A lock system and lock component thereof

Abstract

A smart lock system having a locking core designed for insertion into a lock body. The locking core includes an outer casing, an electronic circuit board, an internal power source, and a controlling device. The electronic circuit board receives commands from a remote device, verifies them, and then drives the controlling device to move the locking mechanism between locked and unlocked configurations. The locking core features a power management system, power being supplied from an internal power source or received from an external power source via an external power interface, which may also recharge the internal power source. This system provides flexibility in power supply options, including internal batteries and external devices, ensuring continuous operation and reducing the need for physical keys. Additionally, the smart lock system supports wired or wireless communication for remote control and monitoring, enhancing security and convenience.

Description

[0001] A LOCK SYSTEM AND LOCK COMPONENT THEREOF

[0002] CROSS REFERENCE TO RELATED APPLICATIONS

[0003] This application relates to and claims priority from New Zealand provisional application No. 810305 filed 22 April 2024, the entire contents of which are incorporated herein by reference.

[0004] FIELD OF THE INVENTION

[0005] The invention relates to lock systems and locks, particularly smart locks or remotely controlled locks and locking systems. In particular, but not exclusively, the invention relates to a lock system including a locking component being a locking core or insert for a lock including a padlock.

[0006] BACKGROUND

[0007] Locks are commonly used for both security and safety and traditionally have required a specific key to open and close the lock. However, this can lead to issues if different personnel are required to access the lock or if the key is lost. To address this issue electronic or smart locks have been developed. Such smart locks are designed to digitise access and prevent the need for people to carry physical specific keys and go some way to solving the issues with a specific physical key. However, these key-less locks require power to function.

[0008] Some current smart locks use a smart key that may store access permissions to multiple locks in order to open the smart lock. Although these are better than a physical key, they still suffer from the problem that users must carry a proprietary hardware device to gain access to the lock.

[0009] For organisations with a network of locks spread across a range of assets, there is considerable time and expense in ensuring the required keys or access devices are available to the user when required.

[0010] It would be desirable to increase efficiency and reduce the large number of wasted hours travelling to a location to uplift the correct keys or other activating devices. There are further benefits with a smart lock in providing a digital audit trail, which captures all activity across the locking network and the ability to remotely grant & revoke access permissions to different users.

[0011] Locks such as cabinet locks and padlocks are commonly used to secure a range of assets and many such assets such as compound gates or utility storage cabinets, may be in exposed locations and may be more prone to damage such as environmental impacts for weather that may impact the locks ability to function. Thus, rendering the connection features of the lock unusable. However, for some locks such as a padlock, the metal outer body of the padlock may still be useable. Thus, it is desirable to have a replaceable smart locking insert or locking core configured to fit within the inside of the body of an existing mechanical lock such as a padlock. Such a locking insert or core may replace the traditional padlock core insert that is opened with a key to create a smart padlock. WO 2022 / 032354 describes a locking core for insertion into a locking body. However, this locking core has a number of significant limitations in that the locking core does not comprise an internal battery but requires the use of a proprietary battery pack to externally connect to the base of the locking core in order to provide it with the necessary power to operate. If a user arrives at such a padlock without this specific battery pack, they have no way of accessing the padlock.

[0012] Other smart locks may comprise an internal battery to provide power to enable control of the locking mechanism. The internal battery is generally a replaceable battery that has a limited lifetime before it needs to be replaced. If the battery is flat when the user arrives at the lock location there is limited or no means to access the lock without replacing the battery. Thus, there is a need for users to carry spare batteries to maintain the lock function. Some locks may provide a jump-start function to allow the lock to be unlocked when the internal battery is flat using a battery, such as a 9 volt battery, to provide a power burst to unlock the lock. However, this still requires the user to carry a battery to gain access, and the internal battery will still need to be replaced.

[0013] It would be desirable to allow for secure access to the lock for users with any type of mobile smart device without requiring a specific device to access the lock mechanism of the lock. While the smart lock of the invention is described primarily with reference to a padlock it is to be understood that other types of locks may also benefit from have the electronic control system of the lock configured into a locking core. The shape and configuration of the locking core being determined by the structural configuration of the lock. Thus, a locking core may be configured for use in different locks, including but not limited to a padlock, a cabinet lock, cylindrical locks, bicycle locks, deadbolts, a cam lock or any other type of lock.

[0014] It would be desirable to provide an improved lock, or at least to provide the market with a useful choice.

[0015] SUMMARY OF INVENTION

[0016] In a first embodiment of the invention a locking core is configured for insertion into a lock body, the locking core comprising: an outer casing comprising a shell portion configured to be received within the lock body and a base portion configured to extend from the lock body, the shell portion and base portion being sealingly coupled together, an electronic circuit board housed within the outer casing for receiving electronic commands from a remote device, an internal power source coupled to the electronic circuit board; a controlling device housed within the casing and configured to receive power from the internal power source; and an external power interface provided on the base portion and configured to couple to an external power source; the electronic circuit board configured to activate on receipt of a command from the remote device and configured to drive the controlling device following verification of the command, wherein the controlling device is configured to enable movement of a locking mechanism adaptor coupled to and extending from the shell portion of the outer casing to move a locking mechanism of the lock between a locked and an unlocked configuration; and wherein when an external power source is coupled to the external power interface the electronic circuit board is configured to receive power from the external power source for use to drive the controlling device.

[0017] Preferably the verification of the command is performed by the electronic circuit board.

[0018] Preferably the internal power source is rechargeable. In some forms when the external power source is coupled to the external power interface the electronic circuit board is configured to direct power from the external power source to recharge the internal power source. In some forms the electronic circuit board may be configured to control the power source for delivery of power to drive the controlling device.

[0019] In one embodiment the controlling device is a motor, the motor is coupled with the locking mechanism adaptor to cause rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

[0020] In another embodiment the controlling device is a solenoid, the solenoid comprising a moveable shaft configured to be received in a locking aperture within a crank extending within the outer casing, the crank being coupled at a first end to the locking mechanism adaptor and coupled at a second end to the base portion of the outer casing, wherein the driving of the solenoid by the electronic circuit board withdraws the moveable shaft from the locking aperture to enable the crank to be moved, wherein rotation movement of the crank causes rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

[0021] Preferably the second portion of the outer casing is rotated manually to affect the rotation movement of the crank.

[0022] The locking core may further comprise one or more interface component provided on the base portion of the outer casing, the user interface component including one or more of a button and / or a visual indicator. In some forms the locking core may further comprise a frame, the frame configured to align and support the controlling device and locking mechanism adaptor within the shell portion.

[0023] Preferably the locking core may have a dormant mode and an active mode, the dormant mode configured to reserve the power of the internal power source such that power supply to the electronic circuit board from the internal power source is stopped or minimal, the active mode configured to enable power supply to the electronic circuit board from the internal power source. More preferably the locking core is triggered to move from the dormant mode to the active mode when the locking core receives an interaction. The interaction may include one or more of the following: (i) the electronic circuit board receives the electronic commands from the remote device and / or (ii) a user interacts with user interface component provided on the base portion of the outer casing, the user interface component being a button coupled to the electronic circuit board. The button may be configured to receive a predetermined pattern of interactions to provide a manual verification process to activate the electronic circuit board.

[0024] Preferably the dormant mode is the default mode.

[0025] Preferably the command is transmitted wirelessly to the locking core from the remote device. The remote device may be a computer or smartphone. In other forms the commands may be transmitted via a wired connection.

[0026] Preferably a lock may comprise a locking core inserted into the lock body. In some forms the lock is a padlock.

[0027] A further aspect of the invention comprises a system for unlocking a lock including: a locking core for insertion into a lock body, the locking core comprising: an outer casing comprising a shell portion configured to be received within the lock body and a base portion configured to extend from the lock body, the shell portion and base portion being sealingly coupled together, an electronic circuit board housed within the outer casing for receiving electronic commands from a remote device, an internal power source coupled to the electronic circuit board, an external power interface configured to couple to an external power source, a controlling device housed within the casing and configured to receive power from the internal power source, the electronic circuit board configured to activate on receipt of a command from the remote device and configured to drive the controlling device following verification of the command by the remote device, wherein the controlling device is configured to enable movement of a locking mechanism adaptor coupled to and extending from the shell portion of the outer casing to move a locking mechanism of the lock between a locked and an unlocked configuration; and wherein when an external power source is coupled to the external power interface the electronic circuit board is configured to receive power from the external power source for use to drive the controlling device.

