their compacted position when disengaging the lock). When the locking plate 110 is engaged with the strike plate 80 on the doorframe, any pressure to open the door 12 acts through the wedges 118, 120 and increases the pressure between the two plates 80, 110, making it harder and harder to force entry.

The strength of the assembly comes from a) the shape of the main lock body 40, forming in effect a steel element around the cut-out area 14 in the door 12, and b) there being no cut-out in the frame, just a few screws. The lock could be much longer than a conventional lock (either one long lock or twin controlled locks), meaning the strike plate 80 could also be much longer, thereby spreading the load along the doorframe 74.

The fitting of the assembly is much easier as one (or two) cut-outs 14 are shallow scallop shapes through the entire thickness of the edge of the door 12, meaning the cut-out(s) for the lock could be made very quickly with a jigsaw or router. The lock body 40 would be held in place and holes would be drilled through the fixing holes and the bolts installed. The lock is not dependent on bolts but they would ensure the body is held tight to the door. It is to be understood that the bolts in this embodiment and all other embodiments are preferably tamperproof or security bolts.

To fit the receiving plate 80, a small smear of marking paste could be rubbed on the end of the actual lock points, the door 12 would be held shut and the lock activated, then retracted. There would now be a line left on the frame and the slot in the receiving plate would be lined up with this and screwed to the frame.

The wedges 118 120 and all internal passing faces would be made of or coated with PTFE/Teflon type material.

While the specific embodiments focus on a lock assembly, the teachings herein are equally applicable to door latches. As door latches are commonplace in the art, the skilled person will readily know how to modify the specific described and shown embodiments for a door latch. Similarly, the teachings herein are applicable to other types of lock or latch including, for example, bathroom locks.

All elements of the described embodiments are combinable with one another.

The disclosure in the abstract accompanying this application is incorporated herein by reference.

Claims

CLAIMS1. A door lock or latch assembly including a lock or latch body having a body perimeter, a portion of the perimeter being a door edge profile; and at least one door side fixation panel fixed or fixable in direct contact with the lock or latch body to a side of the door edge profile; the or each door side fixation panel extending beyond the perimeter of the lock or latch body in at least one direction away from the door edge profile; whereby in use the lock or latch assembly is fitted to a door having an edge, first and second door sides extending from the edge and a door thickness; wherein the lock or latch body is received in a door cut-out extending through the thickness of the door with the lock or latch body door edge profile substantially aligned with a door edge, and with the or each fixation panel extending over a respective door side and attached directly both to the lock or latch body and the door.
2. A door lock or latch assembly according to claim 1, comprising first and second fixation panels each fixed or fixable to the lock or latch body on opposing sides thereof, the fixation panels being configured to extend over opposing sides of a door.
3. A door lock or latch assembly according to claim 1 or 2, wherein the or each door fixation panel extends at least in a direction away from the door edge profile and/or at least in one direction orthogonal to a plane of the door edge profile.
4. A door lock or latch assembly according to any preceding claim, wherein the door edge profile of the lock or latch body is aligned with or extends beyond the at least one door fixation profile in a plane of the door edge profile.
5. A door lock or latch assembly according to any preceding claim, wherein the at least one door fixation panel extends beyond the lock or latch body in all directions save for the door edge profile.
6. A door lock or latch assembly according to any preceding claim, wherein the at least one fixation panel and the lock or latch body are formed as an integral unit.
7. A door lock or latch assembly according to any preceding claim, wherein the at least one fixation panel and lock or latch body are formed as a unitary piece.
8. A door lock or latch assembly according to any preceding claim, wherein the or each door fixation panel comprises at least one hole for receiving a fixation bolt or screw.
9. A door lock or latch assembly according to any preceding claim, in combination with a door, wherein the lock or latch body is sized to the thickness of the door.
10. A door lock or latch assembly according to any preceding claim, comprising a surface mounted door frame strike plate.
11. A door lock or latch assembly according to any preceding claim, including a plurality of lock or latch bodies fixed or fixable to the at least one fixation panel.
12. A kit comprising a door or latch lock assembly according to any preceding claim and a template shaped and sized to the lock or latch body and having first and second substantially parallel side flanges coupled together in spaced relationship, the template denoting a section of a door structure to be cut out through a thickness of the door for receiving the door lock or latch assembly.
13. A kit according to claim 12, wherein the template first and second side flanges are coupled together by an end flange.
14. A kit according to claim 12 or 13, wherein the template has at least a depth larger than a depth of the lock or latch body.
15. A kit according to claim 12, 13 or 14, wherein the template is made of a plastics, cardboard or other material.
16. A kit according to any one of claims 12 to 15, wherein there are provided a plurality of templates.
17. A kit according to claim 16, wherein the templates are connected together in a longitudinally spaced relationship.
18. A method of fitting a lock or latch assembly to a door, the door having an edge, first and second door sides extending from the edge and a door thickness, the method including the steps of: forming at least one cut-out in the edge of the door through the thickness of the door; fitting to the door a lock or latch assembly comprising a lock or latch body having a body perimeter, a portion of the perimeter being a door edge profile; and at least one door side fixation panel fixed or fixable directly to the lock or latch body; the or each door side fixation panel extending beyond the perimeter of the lock or latch body in at least one direction away from the door edge profile; said fitting comprising locating the lock or latch body in the cut-out with the lock or latch body door edge profile disposed along said door edge, whereby the at least one door side fixation panel is positioned over a respective side the door and extending beyond the cut-out, and fixing the or each door fixation panel to the door.
19. A method according to claim 18, wherein the fixing step includes bolting, screwing or bonding the at least one fixation plate to the door.
20. A method according to claim 18 or 19, wherein the step of forming the at least one cut-out is by use of a template sized and shaped to the lock or latch body.
21. A lock assembly comprising a lock mechanism provided with at least one lock bolt, a support to which the at least one lock bolt is fitted, a lock housing, first and second inter-engaging wedge elements, wherein the first wedge element cooperates with the at least one lock bolt and the second wedge element cooperates with the lock housing, wherein relative movement between the first and second wedge elements causes movement of the lock bolt support and at least one lock bolt between unlocked and locked positions.
22. A lock assembly according to claim 21, including an actuator mechanism configured to move the lock bolt support at least in the locked position.
23. A lock assembly according to claim 22, wherein the actuator mechanism is configured to move the lock bolt support both the locked and unlocked positions.
24. A lock assembly according to claim 22 or 23, wherein the actuator mechanism acts on the lock bolt.
25. A lock assembly according to claim 22, 23 or 24, wherein the actuator mechanism is motorised or magnetic.
26. A lock assembly according to any one of claims 21 to 25, including a biasing element, for biasing the lock bolt support into the unlocked condition.
27. A lock assembly according to any one of claims 21 to 26, wherein the first and second wedges are aligned with the plane of the door, such that pressure applied to the door causes movement of the first and second wedges towards the locked condition.
28. A lock assembly according to any one of claims 21 to 27, including pluralities of at least one of the first and second wedges, arranged in interdigitating manner.
29. A lock assembly according to any one of claims 1 to 11 and any one of claims 21 to 28.