[0028] In some forms the internal power source is a battery, preferably the battery is rechargeable.

[0029] In some forms when the external power source is coupled to the external power interface the electronic circuit board is configured to direct power from the external power source to recharge the battery. The electronic circuit board may be configured to control the power source for delivery of power to drive the controlling device.

[0030] In some embodiments the controlling device is a motor, the motor is coupled with the locking mechanism adaptor to cause rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

[0031] In an alternative embodiment the controlling device is a solenoid, the solenoid comprising a moveable shaft configured to be received in a locking aperture within a crank extending within the outer casing, the crank being coupled at a first end to the locking mechanism adaptor and coupled at a second end to the base portion of the outer casing, wherein the driving of the solenoid by the electronic circuit board withdraws the moveable shaft from the locking aperture to enable the crank to be moved, wherein rotation movement of the crank causes rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

[0032] In a preferred form the second portion of the outer casing is rotated manually to affect the rotation movement of the crank.

[0033] The system may further include one or more interface component provided on the base portion of the outer casing, the user interface component including one or more of a button and / or a visual indicator.

[0034] The locking core of the system may further comprise a frame, the frame configured to align the frame configured to support and align the controlling device and locking mechanism adaptor within the shell portion.

[0035] The locking core may have a dormant mode and an active mode, the dormant mode configured to reserve the power of the internal power source such that power supply to the electronic circuit board from the internal power source is stopped or minimal, the active mode configured to enable power supply to the electronic circuit board from the internal power source. The locking core may be triggered to move from the dormant mode to the active mode when the locking core receives an interaction. The interaction may include one or more of the following: (i) the electronic circuit board receives the electronic commands from the remote device and / or (ii) a user interacts with user interface component provided on the base portion of the outer casing, the user interface component being a button coupled to the electronic circuit board. In some forms the button may be configured to receive a predetermined pattern of interactions to provide a manual verification process to activate the electronic circuit board.

[0036] Preferably the dormant mode is the default mode.

[0037] In a preferred system the command is transmitted wirelessly to the locking core from the remote device. The remote device may be a computer or smartphone. In other forms the command may be transmitted by a wired connection.

[0038] In some forms the system may further include a lock which is fitted with the locking core. In some forms the lock is a padlock having a body that is fitted with the locking core. A lock may comprise a locking system as described.

[0039] A further aspect of the invention include a method of using a system including a locking core to unlock a lock, the method comprising the steps of activating the electronic circuit board within the locking core; locating and receiving a command from a remote device; verifying the command and activating the controlling device to receive power from the internal power source and / or an external power source if connected to move the locking mechanism adaptor coupled to move the locking mechanism of the lock to the unlocked configuration to release a latch of the lock.

[0040] Another aspect of the invention includes a method of upgrading a lock to include a locking core comprising the step of: removing a lock controlling component from a lock body of the lock; inserting a locking core such that the locking mechanism adaptor is engaged with a locking mechanism of the lock to facilitate movement of the lock mechanism by the locking mechanism adaptor when the controlling device is driven by the electronic circuit board in the locking core; securing the locking core to the lock body.

[0041] An aspect of the invention provides a lock insert or locking core configured to be inserted into a lock body.

[0042] The lock insert comprising an electronic locking component, an internal power source and an external power supply interface configured to enable connection to an external power source, in a first mode the internal power source configured to provide power to electronic locking component to unlock the lock, in a second mode an external power source is connected via the external power supply interface and is configured to provide power directly to the electronic locking component to unlock the lock. The first mode is the default phase when the internal power source is charged. The second mode may be used when the internal power charge is low, depleted or as an alternative to save the internal power source power.

[0043] In some forms the internal power source may be rechargeable. The external power source may be configured to recharge the internal power source.

[0044] In some forms the internal power source may be non-rechargeable, but user replaceable, such as a replaceable non-rechargeable primary cell battery. The external power source may be configured to directly power the lock in this case to avoid damage to the internal power reservoir or source. The external power source at least provides power to power the lock to provide access. In some forms the external power source may support simultaneously powering the lock and recharging the internal power source.

[0045] The external power source may include a connection port to receive a hard wired connection. The connection port may include any type of common connection port, for example, a Universal Serial Bus (USB) type connection port including USB-C port, micro-USB, lightning port or other such connection ports. Such connection ports may facilitate connection to numerous available portable devices including a portable battery or power bank, laptop, tablet, smartphone, mains power adaptor, 12V adaptor and similar power devices.

[0046] Another aspect of the invention provides a smart lock system comprising a replaceable lock insert.

[0047] In some forms the external power source may be configured to provide power wirelessly from a smart device, such as a smartphone. Any wireless technology that may provide power to another device may be used, including, but not limited to, NFC power harvesting and delivery, wireless charging from inductive coils (i.e. Qi compliant) and reverse (bilateral) wireless charging from smartphones as provided in many new smartphones.

[0048] Power may also be provided using an accessory power source such as via a power sleeve device that is designed to couple with a locking core within a padlock to provide a power source. The power sleeve comprises an embedded power source configured to deliver the power to the smart padlock. In some forms the power sleeve may be configured to couple to a smart padlock and provide rechargeable power to the smart padlock. The power sleeve may comprise embedded solar cells to provide a constant charging trickle to the locks internal power reservoir. In some forms the power sleeve may comprise an embedded receiver or coil for rapid reverse wireless charging from a user's smartphone or other wireless power device.

[0049] Preferably the lock system comprises a hybrid power management system such that at least two forms of external power source are configured to provide power to the lock. Preferably three or more. In other forms the invention comprises a power sleeve configured to engage with a lock and / or locking core to provide power to control the lock. Preferably the power sleeve includes a solar panel configured to provide continuous power supply to the lock and / or locking core.

[0050] A smart lock system comprising the locking core of the invention is designed to allow users with a range of power supply options to access a smart lock. The user may also access the smart lock system with any type of smartphone by enabling different power supplying systems to provide power from the smartphone to the lock. The power may be provided via Near-Field Communication (NFC), or other wireless power system (such as Qi standard) or via cable, such as a USB-C connection. The smart lock system comprising the locking core of the invention may use wireless communications including, but are not limited to, Bluetooth (BLE), Near-Field Communication (NFC), Low Power Wide Area (LPWA), Ultra- wideband (UWB) and Wi-Fi to communicate with a smart device such as a smartphone.

[0051] This approach means that the smart padlock system can support virtually any smartphone make or model on the market, and provide users with a significant degree of flexibility when it comes to the power supply required for a particular unlock. Thus, reducing time wasted in failed attempts at accessing locks.

[0052] BRIEF DESCRIPTION OF DRAWINGS

[0053] One or more embodiments of the invention will be described by way of example only, and without intending to be limiting, with reference to the accompanying drawings, in which: is an exemplary smart padlock comprising a locking core according to an embodiment of the invention; is an exploded view of the padlock of Figure 1A; is a cross-sectional view of the padlock of Figure 1A; are views of an exemplary locking core as seen in figures 1A-1C; is a cross-sectional view of the exemplary locking core according to an embodiment of the invention;

[0054] Figure 3B is an exploded view of an exemplary locking core of Figure 3A;

[0055] Figures 4A to 4G are views of internal components of the locking core according to Figure 3A and

[0056] 3B; is an exemplary main PCB for a locking core according to an embodiment of the invention; is an exemplary view of a switch PCB according to an embodiment of the invention; illustrates exemplary external power supply options for use with the locking core; is a flowchart of a power management system for a locking core according to an aspect of the invention; igure 9 is a diagram of a communication system for a locking core power system according to an aspect of the invention; is a diagram showing the operation of a smart padlock containing a locking core of the invention;

[0057] Figure 11 illustrates the process for installation of a locking core into a padlock body according to an aspect of the invention.

[0058] Figure 12 is an exploded view of an exemplary locking core according to another embodiment of the invention; igure 13 is a sectional view of the exemplary locking core according to Figure 12; igures 14A to 14C are views of internal components of the locking core according to Figure 12 and

[0059] Figure 15 show sectional views of an outer casing of the locking core of Figure 12;

[0060] Figure 16 shows views of a crank of the locking core of Figure 12;

[0061] Figure 17 shows views of the frame of the locking core of Figure 12; igure 18 is an exploded view of the power sleeve applied to a padlock;

[0062] Figures 19A to 19G are external views of an exemplary power sleeve according the invention; igures 20A to 20D are views of the internal components of the power sleeve of Figures 19A to 19G;

[0063] Figure 21 shows different views of an exemplary PCB board for the power sleeve according to Figures 19A to 20D;

[0064] Figure 22 are views of an exemplary Qireless (Qi) coil for use in a power sleeve according to the invention; are views of an exemplary solar panel for use in a power sleeve according to the invention; and igure 24A & 24B shows the interaction of a power sleeve internal connector with an external power connector in a lock according to an exemplary embodiment.

[0065] DESCRIPTION OF PREFERRED EMBODIMENTS

[0066] Throughout the Figures, like references refer to like components.

[0067] A locking core of the invention is configured to provide the lock control and / or operational functions to a lock to which it is coupled. The locking core is configured to at least control an unlock function of a lock. The locking core is configured to engage with a moving element of a locking mechanism in a lock to control the movement required to unlock the locking mechanism of the lock. The locking mechanism further provides smart electronic components to enable the lock to be remotely controlled and monitored via the locking core. The locking core may be used to upgrade a lock to a smart lock or may be used as a replaceable sub-component for a lock.

[0068] A locking core 200 and components thereof will be described with reference to Figures 1-6. Figures 1A and IB show a lock in the form of a padlock 10 having an outer casing or lock body 100 into which a locking core 200 is inserted at the base and a shackle 120 is attached at the top. At least a portion of the locking core 200 is received within the lock body 100, preferably a portion of the locking core 200 extends below the lock body 100 to provide additional user interface functionality. The lock body 100 is generally formed of a hard material such as metal case formed of any suitable metal alloy such as steel, stainless steel or brass. However the lock or padlock may be made of other materials such as plastics. The locking core 200 comprises the internal components to control the locking function of the padlock 10.

[0069] The locking core 200 has an outer shell 220 coupled with a base 270 (also referred to as a core endcap) that together form a protective casing for the internal components of the locking core 200. Providing protection from environmental exposure such as wind, rain, dust, vandalism etc. In some forms the outer shell 220 is inserted and secured within the lock body 100 and at least a portion of the base 270 extends below and couples to the bottom portion of the lock body 100. Preferably the base 270 engages with the bottom surface of the lock body 100 such that the entire base 270 extends from the bottom surface of the lock body as shown. The outer shell 220 is inaccessible once installed within the lock body 100.

[0070] The outer shell 220 and base 270 are preferably formed of a solid material, and more preferably of a metal alloy such as brass, aluminium, steels. Although in some forms the outer casing may be formed of a plastic material. The outer shell 220 and base 270 may be manufactured using different processes including casting, milling, forging, machining, Computer Numerical Control (CNC) machining and 3D printing methods such as Fused Deposition Modeling (FDM) and Stereolithography (SLA). In some forms a wide range of finishing treatments may be applied to the outer shell 220 and base 270 to enhance appearance, resilience and durability. Such finishing treatments may have a direct influence on corrosion resistance, strength, surface roughness and aesthetics of the outer shell 220 and base 270.

[0071] The base 270 is exposed on the external surface of the padlock 10 in use and therefore may be exposed to environmental conditions depending on where the padlock 10 is used. The bottom surface of the base 270 may include openings configured to receive user interface components such as a button 280 and / or visual indicator such as an LED diffuser 214, and one or more External Power connectors 215. The base

[0072] 270 preferably has an external profile configured to match the external profile of the padlock body 100. The base 270 may be coupled to the outer shell 220 using anytype of fastening system, including fasteners

[0073] 271 such as screws, rivets or clips or using an adhesive or other common fastening systems. In the illustrated form (see Figures 2A and 2C) the base 270 is coupled to the outer shell 220 using screws 271 that may be inserted through a top face of the base 270. In this form, when the assembled locking core 200 is installed in a padlock 10, the screws 271 are inaccessible without removal from the padlock 10.

[0074] Figures 2A to 2E show external views of an exemplary assembled locking core 200 with the outer shell 220 and base 270 coupled together. An aperture 221 is provide in the top surface of the outer shell 220, a lock mechanism adaptor 290, shown as a cam adaptor 290. A further threaded aperture 222 may be provide in the top surface of the outer shell 220 configured to accept a fastener (not shown) for securing the assembled locking core 200 into the lock 10 in use.

[0075] In a preferred embodiment the locking core 200 is configured as a self-contained smart unit to enable remote or smart control functionality to a lock into which it is inserted. The locking core 200 may be configured to fit within an appropriate part of a lock body to enable smart lock capability. In some forms the locking core 200 may be configured to replace the mechanical key componentry of a lock such as a cylinder cavity for a padlock, as described in more detail below, or some other type of fixture on other locks and structures. The shape and size of the locking core outer shell may be designed to fit the appropriate part of the lock or structure.

[0076] In preferred aspects the locking core 200 uses electro-mechanical components to rotate an appropriate moving element of a locking mechanism of a lock or structure. Preferably the rotation control is enabled by a switch printed circuit board (PCB) 244 that is coupled to the locking mechanism of the lock. The rotation of the electro-mechanical components is transferred to the moving element of the locking mechanism of the lock or structure to perform the unlocking, locking and any other such supported actions. The electro-mechanical components of the locking core 200 may include a controlling device such as a motor 240 coupled to a lock mechanism adaptor 290, an internal power reservoir 213 and main PCB 250 that provides the drivers and / or controllers 252 for the motor 240, power 251, lock controller 255, remote communication 253 and 216 and optionally user interface functionality through switch 281 and LED 282.

[0077] In an exemplary embodiment the invention is described with reference to a padlock 10, wherein a keyed cylinder of a padlock is replaced with a locking core 200 to provide smart and remote functionality to the padlock 10. However, the locking core 200 of the invention should not be considered to be limited to use with a padlock, it may be used for other types of locks, such as cabinet locks or other common asset protecting lock structures.

[0078] The internal components of a locking core 200 according to an embodiment will be described with reference to Figures 3A to 6. Figure 3A shows a cross-sectional view and Figure 3B shows an exploded view of the locking core 200 according to an embodiment. As shown the outer shell 220 is coupled to the base 270 to form a protective outer casing for the locking core 200. Figures 4A to 4G show the assembled internal components of the locking core 200 with the outer shell 220 and base 270 removed. The base 270 may comprise an internal power reservoir 213 and a main PCB 250. The main PCB 250 may include a button switch 281 and LED 282 that are coupled with the user interface components provided on the bottom surface of the base 270, such as the button 280 and LED diffuser 214. The main PCB 250 may also comprise one or more External Power connector 215 that is exposed on the bottom surface of the base 270. The main PCB 250 may further include a lock controller 255, motor driver 252, power controller 251 and remote communication components 253 and 216, described in more detail below.

[0079] The base 270 may include a seal 272 to facilitate an environmental and / or water tight seal with the outer shell 220 when assembled. A seal 223 may similarly be provided to seal aperture 221 in the top of the outer shell 220 in use. The outer shell 220 comprises the locking mechanism control elements that act on the lock 10 in use and is configured and shaped to fit within an internal portion of a lock body 100 and facilitate engagement with the locking mechanism to enable smart lock capability. The outer shell 220 may comprise a frame 230, a motor 240, a switch PCB 244 and locking mechanism adaptor (or cam adaptor) 290.

[0080] The frame 230 forms an internal structure for locating and assembling of the components within the outer shell 220. The frame 230 may include one or more legs to assist in the positioning and alignment of the frame 230 in use. However, it will be appreciated that the configuration of the frame 230 may vary depending on the lock into which the locking core is being inserted into. The frame 230 is configured to align the motor 240 and switch PCB 244 in the required locations to facilitate interaction with the locking mechanism (not shown) of the lock 10. A cavity 232 may be formed in the frame 230 to hold the switch PCB 244. The switch PCB 244 is coupled to the main PCB 250 via an electrical connector 246 that is configured to receive one end of a ribbon cable (not shown). Figures 5A to 5E illustrate an exemplary main PCB 250 of a locking core 200. As indicated by the dashed line circled components in Figure 5A a first side of the main PCB 250 may include power controller components 251, motor drive components 252 and remote communication components 253. The main PCB also includes a lock controller 255 and switch PCB electrical connector 256, adapted to receive a cable such as a ribbon cable to facilitate communication with the switch PCB 244 via an electrical connector 246 on the switch PCB 244 as shown in Figure 6A. The switch PCB electrical connector 246 is configured to receive the opposite end of the cable or ribbon cable (not shown) to facilitate communicative control for the switch PCB 244. The switch PCB, see figures 6A and 6B, may comprise a two layer board with a dual pole dual throw Switch 245 provided on top and switch PCB electrical connector 246 on the bottom. The switch PCB is inserted into the cavity 232 of the frame 230 after first feeding through the ribbon cable (not shown) that connects the switch PCB 244 to the Main PCB 250.

[0081] The opposing second side of the main PCB 250 may comprise the user interface components such as a button switch 281, a visual indicator such as an LED 282, an external power connector 215, and an Antenna 216 that is part of the remote communication system 253. The external power connector 215 is configured to allow the Lock 10 to be powered externally either permanently or temporarily (via a hard wired connection). Preferably the external power connector 215 is a ruggedised and IP rated connection port 215, such as a USB-C port, micro-USB port or similar type of power connection port that supports a range of portable devices that deliver power via a cable, such as a standard USB-C cable. In some forms the external power connector is a receptacle following USB-C standards to facilitate a wide variety of external power supplies to be connected to the lock from range of devices (see for example Figure 7). For example power banks 740, wall plug power supplies 750 such as mobile phone chargers, 12V car chargers 760, a dedicated power pack 770, computers 710, mobile phones 720, and tablets 730 via their USB ports. The external power connector 215 may be used to recharge the internal power reservoir 213 and / or to provide a "Boost" of power if the internal reservoir 213 is fully discharged and unable to run. In some forms the external power supply device may also simultaneously recharge the internal power reservoir 213.

[0082] In some forms the main PCB 250 of the locking core 200 includes an internal charge control circuit for controlling the internal power reservoir 213. The control circuit may be configured to determine if the internal power reservoir 213 needs to be charged when an external power supply is attached. If an external power supply is attached, the charge control circuit may determine the power routing within the locking core 200.

[0083] To assemble the locking core 200, the locking mechanism components are assembled within the outer shell 220 and the base or core endcap 270. The motor 240 that may or may not have an attached gearbox for driving the moving parts. The motor 240 and gearbox specifications may vary as they may be application specific depending on the lock. In one exemplary form the motor 240 may provide 20,000 rpm that is sent through a 7 stage 1,000:1 reduction gearbox. For example, the motor 240 may be an N20 sized 3V DC motor with a reduction gearbox attached. In this form the motor size is a flat sided circle 12mm diameter by 10mm. The gearbox uses circular plates to fit inside of the outer shell 220. It is to be understood that other motors and motor configurations may be used depending on the desired lock application.

[0084] The motor 240 is coupled to the motor driver components 252 on the main PCB 250 to ensure the required electrical specifications are met. The main PCB 250 is then electrically coupled to the switch PCB 244. This motor and switch PCB sub-assembly may be attached to or inserted in the frame 230 of the locking core 200. In some form the motor and switch PCB sub-assembly may be attached by methods such as screws, adhesives, pins and rails or other such fixing means. The internal reservoir or battery 213 is also coupled to the main PCB 250. The combined internal reservoir or battery 213 and main PCB 250 unit together with a button 280 and LED diffuser 214, are fastened to the base or endcap 270 using suitable methods such as adhesives, screws, pins or the like. The outer shell 220 and base or endcap 270 subs-assemblies are then coupled together to form the locking core 200.

[0085] Extra weatherproofing may be added by utilising items and techniques such as O-rings, PCB Potting, gaskets and adhesives or the like. Waterproofing may be provided around the base or end cap 270 and the outer shell 220 or around other exposed components such as the external power connector 215 (USB- C port).

[0086] In some aspect the button 280 may be used to wake up the lock by a user from a sleep or dormant low power state. The button 280 may include, but is not limited to, being a mechanical switch or button, or an electronic detector such as capacitive sensor. In some forms the button 280 may also be configured to be pressed in a specific combination to facilitate unlocking of the padlock in the absence of a specific unlock signal or electronic code from a remote device. Thus acting as an override or backup tap code interface to unlock without remote device. In some cases, users may be issued with a unique code to manually open the lock by entering a sequence of short & long presses.

[0087] To control the locking mechanism (or actuator) of a lock 10 a core locking mechanism is configured to act on and control the locking mechanism (not shown) of the lock 10 in use. The core locking mechanism includes the cam adaptor 290, internal battery 213 and motor 240, which are coupled to motor drive components 252 on the main PCB 250. The motor 240 is coupled to the cam adaptor 290 to facilitate rotation with the motor 240. The locking mechanism adaptor or cam adaptor 290 is configured to transfer the motion of the motor 240 to the locking mechanism of the lock. The adaptor cam 290 is made of a solid material to ensure it can transfer the required torque to the locking mechanism. Such material may include steel, stainless steel, brass, aluminium alloys and some plastics. The cam adaptor 290 preferably has a smooth surface to facilitate ease of slotting in and out of locking mechanism.

[0088] The cam adaptor 290 transfers the rotation of the motor 240 to the internal lock mechanism of the lock or padlock 10 and interacts with the switch PCB to provide feedback to the lock Controller 255. In some forms the cam adaptor 290 includes a bar configured to slot into the internal lock mechanism of the lock or padlock 10 in use. A locating feature may be dictated by the amount of rotation needed to activate the locking mechanism of the lock.

[0089] In some aspects the cam adaptor 290 is configured to engage with a cam shaft of a cam and ball bearing lock mechanism in a lock or to a similar lock mechanism within the lock body 100. The cam adaptor 290 or similar lock mechanism adaptor may act directly or indirectly on the locking mechanism to act on the shackle 120 to lock and unlock the shackle 120 as required.

[0090] Preferably the internal battery 213 is configured to hold sufficient electrical charge to power the locking mechanism of the padlock 10 with no external input required for a minimum period of time. For example, the internal battery 213 may be a rechargeable battery, a non-rechargeable primary cell battery, or a capacitor or any other known small power source. In one form the internal battery 213 is a 3.7V, 200mAh capacity, Li-Ion chemistry rechargeable battery.

[0091] The locking core 200 is configured to be inserted into the base of the outer body 100 of a lock such as a padlock 10. The locking core 200 may be incorporated into a lock body 100 at the time of manufacture or be inserted at a later time. The locking core 200 may also be used to replace the locking system of an existing lock or padlock 10. As seen in figure 11 a locking body 100 may have a smart locking core 200 inserted into the locking body 100 as shown. In some cases the locking body 100 may have an old lock mechanism removed and replaced with a locking core 200. The locking core 200 may be secured to the outer casing or body 100 of the padlock via a screw or other fastening means. Preferably the locking core 200 is removably inserted within an outer body 100 to allow replacement of the locking core if required for maintenance or to upgrade the lock to a smart lock.

[0092] In some aspects the locking core 200 comprises a outer shell 220, preferably a weatherproof outer shell 220, to hold, protect, align and position the electricals within the locking core 200. The outer shell 220 is made of a suitable material and is shaped to fit matching profiles on the internal of lock body 100 while having any profiles needed for receiving the electricals. The outer shell 220 may have provision for utilising the attachment methods commonly used by the lock's mechanical key cylinder uses. There may be a range of different outer shell configurations to match with different locks and / or padlocks outer body 100 configurations. The base or core endcap 270 forms part of the weatherproof casing for the locking core 200 and may be configured to assist with holding, protecting, aligning and positioning the electricals within the locking core 200. The base or core endcap 270 may be made of a suitable material and is shaped to fit matching profiles on the internal of lock body 100.

[0093] The base of the locking core 200 may comprise an external power interface or power port 215, such as a USB-C port to allow connection to an external device to provide power to the lock and / or to recharge the internal power reservoir or battery 213. The button 280 and visual indicator's LED diffuser 214 are also located on the base of the locking body 200. It is to be understood that the positions of the components may be varied. It is also to be understood that the actuator may include a different mechanism such as a solenoid to activate a locking mechanism instead of a motor and cam arrangement.

[0094] In some forms the locking core 200 is configured to provide wireless communication. The wireless communications may be used to provide signals to the lock controller 255 for operations and to perform functions such as, but not limited to; unlocking and locking. Examples of wireless communications include, but are not limited to; Bluetooth (BLE), Near-Field Communication (NFC), Low Power Wide Area (LPWA), Ultra-wideband (UWB) and Wi-Fi.

[0095] The controller includes a communication component configured to send and receive information such as status and lock access information to a remote device such as a server, computer or control centre. The controller may communicate via a portable device such as a smartphone or other suitable electronic device. Preferably the controller will have the ability to report the level of charge of the internal reservoir or battery 213 of the lock 10. The controller 255 may also be configured to detect and report when an external power source has been connected. The two way communication allows the lock to send data back to the remote device, for example battery status, detection of errors, access to the lock, locked status, access time and other such data.

[0096] An example operation of the locking core being inserted into a keyed mechanical padlock (referred to as keyed padlock) to upgrade the padlock to a smart padlock will be described. Firstly the lock mechanism of the keyed padlock will be described, the lock mechanism involves manipulation of a key inside a double cylinder to unlock the padlock. The distal end of the cylinder may have an arm, or bar, that interacts with a specially profiled cam. The cam is spring loaded and acts on two bearing balls that release or hold the shackle of the keyed padlock by interacting with notches cut into the shackle. In this example if the keyed padlock is closed, the ball bearings are pressed into the shackle notches by the cam. Unlocking the keyed padlock using the key rotates the cam such that indents on the cam are lined up with the bearing balls, giving the ball bearings freedom to move. A spring beneath the shackle will pop the shackle up once sufficient clearance from the bearing balls has been achieved. To relock the keyed padlock, a user rotates the key back to the locked position then pushes the shackle back into the lock and the shackle interaction with the bearing balls will trip the cam, such that the cam's spring rotates it back to a locked position. To allow installation of the locking core into the locked body of the keyed padlock initially requires unlocking the keyed padlock using the key. The cylinder is removed from the lock body of the keyed padlock, for example by unscrewing the cylinder from the lock body. Generally such screws are accessible once the shackle of the keyed padlock is released. The cylinder is removed or slid out of the lock body of the keyed padlock. The locking core 200 may then be inserted or slid in to replace the cylinder and secured using the same or a replacement screw.

[0097] Once the locking core 200 is installed, a remote command is received by the lock controller 255 to perform a decryption and / or authorisation process to check validity. If the command is invalid, the Lock Controller will send an error message through the remote connection and may also light up the LED 282 on the main PCB 250 as a visual indication to the user. If the command is valid, the Lock Controller may initiate the requested unlock function. To unlock the upgraded smart padlock power is sent to the Motor 240 of the appropriate voltage and polarity to rotate the motor 240 in the required direction. Subject on required power levels, dedicated Motor Driver componentry may be needed to provide sufficient current and voltage to the motor. The speed of the motor crank rotation may be controlled by the Lock Controller within a range that is determined by the gearbox (if any) attached to the Motor 240. This may be achieved by changing electric current and / or voltage levels, such as using Pulse Width Modulation (PWM) techniques.

[0098] The cam adapter 290 is coupled to the shaft of the motor 240 via a receptacle shaped to securely receive the motor shaft. This receptacle is shaped and sized to fit the selected motor 240. The cam adaptor 290 comprises features configured to interact with a switch located on the Switch PCB 244 that is connected to the Main PCB 250 via a ribbon cable. The actuation of the switches allows the Lock Controller 255 to identify the rotational position of the Cam Adaptor 290 in use. The lock controller 255 may then send a signal to stop or drive the motor in appropriate direction as required to complete the requested action. In an alternative arrangement the cam adaptor positioning may be detected using other methods such as encoders mounted to motors, using Servo-motors or photosensitive electronics and features.

[0099] In this embodiment the Cam Adaptor 290 is designed to slide onto the shaft of the motor 240 easily with no fastening method. In other applications the Cam Adaptor 290 may be permanently or removably fastened using adhesives, screws or pins.

[0100] For some keyed padlocks it may be possible to support Unlock and Shackle remove operations using the locking core 200. The locking core 200 being able to perform this using an appropriately configured Cam Adaptor 290. In one form the cam adaptor 290 has an arm, or bar 292 (as seen in Figure 4A) of a configured profile and size to interact with the spring loaded cam inside of the keyed padlock. As the Lock Controller 255 drives the motor to move the cam adaptor 290 the cam within the keyed padlock is rotated.

[0101] Once the requested unlock operation is completed, this being determined by the Lock Controller due to position sensing, the Lock Controller may send a status message via the remote communications channel and may also light up the LED 282 on the Main PCB 250. The LED 282 may be lit in different colours and patterns or pulses to indicate the completed request.

[0102] Once the user has received feedback of the completed action, such as an unlock event, they may pull on the shackle to release it from the lock body. In some forms the shackle may have popped out of the Lock Body due to the lock's spring.

[0103] After a preset period of time, in some forms the preset time may be configurable by the user, the Lock Controller 255 may trigger an arming procedure that will rotate the Cam Adaptor 290 back to its starting position. This may allow for the upgraded keyed lock relock mechanism to function when it is triggered by shackle insertion. When the user decided to lock the padlock they may push the Shackle back into the Lock Body to trigger the relocking mechanism of the keyed padlock. The relock mechanism may be free to function as long as the user has waited the required preset period of time for the Lock Component to arm. If before the preset period of time, the shackle may not lock and pop up. The user may retry to insert the shackle into the padlock after the preset period of time have expired.

[0104] Once the user has locked the padlock they may shutdown or disconnect any devices used for remote communication, and / or remove any connected accessories (such as and external power supply) and leave the padlock in a secure state.

[0105] If at any point there is an error, such as invalid command, motor failure or blockage of the mechanism, the Lock Controller may use the switch to determine position of the Cam adaptor 290 and try to reverse direction or simply stop applying power as required. Suitable error messages may be sent via the remote communication channels, and optionally also via the LED 282 on the main PCB 250 for example by flashing in certain patterns and colours. Several error management and correction steps may be added to the Lock Controller programming to aid resolution.

[0106] Figure 8 shows a schematic of a power management system for a smart lock system with a locking core 200 according to the invention. The power management system is adapted to receive power from a range of different external devices as a power source. The different external devices may use a range of different external interfaces to deliver the power including hard wired connections and wireless power connection options. As seen in Fig. 8 the lock controller 255, internal reservoir 213 and lock operations are all aspects that occur within the locking core 200 of the lock. The locking core 200 includes an internal power source 213 or reservoir configured to provide power to the locking mechanism of the lock. If the internal reservoir 213 is discharged then the controller is configured to receive power from an external device if connected to provide the lock operations 850 and / or to recharge the internal reservoir 845.

[0107] When an external power source (810, 812 or 814) is connected through one of the external power interfaces 215 available on the locking core (e.g. the inbuilt USB-C port) 820. The power management system shown in Fig. 8 is configured to detect the presence of a connecter external power supply 830. If present the signal is sent to the power protection circuitry 832 to ensure that all lock functions are correctly powered and may also be configured to check the power level of the internal power reservoir 834 and if required divert power to charge the internal power reservoir 845 using the charge control circuit 836. If no external power supply is detected the controller will be configured to discharge power from the internal power reservoir 840. This is achieved through dedicated circuitry on the main PCB 250 to ensure that power, volt and / or ampere limits aren't exceeded.

[0108] During operation of the locking core the electrical power that may being used by locking core is preferably controlled by the power management system on the main PCB independent of what lock / unlock operations may be being performed as outline in Figure 8.

[0109] Figures 9 and 10 are exemplary operational flow charts showing operation flows for the lock system comprising a locking core 200 when activated by a user according to an embodiment. These are example operations flows and it will be appreciated that other operational flows may be used or some steps may be changed, replaced, reordered or removed. A user needs to be running an authorised remote device with specific application (such as the Applicant's LockVue™ App) to communicate with the locking core 200. The application will be authenticated by a remote software platform before access will be granted to the lock core 200.

[0110] As illustrated in Figure 9, in a first step 910, to open the lock 10, the user may engage with the lock 10 by pressing the button 280 on bottom of the locking core 200 and embedded in the base 270. The locking core 200 may be initially activated by pressing the button 280 on bottom of the locking core 200 and embedded in the base 270. This will result in the lock being woken up from a low power mode to an access mode in step 915 where the controller enables or awaits wired or wireless communication, such as Bluetooth™, for connection from a remote device. A timer is triggered by the controller in step 920 to preserve the power supply and may be configured to provide the access mode for a predetermined period of time, such as 30 seconds. If no remote device is detected by the controller within the predetermined time period the controller will switch the locking core back to the low power mode (dormant mode) in step 925. If the controller does receive a signal from the remote device within the predetermined time period then the controller awaits a command to be sent in step 930 and once a command is received from the device in step 935 the system will conduct a verification step 840 to determine the command and user validity. The verification system may include an encryption subsystem step 945, such that valid unlocking commands may be protected and verified by the firmware running on the main PCB 250 using encryption protocols such as AES. If the verification step determined the command is valid the controller will proceed to perform the required action and send an update to the remote device in step 950. Alternatively, if the verification step determines the command is invalid an error message may be sent to the remote device and the controller may disconnect from the remote device in step 955.

[0111] As illustrated in Figure 10, a user may first access a mobile application to enable remote communication with the locking core and provide an audit log of the actions performed by the user 1010. The user may select the method of interacting with the locking core 1020. A button on the locking core may be pressed to wake up the locking core 1030 or a button pressing code may be utilised 1035. The user may alternatively select the desired locking core using the App 1040 and use wireless communication such as Bluetooth™ to communicate with the locking core to unlock the lock.

[0112] Alternatively the use may use a wired connection to communicate with the locking core to unlock the lock. An authorisation check is performed 1050 to ensure the user logged into the App is authorised to access the locking core. Generally, a user will use a remote device such as a mobile phone and / or computer app (for example the Applicants LockVue™ app) to be securely authenticated, or logged in 1050, and enable secure communication with the lock controller over wired or wireless systems to ensure only authorised personnel can interact with the locking core. If no authorisation is provided an error message will be sent to the user 1025 via the App and optionally indicated on the locking core. If the user is authorised to access the locking core then the locking core will be unlocked 1060. The lock controller will activate the motor via the lock control circuit 1070. The motor will be triggered to rotate in the appropriate rotational direction causing the cam adaptor coupled to the lock mechanism cam of the lock to rotate to perform the unlock function 1080. Once unlocked the locking core sends a wireless communication to the App that the lock has been unlocked 1090.

[0113] If any of these actions waking up of the electronics on the main PCB board 250 from a low power state to an access state may be indicated by a visual indicator 282, such as an LED lighting up on the main PCB 250. Other indicators may include a sound instead of a light. Furthermore, if the lock was in an unlocked state the PCB 250 will trigger a locking function before the user can interact further.

[0114] Upon receipt of a valid unlocking request from the mobile application running on the remote device, the PCB 250 will trigger the motor 240 to lock or unlock the lock. The motor 240 acts via the attached gearbox on the lock cam 111 inside the locking core. It does this through an adaptor Cam 290 that facilitates the "plug and play" nature of installing the core unit into a padlock outer body 100. When the motor 240 acts via the adapting core cam 290 on the lock cam 111 it releases pressure on the bearing balls 112 freeing the shackle 120 to move. In the locked state the lock cam 111 is putting pressure on the bearing balls 112 forcing them into the notches on the shackle 120 and thereby preventing release of the shackle 120.

[0115] The main board PCB 250 is able to detect presence of the adapting core cam 290 and uses stored memory of activity to determine if it is in an open or locked position. Once the main PCB 250 determines that the lock is in the open state, it will send a notification to the remote device while simultaneously triggering the visual indicator 282 on the main PCB 250. In the event of a fault or problem, the main PCB 250 will send an update to the remote device and also trigger the visual indicator 282 on the main PCB 250. The visual indicator 282 may provide different visual signals to indicate different states, faults or functions.

[0116] When a user gets confirmation on an unlock state they can pull on the shackle 120 to release it or the shackle may automatically spring release. This unlocking action will push the bearing balls 212 deeper into the lock towards the lock cam 211 body as the notches in the shackle move past them.

[0117] After a predetermined period of time, such as a few seconds e.g. 1 to 10 seconds, 5 second or longer, the main PCB 250 will trigger the motor 240 to lock, and once it has determined this is complete will update the remote device, the visual indicator 282 on main PCB 250 may be activated and begin to initiate disconnection from the remote device.

[0118] When a user wishes to re-lock the lock, moving to a locked state, they may push or insert the shackle 120 back into the lock body 100. A spring return feature of the lock cam will rotate it back into a locked position.

[0119] Manual embodiment

[0120] In an alternative embodiment of the locking core 400 is illustrated in Figures 12 to 17. Many of the components in this locking core 400 embodiment are the same as described in the above locking core 200 embodiment as indicated by the use of the same item numbering. Such components will not be described in detail again as they have substantially the same features and functions as described above. In this locking core 400 the electronic components are configured to release a rotating member to enable manual manipulation by the user to directly unlock the lock or padlock.

[0121] Operation of the locking core 400 uses electro-mechanical components to release a "latching" component from a crank 494. This internal unlatching then allows the user to manually rotate the crank 494 to effect unlocking and / or locking. The rotation of the crank 494, which is coupled via the cam adaptor 490 to the locking mechanism of the lock or structure, facilitates the action to perform the unlocking, locking and any other actions supported.

[0122] The locking core 400 according to an embodiment comprises an outer shell 420 coupled to a base 270 in a similar manner as described. However, the outer shell 420 may have a different form to fit the components of the locking core 400. The outer shell 420 is configured to receive a frame 430, the shaft 497 of the crank 494, the lock mechanism adaptor or cam adaptor 490 and a controlling device such as a solenoid 445. The configuration of the outer shell 420 may vary as it is adapted to fit the internal space of a lock body in a lock into which the locking core 400 is inserted.

[0123] Furthermore a main PCB 250 is configured to provide the lock controller, remote communication and user interface functions as described above. Similarly the base preferably comprises an internal power reservoir 213, a button 280 and visual indicator such as a LED diffuser 214 accessible on the base 270. One or more external power connectors 215 may also be provided on the base 270

[0124] In one embodiment the locking core 400 comprises a solenoid 445 instead of a motor and consequently the main PCB 250 includes a driver for the solenoid 445 in place of the motor driver. The solenoid 445 may be any commercially available solenoid that will perform the required function and fit within the locking core 400, in one form the solenoid is a 3V DC solenoid. The solenoid 445 may be housed by the frame 430 to ensure the correct positioning within the outer shell 420. The solenoid 445 comprises a shaft 446 that acts as the latching component that is configured to be received within an aperture 496 provided in the crank 494. The aperture 496 is preferably located in the crank base 495. When the shaft 446 of the solenoid 445 is inserted into the aperture 496 the crank 494 is prevented from being rotated. The crank 494 comprises a crank base 495 with a shaft 497 extending therefrom. The shaft 497 of the crank 494 is configured to be received within a portion of the frame 430. Protrusions 498 may be provided on the tip of the shaft 497 that are configured to engage with the frame 430 to retain the crank 494 within the locking core 400 and to prevent removal of the crank 494 in use. In some forms the protrusions 498 may interact with pins or screws inserted through openings in the outer shell 420 to prevent over rotation, such as rotation that may allow crank 494 removal.

[0125] The frame 430 is configured to receive and align the solenoid 445 and the crank shaft 497. The frame 430 may also comprises a channel 435 configured to receive the protrusions 498 on the tip of the crank shaft 497. The frame 430 is configured to receive the crank shaft 497 and solenoid 446 and includes an aperture 432 to allow the solenoid shaft to extend therethrough to engage with the aperture 496 in the crank base 495. The frame 430 may have different configurations to receive cranks 494 of different configurations. The tip of the crank shaft 497 is configured to couple with a locking mechanism adaptor or cam adaptor 490 that is configured to engage with a moving element of a locking mechanism of a lock (not shown) in use as described above. The cam adaptor 490 is configured to transfer the motion of the crank 494 to the moving element of the locking mechanism of the lock into which the locking core 400 is inserted. In some forms the crank 494 and the cam adaptor 490 may be integrally formed, in other forms the crank 494 and cam adaptor 490 are formed as two components configured to couple together to transfer the rotation of the crank 494 to the moving element of the locking mechanism of the lock in use.

[0126] The crank 494 is preferably formed of a solid material, the solid material having the strength to transfer a required torque to move the locking mechanism of the lock into which the locking core 400 is inserted. The crank may be made of a metal alloy such as steel, stainless steel, brass, or a plastic.

[0127] In operation the crank 494 is latched by the shaft 446 of the solenoid 445 being locked within the aperture 496 in the crank base 495. When the solenoid shaft 446 is removed from the aperture 496, unlatching the crank 494, the crank 494 is free to rotate within a predefined range of motion. The predefined range of motion may be defined by the channel 435 in the frame 430 that receive the protrusions 498. When the crank 494 is unlatched, rotation of the base 270 is enabled. The rotation of the base 270 causes rotation of the crank 494 which then transfers rotation to the Cam Adaptor 490 to rotate a moving element of the locking mechanism coupled thereto. The cam adaptor 490 is configured to engage with the applicable moving element of the locking mechanism in the lock into which the locking core is inserted.

[0128] The shaft tip of the Crank 494 has features that sit in the channel or slot in the Frame to prevent removal. These features interact with pins or screws inserted through openings in the Shell to prevent over rotation, and / or rotation to the removal position.

[0129] The installation of the locking core 400 into a lock such as a padlock requires initial removal of the locking operational component such as the cylinder of a keyed padlock as described above. The locking core 400 is then inserted to replace the removed operational component or cylinder and secured in place as described using a screw or other fastener.

[0130] Once the locking core 400 is installed within the lock a remote command may be received by the lock Controller via an App as described above. Decryption and / or authorisation processes to check validity of the user may also be completed as described above. Such that similarly if the command is invalid, the Lock Controller will send an error message through the remote connection and may also light up an LED on the PCB that may be seen by the user. If the command is valid, the Lock Controller will initiate the requested unlock.

[0131] To unlock the lock comprising the locking core 400 power is sent to the solenoid 445 of appropriate voltage, and if necessary, polarity. Depending on required power levels dedicated Driver componentry may be required on the main PCB 250 to provide sufficient current and voltage to the Solenoid 445. In alternative aspects the solenoid 445 may be replaced with a motor, servo-motor or linear actuator.

[0132] The Lock Controller 255 may send a message and feedback via the Remote Communications 253 and 216 to the App and / or user Interface to signal that it has triggered the solenoid 445. Once power is applied to the solenoid 445, the shaft 446 of the Solenoid 446 is pulled out of the aperture 496 in the crank 494 and into the body of the solenoid 445. This frees the crank 494 to allow rotation.

[0133] Power to the solenoid 445 may be held for as long as desired, ensuring that the user has enough time to perform the unlock. The default position of the solenoid 446 preferably has the solenoid shaft extended through the aperture of the frame 432 and into the aperture 496 of the crank 494.

[0134] In some forms the position of the solenoid 445 may be sensed by the Lock Controller using various methods. A switch may be used to sense when the Solenoid 445 is in the "home" or locked position. The switch may be triggered if the crank 494 has been returned to locked position and power on the solenoid 445 is released. Thus the Lock Controller will be notified that the solenoid power was successful if the switch is released.

[0135] The Cam Adaptor 490 may interact with a lock cam inside of the lock or padlock into which the locking core 400 is inserted to interact with the Crank 494. The lock cam is rotated by the motion of the crank 494 and subsequently rotates the lock cam inside the lock or padlock to clear the locking mechanism such as bearing balls and free the shackle in a similar manner as described above.

[0136] Once the requested operation is completed (which the Lock Controller knows due to position sensing) the Lock Controller may send a status message via the remote communications channel and may also light up the LED 282 on the Main PCB 250. The LED 282 may be lit in different colours and patterns or pulses to indicate the completed request.

[0137] Once the user has received feedback of the completed unlocking they may pull on the shackle to release, if it has not already been popped out of the Lock Body by an internal lock spring. After a predetermined period of time, preferably a configurable predetermined period of time, the Lock Controller will "arm' for locking by releasing the Solenoid 445.

[0138] In some form features may be provide on the Crank 494 to ramp or push, the solenoid shaft 446 to allow for rotation back to the locked position without needing to apply power to Solenoid 445.

[0139] In some forms to re-lock the lock a user may rotate the Crank 494 back to a locked position and push the shackle back into the lock body. This relock mechanism may be free to lock as long as the user has rotated the Crank back to the locked position. If the crank 494 remains in the rotated unlock position, the shackle may pop up or be prevented from locking requiring the user to try again. In some forms a message may be provided via wireless communication to the App to advise the crank 494 is in the unlock position.

[0140] Once the user has locked the lock they may shutdown or disconnect any devices used for the remote communication, remove any connected accessories such as an external power supply if connected and leave the lock in a secure state.

[0141] If at any point there is an error, such as invalid command, solenoid failure or blockage of the lock mechanism, the Lock Controller may use the switch to determine position of the Cam and try to reverse direction or simply stop applying power as required. Suitable error messages may be sent via the remote communication channels, and also via the LED 282 on the main PCB flashing in certain patterns and colours. Several error management and correction steps may be provided to the Lock Controller programming to aid resolution.

[0142] Power Sleeve

[0143] In a further aspect of the invention a power sleeve 1900 may be configured to provide extra power supply options to a lock 10 or locking core 200, 400 coupled to a lock 10. The power sleeve 1900 as shown in Figures 19 to 24B may be coupled to or integrated with a lock or locking core within a lock. The Power Sleeve 1900 may be configured to provide power to a lock or locking core indefinitely to facilitate operation of the lock and / or locking core without requiring connection of external power devices and / or expanding the devices able to be used for powering the lock.

[0144] Power Sleeve 1900 may include a Solar Panel 1910 and / or a Qi compatible wireless power coil 1920 or other forms of renewable or wireless charging. The Solar Cell 1910 may allow for a continuous trickle of charge to the internal power reservoir in the lock or locking core. This may significantly increase the unattended lifetime of the Lock or locking core when using the Internal Power Reservoir. The Qi compatible wireless power coil 1920 may allow for use of external devices that provide wireless charging capability. For example some smartphones such as the Samsung™ S series of smartphones such as S23, S24 and S25. This may allow users to provide power to the lock or locking core without the need for cables. The Qi wireless power coil 1920 configured to provide a power boost from an external device.

[0145] The power sleeve 1900 preferably comprises a sleeve PCB 1930 configured to regulate the power coming from the solar panel 1910 or Qi compatible wireless power coil 1920 or other such power supplying options and ensures that acceptable power levels are sent to the Lock. The Power Sleeve 1900 may be offered as an accessory that interacts with the Lock via the External Power Connector on the smart lock 10 or locking core 200, 400. A power control sleeve PCB 1930 may direct power where needed. The Power Sleeve 1900 may be manufactured with a connection 1915 to engage with the external power connector 215 on the lock or locking core. In some forms the connection 1915 may be coupled with a further external power connector 1916 to still allow connection of an external power supply to the lock or locking core when the power sleeve is coupled to the lock or locking core.

[0146] An outer casing of the power sleeve 1900 may comprise an upper portion 1940 and a base portion 1950 that are coupled together to provide a protective housing. The upper portion 1940 and Base portion may be connected using methods such as adhesives or fasteners or snap fit ridges. The outer casing 1940, 1950 may be formed of any durable material such as plastic or Nylon. The outer casing 1940, 1950 may be configured to provide alignment for the components. Recesses and ribs may be provided in the outer casing to enable required positioning and secure location of components, such as the Sleeve PCB 1930 as that may have strict requirements for successful connection to the Lock.

[0147] Openings provided in the base 1950 to allow for extensions of the Button 280 and LED Diffuser 214, as well as an optional Sleeve External Power Connector 1916 to allow same type of external power devices as for a Lock or locking core. In some forms the power sleeve 1900 may comprise an internal connector 1915 configured to couple to the external power connector on a Lock or locking core to send power to the lock or locking core. The power sleeve may further include a sleeve external power connector 1916 configured to provide the same capability as the lock or locking core external power connector 215, i.e. to allow coupling to an external power supply. Furthermore, the power sleeve 1900 may be configured to control incoming power sources and ensure limits of the Power Control for the lock or locking core are not exceeded.

[0148] While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Further, the above embodiments may be implemented individually, or may be combined where compatible. Additional advantages and modifications, including combinations of the above embodiments, will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept.

Claims

CLAIMS1. A locking core configured for insertion into a lock body, the locking core comprising: an outer casing comprising a shell portion configured to be received within the lock body and a base portion configured to extend from the lock body, the shell portion and base portion being sealingly coupled together, an electronic circuit board housed within the outer casing for receiving electronic commands from a remote device, an internal power source coupled to the electronic circuit board; a controlling device housed within the casing and configured to receive power from the internal power source ; and an external power interface provided on the base portion and configured to couple to an external power source; the electronic circuit board configured to activate on receipt of a command from the remote device and configured to drive the controlling device following verification of the command, wherein the controlling device is configured to enable movement of a locking mechanism adaptor coupled to and extending from the shell portion of the outer casing to move a locking mechanism of the lock between a locked and an unlocked configuration; and wherein when an external power source is coupled to the external power interface the electronic circuit board is configured to receive power from the external power source for use to drive the controlling device.

2. The locking core according to claim 1 wherein the verification of the command is performed by the electronic circuit board.

3. The locking core according to any one of claims 1 or 2, wherein the internal power source is rechargeable.

4. The locking core according to any one of claims 1 to 3, wherein when the external power source is coupled to the external power interface the electronic circuit board is configured to direct power from the external power source to recharge the internal power source.

5. The locking core of any one of claims 1 to 4 wherein the electronic circuit board is configured to control the power source for delivery of power to drive the controlling device.

6. The locking core of any one of claims 1 to 5, wherein the controlling device is a motor, the motor is coupled with the locking mechanism adaptor to cause rotational movement of the lockingmechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

7. The locking core of any one of claims 1 to 5, wherein the controlling device is a solenoid, the solenoid comprising: a moveable shaft configured to be received in a locking aperture within a crank extending within the outer casing, the crank being coupled at a first end to the locking mechanism adaptor and coupled at a second end to the base portion of the outer casing, wherein the driving of the solenoid by the electronic circuit board withdraws the moveable shaft from the locking aperture to enable the crank to be moved, wherein rotation movement of the crank causes rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

8. The locking core of claim 7, wherein the second portion of the outer casing is rotated manually to affect the rotation movement of the crank.

9. The locking core of any one of claims 1 to 8, further comprising one or more interface component provided on the base portion of the outer casing, the user interface component including one or more of a button and / or a visual indicator.

10. The locking core of any one of claims 1 to 9, further comprising a frame, the frame configured to align and support the controlling device and locking mechanism adaptor within the shell portion.

11. The locking core of any one of claims 1 to 10 wherein the locking core has a dormant mode and an active mode, the dormant mode configured to reserve the power of the internal power source such that power supply to the electronic circuit board from the internal power source is stopped or minimal, the active mode configured to enable power supply to the electronic circuit board from the internal power source.

12. The locking core of claim 11, wherein the locking core is triggered to move from the dormant mode to the active mode when the locking core receives an interaction.

13. The locking core of claim 12, wherein the interaction is one or more of the following: (i) the electronic circuit board receives the electronic commands from the remote device and / or (ii) a user interacts with user interface component provided on the base portion of the outer casing, the user interface component being a button coupled to the electronic circuit board.

14. The locking core of claim 13, wherein the button is configured to receive a predetermined pattern of interactions to provide a manual verification process to activate the electronic circuit board.

15. The locking core of any one of claims 11 to 14, wherein the dormant mode is the default mode.

16. The locking core of any one of claims 1 to 15, wherein the command is transmitted wirelessly to the locking core from the remote device.

17. The locking core of claim 16, wherein the remote device is a computer or smartphone.

18. The locking core of any one of claims 1 to 17, wherein the external power source is a power sleeve.

19. A lock comprising a locking core inserted into the lock body according to any one of claims 1 to 17.

20. The lock according to claim 19, wherein the lock is a padlock.

21. A system for unlocking a lock including: a locking core for insertion into a lock body, the locking core comprising: an outer casing comprising a shell portion configured to be received within the lock body and a base portion configured to extend from the lock body, the shell portion and base portion being sealingly coupled together, an electronic circuit board housed within the outer casing for receiving electronic commands from a remote device, an internal power source coupled to the electronic circuit board, an external power interface configured to couple to an external power source, a controlling device housed within the casing and configured to receive power from the internal power source, the electronic circuit board configured to activate on receipt of a command from the remote device and configured to drive the controlling device following verification of the command, wherein the controlling device is configured to enable movement of a locking mechanism adaptor coupled to and extending from the shell portion of the outer casing to move a locking mechanism of the lock between a locked and an unlocked configuration; and wherein when an external power source is coupled to the external power interface the electronic circuit board is configured to receive power from the external power source for use to drive the controlling device.

22. The system of claim 21, in which the internal power source is a battery.

23. The system of claim 22, wherein the battery is rechargeable.

24. The system of claims 23, wherein when the external power source is coupled to the external power interface the electronic circuit board is configured to direct power from the external power source to recharge the battery.

25. The system of any one of claims 21 to 24 wherein the electronic circuit board is configured to control the power source for delivery of power to drive the controlling device.

26. The system of any one of claims 21 to 25, wherein the controlling device is a motor, the motor is coupled with the locking mechanism adaptor to cause rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

27. The system of any one of claims 21 to 26, wherein the controlling device is a solenoid, the solenoid comprising: a moveable shaft configured to be received in a locking aperture within a crank extending within the outer casing, the crank being coupled at a first end to the locking mechanism adaptor and coupled at a second end to the base portion of the outer casing, wherein the driving of the solenoid by the electronic circuit board withdraws the moveable shaft from the locking aperture to enable the crank to be moved, wherein rotation movement of the crank causes rotational movement of the locking mechanism adaptor to move the locking mechanism of the lock between the locked and unlocked configurations.

28. The system of claim 27, wherein the second portion of the outer casing is rotated manually to affect the rotation movement of the crank.

29. The system of any one of claims 21 to 28, further comprises one or more interface component provided on the base portion of the outer casing, the user interface component including one or more of a button and / or a visual indicator.

30. The system of any one of claims 21 to 29, further comprising a frame, the frame configured to align the frame configured to support and align the controlling device and locking mechanism adaptor within the shell portion.

31. The system of any one of claims 21 to 30 wherein the locking core has a dormant mode and an active mode, the dormant mode configured to reserve the power of the internal power source such that power supply to the electronic circuit board from the internal power source is stopped or minimal, the active mode configured to enable power supply to the electronic circuit board from the internal power source.

32. The system of claim 31, wherein the locking core is triggered to move from the dormant mode to the active mode when the locking core receives an interaction.

33. The system of claim 32 wherein the interaction is one or more of the following: (i) the electronic circuit board receives the electronic commands from the remote device and / or (ii) a user interacts with user interface component provided on the base portion of the outer casing, the user interface component being a button coupled to the electronic circuit board.

34. The system of claim 33, wherein the button is configured to receive a predetermined pattern of interactions to provide a manual verification process to activate the electronic circuit board.

35. The system of any one of claims 31 to 34, wherein the dormant mode is the default mode.

36. The system of any one of claims 21 to 35, wherein the command is transmitted wirelessly to the locking core from the remote device.

37. The system of claim 36, wherein the remote device is a computer or smartphone.

38. The system of any one of the claims 21 to 37 further including a lock which is fitted with the locking core.

39. The system of claim 38 wherein the lock is a padlock having a body that is fitted with the locking core.

40. A lock comprising a locking system of any one of claim 21 to 39.

41. A method of using the system of any one of claims 21 to 40 to unlock a lock, the method comprising the steps of: activating the electronic circuit board within the locking core; locating and receiving a command from a remote device; verifying the command and activating the controlling device to receive power from the internal power source and / or an external power source if connected to move the locking mechanism adaptor coupled to move the locking mechanism of the lock to the unlocked configuration to release a latch of the lock.

42. A method of upgrading a lock to include a locking core comprising the step of: removing a lock controlling component from a lock body of the lock; inserting a locking core according to any one of claims 1 to 18, such that the locking mechanism adaptor is engaged with a locking mechanism of the lock to facilitate movement of the lockmechanism by the locking mechanism adaptor when the controlling device is driven by the electronic circuit board in the locking core; securing the locking core to the lock body.

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